EMISSION MEASUREMENT SUMMARY REPORT 

FILTERABLE PARTICULATE MATTER 

FURNACES 1 and 12 

ERAMET MARIETTA, INC. 

MARIETTA, OHIO 

Prepared for: 

Eramet Marietta, Inc. 

P.O. Box 299 

State Route 7 South 

Marietta, Ohio 45750-0299 

Prepared by: 

Environmental Quality Management, Inc. 

1800 Carillon Boulevard 

Cincinnati, Ohio 45240 

(800) 229-7495 

www.eqm.com 

EQ PN: 050352.0030 

April 2014 
ii

CONTENTS 

Section Page 

1. Introduction ...................................................................................................................... 1-1

2. Summary of Test Results ................................................................................................. 2-1

3. Sampling and Analytical Procedures ............................................................................... 3-1

3.2 Stack Gas Volumetric Flow Rate ........................................................................... 3-1

3.3 Stack Gas Dry Molecular Weight ........................................................................... 3-1

3.4 Stack Gas Moisture Content ................................................................................... 3-2

3.5 Filterable Particulate Matter ................................................................................... 3-2

3.6 Visible Emission Observations ............................................................................... 3-2

4. Process Description/Sampling Locations ........................................................................ 4-1

5. Quality Assurance and Quality Control ........................................................................... 5-1

5.1 Field Sampling ........................................................................................................ 5-1

5.2 Calibration Procedures and Frequency ................................................................... 5-1

APPENDICES 

Appendix A Calculations

Appendix B Raw Field Data

Appendix C Analytical Data

Appendix D Process Data and Visible Emission Observation Data

Appendix E Quality Assurance/Quality Control
iii

FIGURES 

No. Page 

Figure 3-1. EPA Method 5 Sampling Train............................................................................... 3-3

Figure 4-1. Sampling Locations ................................................................................................ 4-1

TABLES 

No. Page 

Table 1-1. Sampling Locations and Test Parameters ............................................................... 1-1

Table 2-1. Furnace No. 12 Stack Gas Conditions .................................................................... 2-2

Table 2-2. Furnace No. 12 Particulate Emissions and Process Operations .............................. 2-2

Table 2-3. Furnace No. 1 Stack Gas Conditions ...................................................................... 2-3

Table 2-4. Furnace No. 1 PM Emissions and Process Operations ........................................... 2-4

Table 2-5. Furnace No.1 Baghouse Pressure Drop .................................................................. 2-4

Table 4-1. Sampling location parameters ................................................................................. 4-1

Table 5-1. Field Equipment Calibrations ................................................................................. 5-2

Table 5-2. Field Checks of Sampling Equipment .................................................................... 5-2
1-1

1. INTRODUCTION 

On March 25th and 26th 2014, Environmental Quality Management, Inc. (EQ) personnel 

conducted a compliance air emission program at the Eramet Marietta Inc. (Eramet) facility in 

Marietta, Ohio. Sampling was conducted following the procedures of EPA Reference Methods 1 

through 5 to quantify emissions of filterable particulate matter from Furnace No. 12. Sampling 

was conducted following the procedures of EPA Reference Methods 1 through 5to quantify 

emissions of filterable particulate matter from Furnace No. 1. 

EQ utilized EPA Reference Methods 1 and 2 to calculate stack gas velocities and 

temperatures. EPA Method 3 was used to determine the stack gas molecular weight. Moisture 

and filterable particulate matter were measured following the procedures of EPA Methods 4 and 

5 respectively. An outline of the specific sampling methods and parameters utilized is provided 

in Table 1-1 and detailed in Section 3. 

Mr. John Hughes of Eramet monitored process operations during testing. Ms. Lisa 

Duvall of the Ohio Environmental Protection Agency (Ohio EPA) observed process operations 

and sampling efforts. Mr. Tom Gerstle of EQ managed the sampling effort. Messrs. Dan 

Scheffel, Doug Allen, Benjamin Fern, Gary Drexler, Chris Janzen, Andrew Kriegbaum, Karl 

Mastalski, TJ Wigmore, and Jeffery Cavanaugh of EQ conducted the emission testing. 

Table 1-1. Sampling Locations and Test Parameters 

Stack I.D.

Test 

Method Parameter

No. of 

Samples

Run Time/Sample, 

min

Furnace No.12

Scrubber Exhaust

March 25, 2014

1-2

3

4

5

9

Flow

CO2/O2

Moisture

Filterable PM

Opacity

3

3

3

3

1

60

60

60

60

60

Furnace No.1

Main Baghouse and

Taphole Baghouse 

Exhaust

March 25-26, 2014

1-2

3

4

5

9

Flow

CO2/O2

Moisture

Filterable PM

Opacity

3

3

3

3

1

60

60

60

60

60
2-1

2. SUMMARY OF TEST RESULTS

Furnace No. 12 (scrubber exhaust) was sampled on March 25, 2014 to quantify emissions 

of filterable particulate. Furnace No. 12 was sampled at a maximum furnace load, approximately 

19.58 MW. Three 1-hour test runs were conducted at the Furnace No. 12 scrubber exhaust to 

determine the concentration and mass emission rate of filterable particulate matter. Sampling 

was conducted following EPA Reference Methods 1 through 5. 

Furnace No. 1 (2 baghouse exhausts) was sampled on March 25- 26, 2014 to quantify 

emissions of filterable particulate. The main baghouse controls emissions from the furnace and 

the taphole baghouse controls emissions from the tapping operations. The furnace was sampled 

at a maximum furnace load, approximately 25.49 MW. Three 1-hour test runs were conducted at 

each baghouse. Test Runs 1 and 2 were completed during a Tap. Sampling was conducted 

following EPA Reference Methods 1 through 5. 

Table 2-1 summarizes the stack gas conditions measured during each sampling run for 

Furnace No. 12. Stack gas velocity and temperature, volumetric flow rates, gas composition 

(CO2 and O2), and moisture content are detailed for each test run. 

Table 2-2 summarizes the filterable particulate matter and pertinent production data for 

each test run for Furnace No. 12. In addition, a tap was conducted during all three test runs. 

Table 2-3 summarizes the stack gas conditions measured during three test runs for 

Furnace No. 1. Stack gas velocity and temperature, volumetric flow rates, gas composition (CO2

and O2), and moisture content are detailed for each test run. 

Table 2-4 summarizes the filterable particulate matter and pertinent production data for 

each test run for Furnace No. 1. In addition, a tap was conducted during all three test runs. 

Example calculations are included as Appendix A, raw field data is included as Appendix 

B, analytical data is included in Appendix C, process and visible emissions observation data are 

included in Appendix D, and quality assurance/quality control data are located in Appendix E. 
2-2

Table 2-1. Furnace No. 12 Stack Gas Conditions 

March 25, 2014 Eramet, Marietta, Ohio 

Run No. Time

Stack Gas 

Velocity, 

fpsa

Volumetric Flow Rate

Temp, F

Moisture, 

acfmbdscfmc % CO2, % O2, %

12-1 0757-0900 59.3 176,325 158,075 112 3.2 0.0 20.5

12-2 0923-1026 61.2 182,015 162,619 114 3.7 0.0 20.5

12-3 1050-1153 60.0 178,469 158,290 116 4.1 0.0 20.5

Average 60.1 178,936 159,661 114 3.7 0.0 20.5

a

Feet per second. 

bActual cubic feet per minute. 

cDry standard cubic feet per minute. 

Table 2-2. Furnace No. 12 Particulate Emissions and Process Operations 

March 25, 2014 Eramet, Marietta, Ohio 

Run No. Time

Filterable Particulate Matter

Process Throughput Tons/hr 

at furnace load (MW)

Pressure Drop, 

inches of water

Concentration

grdscfa

Mass Rate

lb/hrb

12-1 0757-0900 6.78E-03 9.2 23.56 at 19.09 MW 55.6 east 55.7 west

12-2 0923-1026 8.21E-03 11.4 23.56 at 20.05 MW 55.5 east 55.5 west

12-3 1050-1153 9.48E-03 12.9 23.56 at 19.61 MW 55.2 east 55.3 west

Average 8.15E-03 11.2 23.56 at 19.58 MW 55.4 east 55.5 west

aGrains per dry standard cubic foot. 

b

Pounds per hour. 
2-3

Table 2-3. Furnace No. 1 Stack Gas Conditions 

March 25-26, 2014 Eramet, Marietta, Ohio 

Run No. Time

Stack Gas 

Velocity, 

fpsa

Volumetric Flow Rate

Temp, F

Moisture, 

acfmbdscfmc % CO2, % O2, %

Furnace No. 1 Main Baghouse

MB-1 1411-1517 52.8 248,628 223,043 126 0.7 0.0 20.5

MB-2 0750-0856 51.7 243,697 220,118 124 1.0 0.0 20.5

MB-3 0910-1017 50.2 236,509 205,889 135 2.8 00 20.5

Average 51.6 242,944 216,350 128 1.5 0.0 20.5

Furnace No. 1 Tap Hole Baghouse

TB-1 1411-1517 46.4 59,112 57,861 62 0.9 0.0 21.0

TB-2 0750-0856 42.9 54,643 56,507 51 0.3 0.0 20.5

TB-3 0910-1017 44.2 56,381 58,330 47 1.2 0.0 20.5

Average 44.5 56,712 57,566 53 0.8 0.0 20.7

a

Feet per second. 

bActual cubic feet per minute. 

cDry standard cubic feet per minute. 
2-4

Table 2-4. Furnace No. 1 PM Emissions and Process Operations 

March 25-26, 2014Eramet, Marietta, Ohio

Run No. Time

Filterable Particulate Matter

Process Throughput 

Tons/hr at furnace load 

(MW)

Concentration

Mass Rate

gr/dscfalb/hrb

Furnace No. 1 Main Baghouse

MB-1 1411-1517 2.13E-03 4.08 30.19 at 22.76MW

MB-2 0750-0856 8.90E-04 1.68 32.81 at 26.47MW

MB-3 0910-1017 1.88E-03 3.31 32.81 at 27.24MW

Average 1.63E-03 3.02 31.94 at 25.49MW

Furnace No. 1 Taphole Baghouse

TB-1 1411-1517 6.65E-03 3.30 30.19 at 22.76MW

TB-2 0750-0856 1.07E-02 5.16 32.81 at 26.47MW

TB-3 0910-1017 4.01E-03 2.01 32.81 at 27.24MW

Average 7.11E-03 3.49 31.94 at 25.49MW

Furnace No. 1 Total

1 8.78E-03 7.4

2 1.16E-02 6.8

3 5.89E-03 5.3

Average 8.76E-03 6.5

aGrains per dry standard cubic foot. 

b

Pounds per hour. 

Table 2-5. Furnace No.1 Baghouse Pressure Drop 

March 25-26, 2014 Eramet, Marietta, OH

Pressure Drop, Inches of Water

Run Time Mod 1 Mod 2 Mod 3 Mod 4 Mod 5 Mod 6 Mod 7 Mod 8

1410-1521 6.59 6.45 6.21 11.36 6.00 6.42 6.01 11.02

0750-0857 7.26 6.52 6.92 11.33 6.83 6.66 6.90 11.48

0910-1017 6.89 7.13 6.59 11.80 6.89 7.01 7.03 11.50

Average 6.91 6.70 6.57 11.49 6.57 6.70 6.65 11.33
3-1

3. SAMPLING AND ANALYTICAL PROCEDURES 

The sampling and analytical procedures used in this test program conformed to EPA 

Reference Methods 1 through 5 as published in the Federal Register. 

3.1 Location of Measurement Sites

EPA Method 1, “Sample Velocity Traverses for Stationary Sources,” was used to select 

representative measurement sites. Sample locations are discussed in Section 4. Exact 

measurements were verified on site. 

3.2 Stack Gas Volumetric Flow Rate 

EPA Method 2, “Determination of Stack Gas Velocity and Volumetric Flow Rates,” was 

used at each location to determine stack gas volumetric flow rates. Standard and Type “S” pitot 

tubes meeting EPA specifications and an inclined manometer were used to measure velocity 

pressures. A calibrated Type “K” thermocouple attached directly to the pitot tube was used to 

measure stack gas temperature. The stack gas velocity was calculated from the average square 

root of the stack gas velocity pressure, average stack gas temperature, stack gas molecular 

weight, and absolute static pressure. The volumetric flow rate is the product of velocity and 

stack cross-sectional area. 

3.3 Stack Gas Dry Molecular Weight 

EPA Method 3, “Gas Analysis for the Determination of Dry Molecular Weight,” was 

used to determine the stack gas dry molecular weight at all sampling locations. Fyrite analyzer 

readings were conducted for oxygen and carbon dioxide. 
3-2

3.4 Stack Gas Moisture Content 

EPA Method 4, “Determination of Moisture Content in Stack Gases,” was used to 

determine stack gas moisture content. This method was conducted as part of each particulate 

measurement run. The initial and final contents of all impingers were determined 

gravimetrically. 

3.5 Filterable Particulate Matter 

EPA Method 5, “Determination of Particulate Emissions from Stationary Sources,” was 

used to determine filterable particulate matter. The sampling train consisted of a nozzle, glasslined probe, heated quartz-fiber filter, and a series of impingers filled with appropriate reagents, 

followed by a vacuum pump, dry gas meter, and calibrated orifice. The probe and filter 

temperatures were maintained at 248o

± 25o F. Thermocouples were used to monitor 

temperatures of the stack gas, sample probe, filter, and impinger exit gas. Three 1-hour sampling 

runs were conducted at Furnace No. 12, and three 1-hour sampling runs were conducted at the 

Furnace No. 1 main and taphole baghouse exhausts. Figure 3-1 is a schematic of the sampling 

system. 

3.6 Visible Emission Observations 

EPA Method 9, “Visual Determination of the Opacity of Emissions from Stationary 

Sources,” was used to determine the opacity from each source during the test program. Each 

source was observed for 60 minutes. 
3-3

Figure 3-1. EPA Method 5 Sampling Train 
4-1

4. PROCESS DESCRIPTION/SAMPLING LOCATIONS 

Eramet Marietta, Inc., operates a facility in Marietta, Ohio. The No. 12 Furnace and No. 

1 Furnace were tested at the facility as part of this test program. The No. 12 Furnace, a 

submerged arc furnace, is rated at 22 MW and utilizes two wet scrubbers to control primary and 

secondary emissions. The scrubbers operate simultaneously and exhaust through a single stack. 

The No. 1 Furnace, a manganese electric arc furnace, is rated at 30MW and a maximum 

production rate of 35 tons per hour. A baghouse controls emissions from the furnace tap hole, 

and a new baghouse, which replaced an existing scrubber, controls emissions from the furnace. 

Table 4-1 presents a summary of the sampling site location. Figure 4-1 is a general 

schematic of the testing locations. 

B

A

C

Direction of

Flow

Figure 4-1. Sampling Locations 

Table 4-1. Sampling location parameters 

Stack Identification

Stack ID, inches

(C)

Distance from Nearest Disturbance No. of Sampling 

Points 

Required,

Total

Upstream, inches

(A)

Downstream, inches

(B)

Furnace No. 12-Scrubber 95.35” >194.0 368.0 24

Furnace No. 1-Main Baghouse 120” 480.0” 480.0” 24

Furnace No. 1 Taphole Baghouse 60”x51” >190.0 95.0 24
5-1

5. QUALITY ASSURANCE AND QUALITY CONTROL 

5.1 Field Sampling 

The field sampling quality assurance for this project included the use of calibrated source 

sampling equipment, reference test methods, and traceability protocols for recording and 

calculating data. The analytical quality assurance included use of validated analytical 

procedures, calibration of analytical instruments, and analysis of control samples and blanks. 

The calibration and quality control procedures used for this test program are described in the 

following subsection, and included in Appendix E of this report. 

5.2 Calibration Procedures and Frequency 

All manual stack gas sampling equipment was calibrated before the test program in 

accordance with the procedures outlined in the Quality Assurance Handbook for Air Pollution 

Measurement Systems, Volume III, EPA-600/4-72-027B. Summarized in Table 5-1 are the stack 

gas sampling equipment calibrations that were performed in preparation for this project. The 

meter boxes were re-calibrated after the test. 

Listed in Table 5-2 are the additional calibration checks that were performed on the 

sampling equipment on site, just prior to the testing, to ensure that equipment was not damaged 

during transport. Calibration checks were conducted before and after each test run. Additional 

calibration information is included in Appendix E of this report. 
5-2

Table 5-1. Field Equipment Calibrationsa

Equipment Calibrated Against Allowable Error

Method 5 meter box Reference test meter

Y +0.02 Y

H@ +0.20 H@

post-test

Y +0.05 Y

Pitot tube Geometric specifications See EPA Method 2

Thermocouple ASTM-3F thermometer +1.5%

Impinger (or condenser 

thermometer) ASTM-3F +2

o

F

Dry gas meter 

thermometer ASTM-3F +5

o

F

Probe nozzles Caliper High-low +0.004 in.

Barometer NBS traceable barometer +0.1 in.Hg

aAs recommended in the Quality Assurance Handbook for Air Pollution Measurement Systems: Volume III. 

Stationary Source-Specific Methods. EPA-600/4-77-027b, August 1977.

Table 5-2. Field Checks of Sampling Equipment 

Equipment Checked Against Allowable Difference

Pitot tube Inspection No visible damage

Thermocouples ASTM 2F or 3F +1.5%

Probe nozzles Caliper High-low 0.004 in.
APPENDIX A 

CALCULATIONS 












APPENDIX B 

RAW FIELD DATA 





















APPENDIX C 

ANALYTICAL DATA 


















APPENDIX D 

PROCESS DATA AND VISIBLE EMISSION OBSERVATION DATA 










APPENDIX E 

QUALITY ASSURANCE/QUALITY CONTROL