# Information Collection Request Boiler MACT Emissions Report

We Energies Valley Power Plant Boiler 4 Outlet Duct Milwaukee, Wisconsin April 27 through 30, 20101520 Kensington Road, Suite 204 Oak Brook, IL 60523-2141 630-521-9400 630-521-9494 fax



# Information Collection Request Boiler MACT Emissions Report

We Energies Valley Power Plant Boiler 4 Outlet Duct Milwaukee, Wisconsin April 27 through 30, 2010

Report Submittal Date June 24, 2010

Prepared By

Platt Environmental Services
Report No. M101702

# Table of Contents

1.0 INTRODUCTION .............................................................................................................................. 1
2.0 EXECUTIVE SUMMARY ................................................................................................................. 2
3.0 TEST METHODOLOGY .................................................................................................................. 3 Method 1 Sample and Velocity Traverse Determination .............................................................3 Method 2 Volumetric Flow Rate Determination ...........................................................................3 Method 3A Oxygen (O2)/Carbon Dioxide (CO2) Determination ..................................................4 OTM27 Filterable Particulate Determination ................................................................................4 OTM 028 Condensable Particulate Determination ......................................................................4 Method 29 Trace Metals Determination .......................................................................................5 Mercury Determination by Method 30B (Sorbent Trap Method) ..................................................5
4.0 TEST RESULTS SUMMARIES ....................................................................................................... 6
5.0 CONCLUSION AND CERTIFICATION ......................................................................................... 10
APPENDIX Test Sectio n Diagrams.......................................................................................................... .....12 Sample Trai n Diagrams .......................................................................................................... ...14 Calculation Nomenclature and Fo rmulas...................................................................................20 Sample Anal ysis Data........................................................................................................... .....35 Reference Method Test Data (Computerized Sheet s)...............................................................69 Calibrati on Data ............................................................................................................... ........105 Gas Certific ation Sheet ........................................................................................................ ....142 Field Data Sheets.............................................................................................................. .......144ICR Boiler MACT Emissions R eport PES Report No.: M101702 We Energies-Valley Power Plant Boiler 4 Outlet Duct April 27 through 30, 2010



### 1 

# 1.0 Introduction

PLATT ENVIRONMENTAL SERVICES (PES) conducted an information collection request (ICR) boiler maximum achievable control technology (MACT) emissions test program for We Energies at the Valley Power Plant on the Boiler 4 Outlet Duct on April 27 through 30, 2010. This report summarizes the results of the test program and test methods used.

The test location, test dates, and test parameters are summarized below, in Table 1.



## Table 1
Test Overview

Test Location Test Dates Test Method Test Parameters
USEPA Method 3A Oxygen (O 2 ), Carbon Dioxide (CO 2 ) Other Test Method 27 (OTM27) <PM2.5 Filterable Particulate, Total Filterable Particulate Other Test Method 28 (OTM 28) Condensable Particulate

USEPA Method 5/29 Antimony (Sb), Arsenic (As), Beryllium (Be), Cadmium (Cd), Chromium (Cr), Cobalt (Co), Lead (Pb), Manganese (Mn), Nickel (Ni), Selenium (Se) and Filterable Particulate Boiler 4 Outlet Duct April 27 through 30, 2010

USEPA Method 30B Mercury (Hg)



### The identification of individuals associ ated with the test program is summarized below in Table 2.



## Table 2
Test Personnel

Location Address Contact Test Facility We Energies Valley Power Plant Milwaukee, Wisconsin Ms. Brenda Bergemann (414) 221-2459 (phone) Brenda.bergemann@we-energies.com Testing Company Representative Platt Environmental Services, Inc. 1520 Kensington Road, Suite 204 Oak Brook, Illinois 60523 Mr. Mark E. Peterson Senior Project Manager (630) 521-9400 (phone) mpeterson@plattenv.com



### The test crew consisted of Messrs. C. Jensen, J. Zeiss, A. Sczygielski, K. Achenbach, D. Quedens, B. Hendricks, M. Platt, and M. Peterson of PES. The purpose of the test program was to eval uate the emissions of the constituents listed in Table 1 to satisfy the USEPA information request.ICR Boiler MACT Emissions R eport PES Report No.: M101702 We Energies-Valley Power Plant Boiler 4 Outlet Duct April 27 through 30, 2010



### 2 

# 2.0 Executive Summary

Selected results of the te st program are summariz ed below, in Table 3. A complete summary of emission test result s follows the narrative portion of this report. 

## Table 3
Test Results

Test Location Test Parameter Emission Rate <PM2.5, filterable, lb/mmBtu 0.0012 >PM2.5, filterable, lb/mmBtu 0.0003
PM, condensable 0.0059 <PM2.5, total, lb/mmBtu 0.0071

Total PM, lb/mmBtu 0.0074 Filterable PM (from M29), lb/mmBtu 0.0034 Sb, lb/mmBtu < 6.04 E-07
As, lb/mmBtu < 6.03 E-07
Be, lb/mmBtu < 1.51 E-07
Cd, lb/mmBtu < 1.51 E-07
Cr, lb/mmBtu 1.94 E-04
Co, lb/mmBtu < 3.04 E-06
Pb, lbs/mmBtu < 4.36 E-07
Mn, lbs/mmBtu 2.58 E-05

Ni, lb/mmBtu 2.28 E-04
Se, lb/mmBtu < 2.39 E-06 Boiler 4 Outlet Duct

Hg, lb/mmBtu 7.34 E-08


### Emission rates were calculated using a st andard fuel factor of 9,780 dscf/mmBtu for Bituminous Coal. Run 2 failed a pos t test leak check and consequently an additional run was added to the test progr am. Additionally, another mercury test was performed on April 29, 2010 after resu lts for the first test run that day indicated no mercury was detected in one sample. The field data sheets for Run 2 and the additional mercury te st are found in the Appendix.
Compounds expressed above as less than or equal to values had a fraction or fractions that were below detection limit s. Detection limits for each fraction were used to determine the emission rate for these compounds.ICR Boiler MACT Emissions R eport PES Report No.: M101702 We Energies-Valley Power Plant Boiler 4 Outlet Duct April 27 through 30, 2010



### 3 

# 3.0 Test Methodology

Emissions testing were conducted followi ng the methods specified in 40 CFR, Part 60, Appendix A and 40CFR63, Appendi x A. Schematics of the sampling trains used and copies of field data sheet s for each test run are included in the Appendix.
The following methodologies were used during the test program:



## Method 1 Sample and Velocity Traverse Determination Test measurement points were selected in accordance with Method 1, 40 CFR, Part 60, Appendix A. The characteristics of the measurement location are summarized below, in Table 4.



## Table 4 Sample Point Selection

Test Location Upstream Distance Downstream Distance Test Parameters Number of Sampling Points Filterable Particulate, Condensable Particulate, Total Particulate, Sb, As, Be, Cd, Cr, Co, Pb, Mn, Ni, and Se 24 Boiler 4 Outlet Duct > 0.5 > 2.0

Hg 3



## Method 2 Volumetric Flow Rate Determination Gas velocity was measured following Meth od 2, 40 CFR, Part 60, Appendix A, for purposes of calculating stack gas volume tric flow rate. An S-type pitot tube, differential pressure gauge, thermocouple and temperature readout were used to determine gas velocity at each sample point. All of t he equipment used was calibrated in accordance with the specificat ions of the Method. Calibration data is presented in the Appendix.ICR Boiler MACT Emissions R eport PES Report No.: M101702 We Energies-Valley Power Plant Boiler 4 Outlet Duct April 27 through 30, 2010



### 4 

## Method 3A Oxygen (O2)/Carbon Dioxide (CO2) Determination A Servomex analyzer was used to determine stack gas oxygen (O 2 

### ) and carbon dioxide content and, by difference, ni trogen content in accordance with Method 3A, 40 CFR, Part 60, Appendix A for purpos es of calculating stack gas molecular weight as well as for calculating emissions on a lb/mmBtu basis. The O 2 

### instrument has a nondisper sive infrared-based detecto r and operates in a range of 0-25%, the CO 2 

### instrument also uses a nondi spersive infrared-based detector and operates in the range of 0-20%. All of the equipment used was calibrated in accordance with the specific ations of the Method.



## OTM27 Filterable Particulate Determination Stack gas filterable particulate c oncentrations and emission rates were determined in accordance with Other Te st Method 27 (OTM27) for determination of particulate matter less than 2.5 micr ons. An Environmental Supply Company, Inc. sampling train was used to sample stack gas at a constant rate, as specified in the Method. Filterable particulate ma tter was separated into two fractions; one containing less than PM 2.5, 

### the other greater than PM 2.5


### .



## OTM 028 Condensable Particulate Determination Stack gas condensable particulate concentrations and emission rates were determined in accordance with the dry draft impinger method, in conjunction with Method OTM27 filterable particulate sampling. Condensable particulate matter was collected in the impinger portion of the Method OTM027 sampling train.
The condensable particulate matter (CP M) was collected in impingers after filterable particulate material was co llected utilizing Method OTM27. The organic and aqueous fractions were then taken to dryness and weighed. The total of all fractions represents the CPM. Compared to the December 17, 1991 promulgated Method 202, this Method includes the addi tion of a condenser, followed by a water dropout impinger immediately afte r the final heated filt er. One modified Greenburg Smith impinger and an ambient temperature f ilter follow the water dropout impinger. A schematic of the sampling train configured with these changes is found in the Appendix.
CPM was collected in the water dropou t, modified Greenburg Smith impinger and ambient filter portion of the sampling tr ain as described in this Method. The impinger contents were purged with nitrogen (N 2 

### ) immediately after sample collection to remove dissolved sulfur dioxide (SO 2 

### ) gases from the impingers. The impinger solution was then extracted with acetone and methylene chloride (MeCl 2 

### ). The organic and aqueous fractions were dried and the residues weighed. The total of the aqueous and or ganic fractions represents the CPM. The samples were analyzed by PES personnel in Des Plaines, Illinois.ICR Boiler MACT Emissions R eport PES Report No.: M101702 We Energies-Valley Power Plant Boiler 4 Outlet Duct April 27 through 30, 2010



### 5 

## Method 29 Trace Metals Determination Stack gas metals concentrations and emission rates were determined in accordance with Method 29. An Environm ental Supply Company, Inc. sampling train was used to sample stack gas, in the manner specifi ed in the Method. Analyses of the samples collected were conducted by Maxxam Analytics, Inc. Samples were analyzed for the following metals, using Inductively Coupled Argon Plasma emission spectroscopy (I CP): Antimony, Arsenic, Beryllium, Cadmium, Chromium, Cobalt, Lead, Manganese, Nickel, and Selenium. All of the equipment used was calibrated in accor dance with the specifications of the Method. Calibration data is presented in the Appendix.



## Mercury Determination by Method 30B (Sorbent Trap Method) Paired trains were utilized using three (3) te st points at the Boiler 4 Outlet Duct.
Per Method 30B sampling, each sample was collected on the paired in-situ sorbent traps. A tube of silic a was used to capture remaining moisture prior to the sample reaching the gas metering system.
The sample train used for this test program was designed by APEX, Inc. and meet all requirements for Method 30B sampling. Samples were analyzed onsite utilizing an Ohio Lumex, Inc. analyze r for total gaseous mercury.ICR Boiler MACT Emissions R eport PES Report No.: M101702 We Energies-Valley Power Plant Boiler 4 Outlet Duct April 27 through 30, 2010



### 6 

# 4.0 Test Results Summaries

Client: Facility: Test Location: Test Method:

Normal Normal Normal 4/27/10 4/29/10 4/30/10

8:00 7:40 8:00 13:54 13:40 13:59 Run 1 Run 3 Run 4 Average

312.8 315.6 320.2 316.2 7.1% 7.8% 7.4% 7.4% 28.02 28.03 28.02 28.02 123.174 127.859 130.031 127.021 43.115 44.040 44.285 43.813 311,299 317,979 319,744 316,341 185,007 187,065 187,560 186,544

12.3 12.6 12.7 12.5 6.2 5.9 5.7 5.9 91.5 91.2 92.9 91.9

0.0004 0.0003 0.0004 0.0004 0.0007 0.0006 0.0006 0.0006 1.053 0.948 0.992 0.998 0.0013 0.0012 0.0012 0.0012

0.0001 0.0001 0.0000 0.0001 0.0002 0.0002 0.0001 0.0002 0.326 0.292 0.120 0.246 0.0004 0.0004 0.0001 0.0003

0.0019 0.0012 0.0022 0.0018 0.0033 0.0020 0.0038 0.0030 5.185 3.231 6.050 4.822 0.0065 0.0039 0.0072 0.0059

0.0023 0.0015 0.0026 0.0021 0.0040 0.0026 0.0044 0.0037 6.2380 4.1790 7.0420 5.820 0.0078 0.0051 0.0084 0.0071

0.0024 0.0016 0.0026 0.0022 0.0042 0.0028 0.0045 0.0038 6.5640 4.4710 7.1620 6.066 0.0082 0.0055 0.0085 0.0074 grains/dscf Stack Conditions End Time

Average %CO 2 by volume, dry basis

Average %O 2 by volume, dry basis

Gas Volumetric Flow Rate, acfm Gas Volumetric Flow Rate, dscfm Average Flue Pressure, in. Hg

Isokinetic Variance

lb/hr lb/mmBtu (Standard Fd Factor) We Energies Valley Power Plant Boiler 4 Outlet Duct

Average Gas Velocity, ft/sec Source Condition Date Start Time

Average Gas Temperature, °F

grains/acf grains/dscf lb/hr lb/mmBtu (Standard Fd Factor) Condensable PM (OTM28) grains/acf grains/dscf lb/hr lb/mmBtu (Standard Fd Factor) lb/mmBtu (Standard Fd Factor)

grains/acf Total PM Filterable >PM2.5 (OTM27) OTM27/OTM28

grains/dscf Filterable <PM2.5 (OTM27)

lb/hr grains/acf Gas Sample Volume, dscf Flue Gas Moisture, percent by volume

Total PM<2.5 grains/acf grains/dscf lb/hr lb/mmBtu (Standard Fd Factor)ICR Boiler MACT Emissions R eport PES Report No.: M101702 We Energies-Valley Power Plant Boiler 4 Outlet Duct April 27 through 30, 2010



### 7 Client: Facility: Test Location: Test Method:

Normal Normal Normal 4/27/10 4/29/10 4/30/10

8:05 7:40 8:00 12:17 11:54 12:14 Run 1 Run 3 Run 4 Average

313.7 315.5 319.9 316.4 6.7% 8.0% 8.5% 7.7% 28.06 28.03 28.06 28.05 140.560 141.238 139.343 140.380 38.868 39.590 39.159 39.206 280,631 285,850 282,737 283,073 167,503 167,773 164,336 166,537

12.3 12.6 12.7 12.5 6.2 6.0 5.8 6.0 101.3 101.7 102.4 101.8

0.0007 0.0009 0.0014 0.0010 0.0012 0.0016 0.0024 0.0017 1.686 2.262 3.400 2.449 0.0023 0.0031 0.0047 0.0034 Stack Conditions End Time

Average %CO 2 by volume, dry basis

Average %O 2 by volume, dry basis

Gas Volumetric Flow Rate, acfm Gas Volumetric Flow Rate, dscfm Average Flue Pressure, in. Hg

Isokinetic Variance We Energies Valley Power Plant Boiler 4 Outlet Duct

Average Gas Velocity, ft/sec Source Condition Date Start Time

Average Gas Temperature, °F

Gas Sample Volume, dscf Flue Gas Moisture, percent by volume

lb/mmBtu (Standard Fd Factor) M5 from M29 Train

grains/dscf

Filterable PM (Method 5)

lb/hr grains/acfICR Boiler MACT Emissions R eport PES Report No.: M101702 We Energies-Valley Power Plant Boiler 4 Outlet Duct April 27 through 30, 2010



### 8 Client: Facility: Test Location: Test Method:

Normal Normal Normal 4/27/10 4/29/10 4/30/10

8:05 7:40 8:00 12:17 11:54 12:14 Run 1 Run 3 Run 4 Average

313.7 315.5 319.9 316.4 6.7% 8.0% 8.5% 7.7%
28.06 28.03 28.06 28.05 140.560 141.238 139.343 140.380 38.868 39.590 39.159 39.206 280,631 285,850 282,737 283,073 167,503 167,773 164,336 166,537

12.3 12.6 12.7 12.5 6.2 6.0 5.8 6.0 101.3 101.7 102.4 101.8

< 0.139 < 0.138 < 0.140 < 0.139 < 0.703 < 0.700 < 0.710 < 0.704 < 4.41E-04 < 4.40E-04 < 4.37E-04 < 4.39E-04 < 6.11E-07 < 6.00E-07 < 6.00E-07 < 6.04E-07

< 0.226 < 0.225 < 0.228 < 0.226 < 0.703 < 0.700 < 0.710 < 0.704 < 4.41E-04 < 4.40E-04 < 4.37E-04 < 4.39E-04 < 6.11E-07 < 6.00E-07 < 6.00E-07 < 6.03E-07

< 0.469 < 0.467 < 0.473 < 0.470 < 0.176 < 0.175 < 0.177 < 0.176 < 1.10E-04 < 1.10E-04 < 1.09E-04 < 1.10E-04 < 1.53E-07 < 1.50E-07 < 1.50E-07 < 1.51E-07

< 0.038 < 0.037 < 0.038 < 0.038 < 0.176 < 0.175 < 0.177 < 0.176 < 1.10E-04 < 1.10E-04 < 1.09E-04 < 1.10E-04 < 1.53E-07 < 1.50E-07 < 1.50E-07 < 1.51E-07

166.824 106.307 38.799 103.977 360.863 229.956 83.928 224.916 2.26E-01 1.45E-01 5.17E-02 1.41E-01 3.13E-04 1.97E-04 7.09E-05 1.94E-04

2.359 1.235 < 0.733 < 1.442 5.784 3.028 < 1.797 < 3.536 3.63E-03 1.90E-03 < 1.11E-03 < 2.21E-03 5.02E-06 2.59E-06 < 1.52E-06 < 3.04E-06

0.083 < 0.048 < 0.045 < 0.059 0.719 < 0.418 < 0.388 < 0.508 4.51E-04 < 2.62E-04 < 2.39E-04 < 3.17E-04 6.24E-07 < 3.58E-07 < 3.28E-07 < 4.36E-07

22.960 10.654 5.610 13.075 52.485 24.354 12.824 29.888 3.29E-02 1.53E-02 7.89E-03 1.87E-02 4.56E-05 2.09E-05 1.08E-05 2.58E-05

208.797 68.494 47.129 108.140 510.036 167.312 115.123 264.157 3.20E-01 1.05E-01 7.09E-02 1.65E-01 4.43E-04 1.43E-04 9.73E-05 2.28E-04

1.377 < 0.586 < 0.579 < 0.847 4.522 < 1.925 < 1.901 < 2.783 2.84E-03 < 1.21E-03 < 1.17E-03 < 1.74E-03 3.93E-06 < 1.65E-06 < 1.61E-06 < 2.39E-06 lb/hr lb/mmBtu

lb/mmBtu Selenium (Se) Emissions ppb ug/dscm lb/hr lb/hr

lb/mmBtu

ppb ug/dscm Manganese (Mn) Emissions lb/mmBtu

ppb ug/dscm Lead (Pb) Emissions

ppb ug/dscm Nickel (Ni) Emissions lb/hr

lb/hr lb/mmBtu lb/mmBtu

ppb ug/dscm Cobalt (Co) Emissions lb/hr lb/hr lb/mmBtu

ppb Chromium (Cr) Emissions Average Gas Velocity, ft/sec Gas Volumetric Flow Rate, acfm

Antimony (Sb) Emissions

ug/dscm lb/mmBtu ppm Isokinetic Variance Gas Volumetric Flow Rate, dscfm Average %CO 2 by volume, dry basis

lb/mmBtu

ppb Start Time

Stack Conditions

Flue Gas Moisture, percent by volume

ppb ug/dscm lb/hr Gas Sample Volume, dscf

Average %O 2 by volume, dry basis Average Gas Temperature, °F

ug/dscm ug/dscm

ug/dscm lb/mmBtu

Beryllium (Be) Emissions lb/hr

Cadmium (Cd) Emissions Arsenic (As) Emissions

ppb

lb/hr Average Flue Pressure, in. Hg Date We Energies Valley Power Plant Boiler 4 Outlet Duct

Source Condition 29

End TimeICR Boiler MACT Emissions R eport PES Report No.: M101702 We Energies-Valley Power Plant Boiler 4 Outlet Duct April 27 through 30, 2010



### 9 Test No. Date Start Time End Time V m (standard L) ng detected ppb ug/dscm ug/wscm lbs/mmBtu (Fd Factor)

1A 4/27/2010 12:00 14:00 182.655 15.00 0.01 0.08 0.08 7.13E-08

1B 4/27/2010 12:00 14:00 174.529 15.00 0.01 0.09 0.08 7.46E-08

15.00 0.01 0.08 0.08 7.29E-08
3-2A 4/29/2010 11:23 13:23 131.623 8.00 0.00 0.06 0.06 5.17E-08

3-2B 4/29/2010 11:23 13:23 128.241 7.00 0.00 0.05 0.05 4.64E-08

7.50 0.00 0.06 0.05 4.91E-08

4A 4/30/2010 8:00 10:00 127.194 15.00 0.01 0.12 0.11 1.00E-07

4B 4/30/2010 8:00 10:00 123.843 14.00 0.01 0.11 0.10 9.62E-08

14.50 0.01 0.12 0.11 9.82E-08

12.33 0.01 0.09 0.08 7.34E-08 Method 30B (Sorbent Trap) Mercury Test Results Summary We Energies Valley Power Plant Boiler 4 Outlet Duct

Overall Average

Run 4 Average Run 1 Average

Run 3-2 AverageICR Boiler MACT Emissions R eport PES Report No.: M101702 We Energies-Valley Power Plant Boiler 4 Outlet Duct April 27 through 30, 2010



### 10 

# 5.0 Conclusion and Certification

PLATT ENVIRONMENTAL SERVICES is pl eased to have been of service to We Energies. If you have any questions regarding this test report, please do not hesitate to contac t us at 630-521-9400.


## CERTIFICATION

As project manager, I hereby certify that this test report represents a true and accurate summary of emi ssions test results and the methodologies employed to obtain those results, and the test program was perfo rmed in accordance with the methods specified in this test report.

PLATT ENVIRONMENTAL SERVICES

________________________ __________ Program Manager Mark E. Peterson

________________________ __________ Quality Assurance Jeffrey M. Crivlare

# APPENDIX