DuPontWashingtonWorksBoiler5TopPerformerforCO30‐dayCEMSTestDataforICROtherOperationalandCoalDataOperationalJohnC.deRuyter‐DuPontJuly18,2012130DayCEMSTestPeriodCOvs O2atBaghouseOutletWWksBoiler5COvsO2yg708090WWksBoiler5COvsO2y=‐3.9492x+52.282R20 073930405060

CO, ppmR2=0.0739010200 2 4 6 8 10 12O2%,Proposedlimits‐220ppm3‐hraverage34ppm10‐dayaverage2Note:O2averageforthe30‐dayperiodattheCEMSlocationwas8.52%comparedtoO2intheboilerusedforO2controlaverageof6.84%30DayCEMSTestPeriodCOvs BoilerHeatInput(B dStO t t)WWksBoiler5COvsHeatInput(HtInCalcfromSteamOutput)(BasedonSteamOutput)60708090y=0.257x‐21.236R2=0.175630405060

CO, ppm01020050100150200250HeatInput,MMBtu/hr3Boilerdesignheatinput=181MMBtu/hr30DayCEMSTestPeriodO2vs HeatInput(B dStO t t)WWksBoiler5O2vsHeatInput(HtInCalcfromSteamOutput)(BasedonSteamOutput)81012y=‐0.0297x+13.128R2=0.4944468

O2, %020 50 100 150 200 250HeatInput,MMBtu/hr430DayCEMSTestPeriodTHCvs COWWksBoiler5THCvsCOy3.54.04.51.52.02.53.0

THC, ppmy=0.0013x+0.1864R2=0.00350.00.51.00 10 20 30 40 50 60 70 80 90CO,ppm530DayCEMSTestPeriodCH4vs COWWksBoiler5CH4vsCOy0.50.6WWksBoiler5CH4vsCO0.20.30.4

CH4, ppmy=0.0002x+0.0237R2=0.00040.00.10 10 20 30 40 50 60 70 80 90COppm,630DayCEMSTestPeriodNon‐CH4HCResiduevs COWWksBoiler5Non‐CH4HCResiduevsCOy0 40.50.6

p pm0.20.30.4

n

‐ CH4 HC Residue, py=0.0002x+0.0237R2=0.00040.00.1

No n0 10 20 30 40 50 60 70 80 90CO,ppm730DayCEMSTestPeriodFormaldehydevs COWWksBoiler5HCOHvsCOyy1.01.21.4WWksBoiler5HCOHvsCOy=0.0008x+0.5007R2=0.00090 40.60.8

HCOH, ppm0.00.20.40 10 20 30 40 50 60 70 80 90CO,ppm8DuPontWashingtonWorksCoalQualityandOperatingvsCEMSOperatingDatafor2009TestPeriod92009DailyQualitySummaryCoalQualitySummaryDataDaily Coal Quality Data for Full Calendar Year 2009Moisture, % Ash, % Volatiles, % Fixed Carbon, % HHV, Btu/lb Sulfur, %Average 5.08 7.74 36.45 50.73 12,997 1.11Max21 6311 5040 7355 1113 9432 16....,.Min 2.50 4.87 30.16 42.15 10,759 0.71Median 4.87 7.65 36.36 50.87 13,058 1.07Std Dev 1.67 1.12 1.15 1.65 384 0.27Daily Coal Quality Data for Boiler 5 CEMS Test Period 9/22/09 10/21/09DailyCoalQualityDataforBoiler5CEMSTestPeriod-9/22/09-10/21/09Moisture, % Ash, % Volatiles, % Fixed Carbon, % HHV, Btu/lb Sulfur, %Average 5.10 8.80 36.65 49.42 12,706 1.31Max 7.02 11.41 38.67 51.58 13,163 1.76Min 3.77 7.08 35.26 47.07 12,153 0.82M di4 898 7836 4849 4212 7461 30ean....,.Std Dev 0.85 0.97 0.90 1.13 272 0.20102009DailyCoalMoisture,%2530‐dayCEMStest152010

Moisture, %5100111‐Jan 15‐Feb 1‐Apr 16‐May 30‐Jun 14‐Aug 28‐Sep 12‐Nov 27‐Dec2009DailyCoalHHVBtu/lb14,50015,0002009DailyCoalHHV,Btu/lb30‐dayCEMStest13,50014,00012 00012,50013,000

H HV, Btu/lb11,00011,50012,000

H10,00010,500,1J15F b1A16M30J14A28S12N27D121‐Jan15‐Feb1‐Apr16‐May30‐Jun14‐Aug28‐Sep12‐Nov27‐DecWWkB il5D ilACOD ily=2.2198x+7.2796R2=0.111840WWksBoiler5DailyAverageCOvsDailyAverageCoalMoisture30352025

C O, ppm1015

C050123456789C lM it%13CoalMoisture,%y=‐230.16x+13889R2=0.4879DailyAverageCoalHHVvsDailyAverageCoalMoistureR0.487913 00013,20013,40013,60012 40012,60012,80013,000

HHV, Btu/lb11 80012,00012,20012,400

Coal11,60011,8000 1 2 3 4 5 6 7 8 9 10CoalMoisture,%14y=‐0.0108x+156.09R2=0.287940WWksBoiler5DailyAverageCOvsDailyAverageCoalHHV3035402025

CO, ppm51015011,000 11,500 12,000 12,500 13,000 13,500CoalHHV,Btu/lb15Boiler5DailyAverageSteamGenerationE l di1⁄2D iixcungData<esgnCapactyDaily Average Boiler 5 Steam Generation forAverage 126Max148DailyAverageBoiler5SteamGenerationforFull Calendar Year 2009 when Operating >1/2Capacity, KpphMax148Min 102Median 110Std Dev 63Number of days operating>1/2 load19052%Numberofdaysoperating1/2loadAverage120Daily Average Boiler 5 Steam Generation forCEMS Test Period- 9/22/09-10/21/09, Kpphe ageMax 143Min 111Median 123Std Dev 2416Conclusions‐1of4•Slide2‐COvariationvs O2atthemeasurementlocationappearsreasonablefortheoperatingloadduringtheperiod–DifferenceinO2betweenboiler/furnacecontrolpointandCEMSlocation(baghouseoutlet)isreasonableat1.68%andisindicativeoflimitedcasinginleakage•Slide3‐COvs heatinputvariationappearsreasonableforthetestperiod–HigherCOathigherheatinputs–Butnooperation<~110MMBtu/hrheatinputoccurredduringthatperiod,sonoindicationoflowloadCO•Slide4‐O2vs heatinputisanormaltrendforaspreaderstokercoalfiredboilerinthatloadrange,indicatingincreasingexcessairwithlowerloads17Conclusions‐2of4•Slides5,6,7,8‐CEMSdataforTHC,CH4,Non‐CH4Conclusions2of4,,,,,Residue,andFormaldehydevs COoverthe30daytestperiodallshowNOcorrelationofthoseemissionsvsCO–NodatawasavailablewithCOemissionrates>90ppmduringthattimeperiod•ItislikelytherewouldbesomelevelofcorrelationathighCOemissionrates•NootherCOvs otheremissionsdataisavailableforthatboiler–DatadoesnotsupportsettingaCOlimitatlessthan100ppm18Conclusions‐3of4•Slides10,11,12‐Coalqualityduringthe30daytestperiodexhibitedli tiii tdHHVthhthtiConclusions3of4lowervariationinmoistureandHHVthanshownovertheentireyearforthatfacility•Slide13‐CoalqualityimpactsCOemissionsHighermoisturecoalcorrelateswithhigherCOemissionsduetotheneed–moisturecorrelatesemissionsforcoaldryinganddelayedcombustion•Basedondailyaveragedataduringthe30dayCEMStestperiod•Slide14‐HighermoisturecorrelateswithlowerHHV•Slide15‐LowerHHVrequireshigherfuelinputforequalsteamoutputthanwithdryer,higherHHVcoal–SignificantcorrelationoflowerHHVwithincreasedCOemissions•Basedondailyaverageaveragedataduringthe30dayCEMStestperiod•Thelimitedtestperioddidnotencompassthefuelvariabilityforthisfacilityforaoneyearcomparison–Longertermcomparisonslikelywouldshowevenmorevariation–Otherfacilitieslikelyexhibitevenwidervariability19Conclusions‐4of4•Slide16‐Boiler5dailyaveragesteamgenerationratesduringthe30daytestperiodwerewithinaverylimitedrangeConclusions4of430daytestperiodwerewithinaverylimitedrange–Analysislimitedtoloadsover1⁄2load•Dayswith<1⁄2loadaveragewerewhenboilerwasshutdownorinstartup/shutdownduringtheday–Boiler5operated52%of2009days–Inaddition,sitesteamdemandsatthisfacilitydonotcycleseverelysuchaswouldoccuronsiteswithmostlybatchoperations•Rapidsteamdemandcycleswouldcauselessoptimumcontrolandcombustion,resultinginhigherCOemissionrates•FacilitysteamdemandisnotacontrollableconditionrelativetoBoilerMACT•Overall‐additionallatitude/variabilitymustbeincorporatedintothestokercoalfiredboilerMACTCOFloorsettingprocessinordertoforandoperationalvariationsthatdidallowfueloperationalvariationsnotoccurduringtheverylimited30daytestperiod20AdditionalSupplementalChartsfor30‐DayICRCEMSTestDataJuly18,201221y=0.003x+0.0454R2=0.02921.4WashWorksBoiler5HCOHvsHeatInput(HeatInputCalcfromSteamOut)1.01.2

w et0.60.8

a ldehyde, ppm w0.20.4

Form a0.00 50 100 150 200 250HeatInput,MMBtu/hr22y=0.0002x+0.1727R2=0.00034.5WashWorksBoiler5THCvsHeatInput(HeatInputCalcfromSteamOut)3.54.04.52.02.53.0

THC, ppm0.51.01.50.00 50 100 150 200 250HeatInput,MMBtu/hr23y=‐0.0002x+0.0649R2=0.00130 6WashWorksBoiler5CH4vsHeatInput(HeatInputCalcfromSteamOut)0.50.60.30.4

CH4, ppm0.10.20.00 50 100 150 200 250HeatInput,MMBtu/hr24y=0.0106x+0.4264R2=0.00061.4WashWorksBoiler5HCOHvsO21.01.2

m wet0.60.8

m aldehyde, pp m0.20.4

For m0.00 2 4 6 8 10 12O2,%25y=0.0104x+0.1226R2=0.0014 04.5WashWorksBoiler5THCvsO23.03.54.02.02.5

THC, ppm0.51.01.50.00 2 4 6 8 10 12O2,%26y=0.0181x‐0.1269R2=0.01210.6WashWorksBoiler5CH4vsO20.40.50 20.3

CH4 , ppm0.10.20.00 2 4 6 8 10 12O2,%27ConclusionsfromAdditionalChartsAdditional•Noapparentcorrelationoforganicemissionswithapparentcorrelationorganicemissionsheatinput•NoapparentcorrelationoforganicemissionswithfluegasO2/excessairconditions•Thisisaverylimited30‐daydataset•Organicemissionratesareverylow–Predominanceofdataforeachpollutant<1ppm28