Environmental Sampling

Stack Sampling and Analysis Mobile Laboratory Route 2, Box 33
- B, (304) 755
- 1077 Fax (304) 755
- 1099 www. testincorp.com Poca, West Virgin i a 25159 TEST, Inc.



# EVIRONMENTAL PROTECTION AGENCY INFORMATION COLLECTION RULE

STACK TEST PROTOCOL FELMAN PRODUCTION, LLC

LETART, WEST VIRGINIA FURNACE #2 BAGHOUSE (ID# 001

- 01 ) FURNACE #5 BAGHOUSE (ID# 001

- 02 )

WVDEP DAQ PERMIT # R30- 05300004

- 2007

PLANT ID# 03

- 54

- 05300004
MARCH 1, 2013

TEST, INCORPORATED T echnical 

## E nvironmental 

## S ervices 

## T eam

Route 2, Box 33-B, Poca, West Virginia 25159 Ph: (304) 755-1077 Fx: (304) 755-1099Environmental Sampling

Stack Sampling and Analysis Mobile Laboratory Route 2, Box 33
- B, (304) 755
- 1077 Fax (304) 755
- 1099 www. testincorp.com Poca, West Virgin i a 25159 TEST, Inc.



## Table of Contents

Statement of Verification Stack Test Protocol Summary Introduction Description of Process Variances/Exemptions Sampling and Analytical Procedures Sampling Location Safety Example Calculations and Data Sheets

Equipment Calibration AttachmentsEnvironmental Sampling

Stack Sampling and Analysis Mobile Laboratory Route 2, Box 33
- B, (304) 755
- 1077 Fax (304) 755
- 1099 www. testincorp.com Poca, West Virgin i a 25159 TEST, Inc.



## STACK TEST PROTOCOL SUMMARY I. Source Information: A. Name: Felman Production, LLC B. Address: 4442 Graham Station Rd. Letart, West Virginia 25253 C. Person to Contact: John Konrady D. Title: Plant Manager E. Telephone: (304) 882-1401 E. Name of Sources: Furnace #2 Baghouse (ID#001- 01) Furnace #5 Baghouse (ID#001- 02) F. Permit Number: WV DAQ R30-05300004-2007 G. Facility ID: 03-54-05300004

II. Testing Firm Information: A. Name: TEST, Inc. B. Address: Route 2, Box 33-B, Poca, West Virginia, 25159 C. Person to Contact: Paul Chinuntdet, President D. Telephone: (304) 755-1077

III. Tentative Test Date: A. Date: March 13-March 22, 2013 B. Time: 8:00-20:00
IV. Sampling Information A. Pollutants to be sampled: PM, HCl, PCB’s, D/F, PAH’s, As, Cd, Cr, Hg, Mn, Ni, and Pb B. EPA Methods: EPA 1, 2, 3A, 4, 5D, 9, 26A, 29, and 30B; CARB 428 and 429 C. Number of sample runs: 3 per method D. Number of sample points: 12 E. Minimum Sample Time: see table F. Minimum Sample Volume: see table

V. Sampling Locations: A. Stack height: s ee attachment B. Inside diameter: see attachment C. Sampling ports height above ground: see attachment D. Port to upstream distance: see attachment E. Port to downstream distance: see attachmentEnvironmental Sampling

Stack Sampling and Analysis Mobile Laboratory Route 2, Box 33
- B, (304) 755
- 1077 Fax (304) 755
- 1099 www. testincorp.com Poca, West Virgin i a 25159 TEST, Inc.



### Felman Production, LLC Letart, West Virginia Furnace #2 Baghouse (ID# 001 - 01 ) Furnace #5 Baghouse (ID#001 - 02 )
WVDEP DAQ Permit # R30- 05300004

- 2007 Plant ID# 03

- 54

- 05300004

INTRODUCTION Stack emission testing is to be performed at Felman Production, LLC located in Letart, West Virginia, by TEST, Incorporated, of Charleston, West Virginia. The purpose of the testing is to provide emissions data to substantiate the actual emissions from the three baghouses. The testing will be performed to determine the concentrations of particulate matter, hydrogen chloride, multiple metals (arsenic, cadmium, chromium, manganese, nickel, and lead), dioxins/furans, poly chlorinated biphenyls (PCBs), mercury, and polycyclic aromatic hydrocarbons, being emitted into the atmosphere via the Furnace #2 Baghouse and Furnace #5 Baghouse. The testing will be performed according to the Appendix to the Code of Federal Regulations, Title 40, Chapter 1, Part 60, Methods 1, 2, 3A, 4, 5D, 26A, 29, 30B, and California
Air Resources Board Methods 428 and 429.

DESCRIPTION OF PROCESS Felman Production, LLC manufactures manganese and silicon based ferroalloys and is covered by Standard Industrial Classification (SIC) codes 3313 and 3341. The facility consists of three electric submerged arc furnaces, associated sizing equipment and environmental controls.

REQUESTED VARIANCES/EXEMPTIONS There are no requests for variances to the proposed methods.Environmental Sampling

Stack Sampling and Analysis Mobile Laboratory Route 2, Box 33
- B, (304) 755
- 1077 Fax (304) 755
- 1099 www. testincorp.com Poca, West Virgin i a 25159 TEST, Inc.

PROPOSED SCHEDULE The following schedule will be used for the test program at Felman Production, LLC
March 13

–

3 one hour runs each Hg and PAH
March 14

–

3 four hour runs PM/Multiple metals
March 15

–

3 two hour runs each HCl and D/F

– PCB’s Move to Baghouse #2
March 18

–

3 one hour runs each Hg and PAH
March 19

–

3 two hour runs each HCl and D/F

– PCB’s
March 20

–

3 four hour runs PM /Multiple MetalsEnvironmental Sampling

Stack Sampling and Analysis Mobile Laboratory Route 2, Box 33
- B, (304) 755
- 1077 Fax (304) 755
- 1099 www. testincorp.com Poca, West Virgin i a 25159 TEST, Inc.

SAMPLING AND ANALYTICAL PROCEDURES
The testing will follow the procedures in the Appendix to the Code of Federal Regulations, Title 40, Chapter 1, Part 60, Methods 1, 2, 3A, 4, 5D, 26A, 29, and 30B; and CARB 428 and 429.

Number Minimum Minimum Baghouse Of runs per Sample Vol. Run Time Parameter Number Baghouse (DSCF) (Mins) Particulate matter 2 and 5 3 142 240 Multiple metals 2 and 5 3 142 240 PAHs 2 and 5 3 36 60 Mercury 2 and 5 3 1.70 60 Dioxin/Furans/PCBs 2 and 5 3 72 120 Hydrogen chloride 2 and 5 3 72 120

Leak checks will be performed on the sampling trains before and after each run to prevent contamination. All components of the sampling train will be cleaned prior to each run.

Velocity
Th e velocity and stack temperature will be measured according to EPA Methods 1 and 2 at the inlet ducts of each baghouse. Twelve traverse points will be used to measure the velocity at each of two ports for a total of twenty four traverse points. A Type- S Pitot tube and oil gauge manometer will be used to measure the velocity pressure in the inlet duct. The stack temperature will be measured using a type-K thermocouple and digital temperature indicator.

Moisture The flue gas moisture will be determined according to EPA Method 4. The moisture will be determined by measuring the “back

- half” of the particulate matter sampling train.Environmental Sampling

Stack Sampling and Analysis Mobile Laboratory Route 2, Box 33
- B, (304) 755
- 1077 Fax (304) 755
- 1099 www. testincorp.com Poca, West Virgin i a 25159 TEST, Inc.

Hydrogen chloride The hydrogen chloride samples will be taken according to EPA Method 5D and 26A. For each run, samples of ten minute duration will be taken isokinetically from each of the twelve traverse points for a total sampling time of 120 minutes. The minimum sample volume will be at least 72 dscf. Data will be recorded in five minute intervals. Blank samples will be collected for each reagent used during sampling and analyzed for contamination.

The "front-half" of the sampling train will consist of a glass nozzle, heated glass probe (248 o F), and heated teflon filter support with a quartz fiber filter (248 o F). The "b ack -half" of the sampling train will contain the following impingers: Impinger Contents Amount Parameter
1 0.1 N H2SO4 100 ml. HCl
2 0.1 N H2SO4 100 ml. HCl 3 Empty

----- Moisture
4 Silica Gel 400 g Moisture
The “front

- half” of the sampling train will be rinsed with acetone and recovered into an amber glass sample container. The filter will be recovered and placed into container

. The “back

- half” of the sampling train, Impingers 1, 2, and 3, will be measured to determine moisture content, rinsed using de-ionized water, and recovered in amber glass sample jars. Impinger 4 will be measured to
determine moisture content.

The hydrogen chloride samples w ill analyzed according to EPA Method 26A using ion chromatography by Resolution Analytics, Inc. located in Sanford, North Carolina.Environmental Sampling

Stack Sampling and Analysis Mobile Laboratory Route 2, Box 33
- B, (304) 755
- 1077 Fax (304) 755
- 1099 www. testincorp.com Poca, West Virgin i a 25159 TEST, Inc.

Particulate Matter/Multiple Metals The multiple metals samples will be taken according to EPA Methods 5D and 29. For each run, samples of twenty-minute duration will be taken isokinetically from each of the twelve traverse points for a total sampling time of 240 minutes. Data will be recorded at five-minute intervals. The minimum sample volume will be at least 142 dscf. Blank samples will be collected for each reagent used during sampling and analyzed for contamination.

The "front-half" of the sampling train will consist of a glass nozzle, heated glass probe (248 o F + 25 o F), and heated Teflon filter support with a quartz fiber filter (248 o F + 25 o F).

The "back-half" of the sampling train will contain the following impingers: Impinger Contents Amount Parameter
1 5% HNO 3 /10% H 2 O 2 100 ml Multiple Metals
2 5% HNO 3 /10% H 2 O 2 100 ml Multiple Metals
3 Empty

--------- Multiple Metals
4 Silica Gel 400 g Moisture The "front-half" of the sampling train (nozzle, probe, and front-half of filter holder) will be
rinsed with 0.1 N HNO 3 and collected in a leak-free glass sample bottle. The "back-half" collections of the sampling train (back-half of filter holder, impingers 1, 2, 3, and 4, and

co nnectors) will be measured to determine the moisture content and recovered and rinsed using
0.1 N HNO 3 .

The particulate matter emissions will be determined by gravimetric analysis of the filter and acetone front wash. The particulate matter will be determined by TEST, Inc. The metals samples will be analyzed for antimony by inductively coupled argon plasma emission spectroscopy

. The analysis will be performed by Maxxam Laboratories located in Hamilton, New Jersey.Environmental Sampling

Stack Sampling and Analysis Mobile Laboratory Route 2, Box 33
- B, (304) 755
- 1077 Fax (304) 755
- 1099 www. testincorp.com Poca, West Virgin i a 25159 TEST, Inc.

Mercury The mercury samples will be taken according to EPA Method 30B. For each run, paired samples of 120 minute duration will be taken from the center of the baghouse. Data will be recorded at five-minute intervals. The minimum sample volume will be at least 1.70 dscf. A field recovery test and blank samples will be collected for each reagent used during sampling and analyzed for
contamination.

The "front-half" of the sampling train will consist of paired sorbent traps and leak free heated probe. The sorbent traps will be recovered after each run and sealed on both ends. The samples will be analyzed for mercury by UV AA cold vapor analyzers

. The analysis will be performed by Ohio Lumex located in Twinsburg, Ohio.

Dioxins/Furans and Polycyclic Biphenyls
The Dioxins/Furans and PCB’s sa mples will be taken according to California Air Resources Board 428. For each run, samples of ten-minute duration will be taken isokinetically from each ofthe twelve traverse points for a total sampling time of 120 minutes. Data will be recorded at fiveminute intervals. Blank samples will be collected for each reagent used during sampling and analyzed for contamination. All glassware, condensers, adsorbing tubes, and filters will be cleaned and prepared according to the method.

The "front-half" of the sampling train will consist of a glass nozzle, heated glass probe (248 o F), and heated teflon filter support with a glass fiber filter (248 o F).Environmental Sampling

Stack Sampling and Analysis Mobile Laboratory Route 2, Box 33
- B, (304) 755
- 1077 Fax (304) 755
- 1099 www. testincorp.com Poca, West Virgin i a 25159 TEST, Inc.

The "back-half" of the sampling train will contain the following impingers: Impinger Contents Amount Parameter
Condenser Tube
XAD -2 Trap
1 Empty

--------- D/F, PCB’s
2 De -ionized water 100 ml D/F, PCB’s
3 Empty

--------- D/F, PCB’s
4 Silica Gel 400 g Moisture The "front-half" of the sampling train (nozzle, probe, and front-half of filter holder) will be rinsed and brushed three times and rinsed with acetone, hexane, and methylene chloride and collected in Container 1. The filter will be recovered and placed in Container 2. The “back

half” of the filter

holder, connecting glassware before the condenser, and the condenser will be rinsed with acetone, hexane and methylene chloride, and collected in Container 3. The XAD-2 trap will be recovered and replaced. The impinger collections of the sampling train will be measured to determine the moisture content, recovered, and rinsed with acetone, hexane, and methylene chloride.

The samples will be extracted by high-resolution gas chromatography and measured by highresolution mass spectrometry. The analysis will be performed by Maxxam Laboratories in Hamilton, New Jersey.

Polycyclic Aromatic Hydrocarbons The PAHs samples will be taken according to California Air Resources Board 429. For each run, samples of five-minute duration will be taken isokinetically from each of the twelve traverse points for a total sampling time of 60 minutes. Data will be recorded at five-minute intervals. Blank samples will be collected for each reagent used during sampling and analyzed for contamination. All glassware, condensers, adsorbing tubes, and filters will be cleaned an d prepared according to the method.Environmental Sampling

Stack Sampling and Analysis Mobile Laboratory Route 2, Box 33
- B, (304) 755
- 1077 Fax (304) 755
- 1099 www. testincorp.com Poca, West Virgin i a 25159 TEST, Inc.

The "front-half" of the sampling train will consist of a glass nozzle, heated glass probe (248 o F), and heated teflon filter support with a glass fiber filter (248 o F).

The "back-half" of the sampling train will contain the following impingers: Impinger Contents Amount Parameter
Condenser Tube
XAD -2 Trap
1 Empty

--------- PAH
2 NaHCO3/Na2CO3 100 ml PAH
3 NaHCO3/Na2CO3 100 ml PAH
4 Empty

--------- PAH
5 Silica Gel 400 g Moisture

The "front-half" of the sampling train (nozzle, probe, and front-half of filter holder) will be rinsed and brushed three times and rinsed with acetone, hexane, and methylene chloride and collected in Container 1. The filter will be recovered and placed in Container 2. The “back

half” of the filter holder, connecting glassware before the condenser, and the condenser will be rinsed with acetone, hexane and methylene chloride, and collected in Container 3. The XAD-2 trap will be recovered and replaced. The impinger collections of the sampling train will be measured to determine the moisture content, recovered, and rinsed with acetone, hexane, and methylene chloride.

The samples will be extracted by high-resolution gas chromatography and measured by highresolution mass spectrometry. The analysis will be performed by Maxxam Laboratories in Hamilton, New Jersey.Environmental Sampling

Stack Sampling and Analysis Mobile Laboratory Route 2, Box 33
- B, (304) 755
- 1077 Fax (304) 755
- 1099 www. testincorp.com Poca, West Virgin i a 25159 TEST, Inc.

SAMPLING LOCATION

Measurements and distances will be determined on-site.

SAFETY REQUIREMENTS
All personnel entering the plant must follow all rules and regulations set by Felman Production,
LLC general safety rules should be followed which includes protective eyewear, hardhat, and work boots throughout the plant and ear protection in specified areas. Protective covering should be worn when specified. The protective eyewear should be either ANSI approved safety glasses or goggles. Other safety concerns include fall protection, mechanized traffic, and excessive heat from the furnaces. All safety concerns are inherent with an industrial
environment and are not unusual or extreme.

EXAMPLE CALCULATIONS AND FIELD DATA SHEETS
See following attachmentsEnvironmental Sampling

Stack Sampling and Analysis Mobile Laboratory Route 2, Box 33
- B, (304) 755
- 1077 Fax (304) 755
- 1099 www. testincorp.com Poca, West Virgin i a 25159 TEST, Inc.

EQUIPMENT CALIBRATION

Item Description

Probe Nozzle By micrometer per EPA Method 5. Three separate measurements using different diameters each time, and obtain the averag e of the measurements.

Pitot Tube Per EPA Method 2 type pitot tube construction. Default 0.84 will be used.

Dry Gas Meter Orifice Manometer Per EPA Method 5 using a wet test meter. Five (5) point calibration before and after test.
Thermocouple Per EPA Method 2.Area of measurement site Ao = 6308 ft2

Temp. at measurement site To = 200 (F) 660 ( R ) Ambient temp. Tamb = 86 (F) 546 ( R ) Inlet temp. Ti = 406.5 (F) 866.5 ( R ) Inlet gas volume flow rate Qi = 186,393 (DSCFM) 3106.55 (DSCFS)

Eq. 5D-3 Dilution Air Flow Rate

Qi (Ti-To) To-Tamb

Eq. 5D-2 Volumetric Flow Rate

Qo = Qi + Qd

Qo = 8733.766 (DSCFS)

Eq. 5D-1 Average Gas Velocity

Qo Ao

v = 1.384554 (FPS) v = (DSCFS) 

# Method 5D Velocity Calculation

= Qd

Qd = 5627.216mg 1 gr 60 min 1 lb Vmstd 64.8 mg 1 hr 7,000 gr

DSCFM* = Stack Flow Rate

Vmstd* = Volume of dry gas sampled at standard

conditions dry standard cubic feet

* 29.92 "Hg, 68 degrees F (760 mm Hg, 20 degrees C) DSCFM x 

## EXAMPLE CALCULATIONS

x x 

### DIOXINS/FURANS AND PCB'S

lbs/hr = xmg 1 gr 60 min 1 lb Vmstd 64.8 mg 1 hr 7,000 gr

DSCFM* = Stack Flow Rate

Vmstd* = Volume of dry gas sampled at standard

conditions dry standard cubic feet

* 29.92 "Hg, 68 degrees F (760 mm Hg, 20 degrees C) 

## EXAMPLE CALCULATIONS

PAH'S

lbs/hr = x x DSCFM x xM428 Page 102M428 Page 100