Document DG1KbaeOE7EM7a0b4X5ZM285B

ABDOO127283 CONDEA Vista Chemical Aberdeen, Mississippi Air Emissions Test Protocol Multiple Source Compliance Test for Particulate Emissions a. Facility Name. (1) Facility Information CONDEA Vista Chemical Post Office Box 91 New Highway 25 Aberdeen, Mississippi 39730-0091 b. Facility contact person. c. Telephone number. d. Facility permit number. Mr. Kenny Akins 601/369-3637 1840-00014 e. Facility source identification number. f. Proposed test date. g. Source test company. h. Analytical laboratory to perform analysis. MSD007031230 November 1-5, 1999 Entec Services, Inc. 25 Commerce Ave., Suite 104 Hueytown, Alabama 35023 Entec Services, Inc. 25 Commerce Ave., Suite 104 Hueytown, Alabama 35023 (2) Test Objectives a. Purpose of the tests. b. Citation of any applicable State or Federal regulation or permit condition requiring the test. To demonstrate compliance for particulate emissions. Permit 1840-00014 condition Section 5.B.7 specifies that the source shall demonstrate compliance for PM (Method 5) according to the test protocol approved 6/23/98. 3 ABDOO127284 (3) Process Descriptions a. Description of process. b. Description of pollution control system b. Process design rates. c. Proposed operating rate during the testing and verification of the operating rate. d. Description of any stack gas or opacity monitoring systems. e. Description of all air pollution control monitors, when applicable AA-008 Compound Mixing Area AD-001 Blending Silo The particulate emissions on all sources are controlled by either a cartridge filter or bag equipped baghouse. See Attachment "A" Testing will be conducted with the production capacity at or near normal operating capacity. Operating condition during the tests will be recorded and verified by a control room DAS. NA NA f. Pollution control operating parameters that will be recorded during the tests. g. Responsible party for obtaining the operating parameters. The baghouse differential pressure will be recorded at the beginning and at the end of each test run. CONDEA Vista Chemical control room personnel. (4) Safety Considerations a. Identification of any risks. b. List of all necessary or required safety equipment. Sample ports are accessible by ladder and the test area is enclosed by safety rails. Area on ground under sample ports should be made aware that people are working overhead. Hard hat, safety glasses, steel toed shoes. NOMEX or equilivant required while monitoring AD-001. (5) Sampling and Analytical Procedures a. Description of sampling methods to be used. b. Description of analytical methods to be used. c. Number and duration of tests to be conducted. CFR 40 part 60 Appendix "A" Methods 1-5. Gravimetric analysis of the filter and probe wash accurate to 0.1 mg. Three one hour test runs. See also attachment "A". d. Description of minimum sampling Thirty dry standard cubic feet. volumes for each test run. See also attachment "A". 3 ABDOO127285 e. Location where samples will be recovered. f. Explanation of how blank and recovery check results and analytical non-detects will be used in final emission calculations. g. Maximum amount of time a sample will be held after collection prior to analysis. h. Method of storing and transporting samples. Probe wash will be conducted at the location of the test ports. Filters will be transferred to petri dishes in the lab. The total weight of the acetone blank samples will be deducted from the final weight of the probe wash weights based on the volume of acetone used to conduct the probe wash. Five days. Acetone wash will be stored in polypropylene storage containers. The liquid level will be marked to verify no liquid was lost during transporting. The filters will be left in the filter assembly until transported to the laboratory. (6) Sampling Locations and Documentation a. Location of sampling sites. See attachment "A". b. A description of alt emission The particulate emissions exits the process and points. passes through an baghouse to remove the particulate matter and exits the baghouse to the I.D. fan which transfers the cleaned air through the stack into the atmosphere. See also attachment "A". c. Procedure for verifying absence CFR 40 part 60 appendix "A", method 1, of cyclonic or non-parallel stack gas section 2.4. flow. (7) Internal Quality Assurance/Quality Control (QA/QC) Measures. For each Drooosed test method when aDDlicable. a. Citation of the QA/QC procedures specified in the EPA Reference Methods and the EPA Quality Assurance Handbook for Air Pollution Measurement Systems, Volume 111. b. Chain-of-custody procedures and copies of chain-of-custody forms. c. Procedure for conditioning particulate matter filters (before and after source testing). Entec Services, Inc. proposes to follow the QA/QC procedures for the project as outlined in the EPA Quality Assurance Handbook for Air Pollution Measurement Systems, Volume III (EPA/600/R-94/038C) and the Code of Federal Regulations 40 part 60, appendix A, methods 1,2,3,4, and 5. See attachment UB". Entec Services, Inc. proposes to follow the procedures outlined in the CFR 40 Part 60 Appendix "A" Method 5 and the QA/QC procedures outlined in the EPA Quality Assurance Handbook for Air Pollution Measurement Systems, Volume III (EPA/600/R- 94/0380 4 ABDOO127286 d. Procedure for conducting leak Vacuum line and metering system leak checks on vacuum lines, pitot tubes, check - CFR 40 part 60 appendix "A", method flexible bags, fyrite, etc. 5, section 4.1.4. Pitot tubes and lines CFR 40 part 60 appendix "A", method 2, section 3.1. Flexible bags CFR 40 part 60 appendix "A", method 5, section 2.2.6. e. Equipment calibration frequencies, ranges, and acceptable limits. Fyrite CFR 40 part 60. appendix "A", method 3, section 6. Probe nozzle calibrated before and after each test run. acceptable limits- difference between highest and lowest measurement shall not exceed 0.004 in. Pitot tube initial calibration - once every six months. post test calibration - once after field test is performed. acceptable limits - average deviation (A and B side) must be <0.01. Temperature gauges (probe heater, stack gas, meter in, meter out, impinger out, filter box) once after each field use. acceptable limits - must be within 1.5% of the reference standard. Metering system initial calibration - once every six months. acceptable limits - Y factor cannot differ by more than 2% from the average. post test calibration - after each field use at one intermediate orifice setting based on the previous field test maximum orifice reading. acceptable limits - less than 5 % form the initial Y value calibration. 5 ABDOO127287 f. Minimum detection limits of analytical instrumentation. g. Names, addresses and responsible persons sub-contracting h. QA/QC measures associated with the collection and analysis of process and the frequency at which these samples will be collected. i. Methods for interference and matrix effects checks, and number of replicate analyses. j. Methods and concentrations for internal standards (standards additions prior to extraction). k. Methods and concentrations for surrogate standards (standards additions prior to extraction). 1. Methods for recovery checks, field blanks, lab blanks, reagent blanks, proof rinse blanks, and analytical blanks. m. Proposed range of recoveries for data acceptability Entec Services, Inc. proposes to meet the minimum detection limits outlined in the CFR 40 Part 60 Appendix "A" Method 5 and the QA/QC procedures outlined in the EPA Quality Assurance Handbook for Air Pollution Measurement Systems, Volume III (EPA/600/R- 94/038C) N/A N/A N/A N/A N/A CFR 40 part 60 Appendix "A" method 5 section 4.3. Results are reported to the nearest 0.1 mg. (8) Final Test Report Content a. Final report outline. b. Example calculations Cover letter Table of Contents Executive Summary Field and Laboratory Data Production Data Test Procedures Equipment Calibration Test Calculations and Nomenclature. See attachment "C" c. Proposed report submission date November 22, 1999 6 ABDOO127288 ATTACHMENT A Location of Sampling Sites and Operating Conditions During the Testing The following sources will be tested in accordance with the CFR 40 Part 60 Appendix A Method 5: AD-001 (Silo 692) AC-008 Line I resin blower AC-008 Line II resin blower AC-008 Filler blower AC-008 masterbatch resin blower AC-008 Line 1 rework blower AC-008 vacuum system AC-008 silo 477 bin vent AC-008 silo 480 bin vent AC-008 ATH blower AC-008 Line 2 rework blower Due to the short distance of the exhaust exiting to the atmosphere on each of the sources, the length of the exhaust will be extended in order for the exhaust stack to meet the upstream and downstream disturbances as outlined in the CFR 40 Part 60 Appendix A Method 1. The exhaust will be extended using flexible pipe extending from the exhaust to a rigid pipe at the particulate measuring plane. The rigid pipe will have sufficient length to provide a minimum eight duct diameters upstream and two duct diameters downstream from the nearest disturbance. Due to cycling operation of the AC-008 line I resin blower, AC-008 Line II resin blower, AC-008 filler blower, AC-008 masterbatch resin blower, AC-008 Line 1 rework blower, AC-008 vacuum system, AC-008 ATH blower, AC-008 Line 2 rework blower the testing will start and stop as the process blower starts and stops until one hour of sampling is 7 ABDOO127289 completed on each of the sources. The approximate cycling operates for 15 minutes and is idle for 15 minutes. The AC-008 silo 477 bin vent and the AC-008 silo 480 bin vent operate only when trucks are loading therefore sampling will be conducted only as the trucks are loading. The approximate time to load a truck is approximately three hours. To expedite the testing, the loading of the trucks will cease at the end of each one hour test run and commence upon the start of the next test run until the completion of three one hour test runs. The operating conditions of the AD-001 (Silo 692) baghouse will allow for the baghouse to operate continuously for the duration of three one hour test runs. 8 ABDOO127290 ATTACHMENT B CHAIN OF CUSTODY PLANT____________________________________________ DATE SAMPLEDTEST NUMBER RUN NUMBER SAMPLE RECOVERY CONTAINER CODE DESCRIPTION Person engaged in sample recovery____________ Signature_____________________________ Title_________________________________ Location of Recovery__________________ Date_________________________________ Sample(s) recipient (if not recovery person)______ Signature_____________________________ Title_________________________________ D ate_Ti m e Sample storage_______________________ Laboratory person receiving sample_____________ Signauture____________________________ Title_________________________________ Date Ti me Sample storage_______________________ Container Code Analytical Method Date and Time of Signature of Analysis Analyst 9 ABDOO127291 ATTACHMENT C TEST CALCULATIONS I. Determination of Moisture in Stack Gases a. Volume of Water Vapor Collected (Cubic Feet): Vwstd = 0.04707 * (Vic) b. Dry Gas Volume Through Meter (Cubic Feet): Vmstd = 17.64 * Vm * Y * {(Pbar + (H/13.6)) / Tm} c. Moisture Content (Percent): Bws - Vwstd / { Vwstd + Vmstd } * 100 d. Wet Molecular Weight : (Ms) Ms = { Md * (1-Bws) } + { 18.0 * Bws } II. Actual Stack Gas Volume Sampled (Cubic Feet): Vma = { Vmstd * Ts * Pstd ) / { (1-Bws) * Tstd * Ps } III. Determination of Stack Gas Velocity & Volumetric Flow Rate a. Stack Gas Velocity (Feet per Second): Vs = Kp * Cp * (SqR P) * { SqR (Ts / (Ps * Ms) } b. Stack Volumetric Flow Rate (Cubic Feet per Minute): 1. Dry Standard Conditions (Qs) Qs = 60 * (1-Bws) * Vs * As * (Tstd/Ts) * (Ps/Pstd) 2. Actual Conditions (Qa) Qa = Vs * As * 60 IV. Determination of Particulate Concentration (Grainloading) a. Dry Standard Conditions: (cs) cs = 0.01543 # (Mn / Vmstd) b. Actual Conditions: (csl) csl = 0.01543 *( Mn/Vma) V. Emission Rate (Pounds per Hour) E = 60 * Qs # cs / 7000 V. Emission Rate (Pounds per mmBtu) Method 19 Oxygen based F-Factor Dry Basis ErnmBtu = Fd * 20.9* cs / ( 7000 * (20.9 - measured O2) VI. Determination of Acceptability-of Sampling Results: (I) I = ( 0.0945 * Ts * Vmstd ) / { 0 * Vs * Ps * An * ( 1 - Bws ) } 10 ABDOO127292 ATTACHMENT C NOMENCLATURE As An ACF ACFM Bws cs csl Ca Cp delta H dp delta P dscf E E/Btu Fd Kp Ma Maw Mf Mn I Pa Pbar Pm Ps Pstd Qa Qs Tm Ts Tstd 0 Va Vaw Vf Vi Vic Vm Vma Vmstd Vs Vwstd Wa Wf Wi Y Cross-sectional area of stack, square feet Cross-sectional area of nozzle, square feet Actual cubic feet of gas at stack conditions Actual cubic feet of gas per minute at stack conditions Proportion by volume of water vapor in gas stream Particulate concentration in stack gas, gr/dscf Particulate concentration in stack gas, gr/ACF Acetone blank residue concentration, mg/g Pitot tube coefficient Pressure drop across orifice meter, inches water Nozzle diameter, inches Velocity head of stack gas, inches water Cubic feet of dry gas corrected to standard conditions Particulate emission rate, pounds/hour Particulate Emission Rate, pounds/mmBtu F-factor, dscf/mmBtu of fuel heat input Constant (85.49) Mass of residue of acetone after evaporation, mg Mass of residue of acetone blank, mg Particulate matter collected on filter, mg Total particulate matter collected, mg Percent of isokinetic sampling Density of acetone, mg/ml Barometric pressure, inches mercury Barometric pressure of dry gas meter, in. mercury Absolute stack gas pressure, inches mercury Barometric pressure, standard conditions, 29.92 "Hg Volumetric flow rate, actual conditions, ACF/min Volumetric flow rate, dry standard conditions, dscf/min Absolute average dry gas meter temperature, degree R Absolute average stack gas temperature, degree R Absolute temperature at standard conditions, 528 R Total sampling time, minutes Volume of acetone blank, ml Volume of acetone used in wash, ml Final volume of impinger contents, ml Initial volume of impinger contents, ml total volume collected in impingers and silica gel, ml Volume of gas sampled through gas meter, cubic feet Stack gas volume sampled, ACF Volume of gas sampled through gas meter, cubic feet Average stack gas velocity, feet/sec Volume of water vapor in gas sampled, standard cubic feet Weight of residue in acetone wash, mg Final weight of filter or probe wash beaker, g Initial weight of filter or probe wash beaker, g Dry gas meter calibration factor 11