Blast Furnace Casthouse Control Technology and Recent Emissions Test Data

By the fall of 1980, three new and seven retrofit casthouse emission control systems had been installed in North America. A number of prototype systems are being evaluated by steel companies and regulatory agencies. By 1981, the U.S. steel industry had made commitments to install controls on at least 58 additional casthouses in the U.S.

This paper describes the current status of casthouse control technology in the U.S. and Canada as of the spring of 1981, addresses future trends, and presents emissions test data collected in 1980 and 1981. Mass emissions and inhalable particulate test results from sampling at DOFASCO’s No. 3 blast furnace casthouse are presented. Roof monitor visible emissions data are also provided to describe performance of installed and demonstration systems including three J&L plants, Wheeling-Pittsburgh and Bethlehem Steel, and Inland’s new furnace.     

Biogenic Sulfur Gas Emissions from Soils in Eastern and Southeastern United States

Data are presented for the first systematic measurements of biogenic sulfur gas flux from the major soil orders within the eastern and southeastern United States. Sulfur flux samples were collected and analyzed on-site during the fall of 1977, spring and summer of 1978 and summer of 1979. A total of 27 sampling locales in 17 states were examined. Eight additional sites were visited in 1980.

At some locales, two to four soils were examined, providing an even broader sampling of the soil orders. Three of the locales were revisited two or three times during the course of the study to establish the influence of seasonal climatology upon the measured emission rates and chemical composition of the sulfur flux mixtures.

The sulfur gas enhancement of sulfur-free sweep air passing through dynamic emission flux chambers placed over selected sampling areas was determined by combined cryogenic enrichment sampling and wall-coated, open tubular, capillary column, cryogenic gas chromatography (WCOT/GC) using a sulfur selective, flame photometric detector (FPD).

Sulfur gas mixtures varied with soil order, ambient temperature, insolation, soil moisture, cultivation, and vegetative cover. Statistical analyses indicated strong temperature and soil order relationships for sulfur emissions from soils.

Fluxes ranged from 0.001 g to 1940 g of total sulfur as S/m²/yr. The calculated mean annual sulfur flux, weighted by soil order, was 0.03 g S/m²/yr for the study land area, or 110,872 metric tons (mT). The estimated annual average sulfur flux increased from 65 mT per 6400 km² for the land grids in the northernmost east-west grid tier to an average 1800 mT for the land grids in the southern Florida grid tiers.

This systematic sampling of major soils provides a much broader data base for estimating biogenic sulfur flux than previously reported for isolated intertidal sites, and presents the first sulfur flux estimates for inland soils which make up approximately 93% of the land of the eastern United States.     

Electrostatic Stimulation of Fabric Filtration

The concept of electrostatic stimulation of fabric filtration (ESFF) has been investigated at pilot scale. The pilot unit consisted of a conventional baghouse in parallel with an ESFF baghouse, allowing direct comparison. All results reported in this paper are for pulse-cleaned bags in which the electric field was maintained parallel to the fabric surface. The performance of the ESFF baghouse has been superior to the parallel conventional baghouse by several measures. The ESFF baghouse demonstrated: (1) a reduced rate of pressure drop increase during a filtration cycle, (2) lower residual pressure drop, (3) stable operation at higher face velocities, and (4) improved particle removal efficiency. These benefits can be obtained with only minor modifications to conventional pulse-jet hardware and at low electrical power consumption. The indicated ability to operate at increased face velocities with only modest expenditure for electrical hardware leads to very favorable economic projections.     

Change in Pulmonary Function in Children Associated with Air Pollution Episodes

Pulmonary function of approximately 200 school children in Steubenville, OH was measured before and immediately following air pollution alerts in the fall of 1978 and 1979. TSP concentrations exceeded the National Primary Ambient Air Quality 24 h standards in 1978. SO₂ exceeded the standard in 1979. The children were then reexamined in three weekly visits following each alert. Estimated mean Forced Vital Capacity (FVC) was approximately 2% lower following each alert, although the lowest means were observed one to two weeks after the episodes. Forced Expired Volume in 0.75 sec (FEV_0.75) did not change during the 1978 study, but was 4% lower immediately following the 1979 alert. The children were measured again in five weekly examinations in the spring and fall of 1980. Air pollution levels did not exceed the standards on either occasion. In the spring of 1980, estimated mean FVC and FEV_0.75 showed a decline similar to that observed following the alerts in 1978 and 1979. In the fall of 1980, there were no significant differences in the estimated mean FVC or FEV_0.75 between the examinations. A total of 335 children were tested in the four studies, including 194 who participated in more than one study. The evidence for each child from all the studies was combined in a regression analysis of pulmonary function on TSP and SO₂ average concentrations in the previous 24 h. The distribution of the individual regression coefficients was centered significantly below zero, implying a decrease in pulmonary function with increasing TSP and SO₂ concentrations. The magnitude of the median change was less than 1% of the mean FVC and FEV_0.75 over the range of TSP and SO₂ concentrations observed.     

Comparison of Air Pollutant Emissions from Vaporizing and Air Atomizing Waste Oil Heaters

Information presented in this paper is directed to individuals concerned with emissions from combustion of waste crankcase oil for space heating. Studies were performed to characterize gaseous and particulate emissions and vaporizing pot solid residues resulting from the combustion of waste crankcase oil. Two types of waste oil burners were tested. One was a vaporizing oil burner rated at 35.2 kW (120,000 Btu/h heat input), and the other was an air atomizing oil burner rated at 73.3 kW (250,000 Btu/h heat input). Except for NO_X and SO_X, gaseous emissions were similar to those from conventional distillate oil combustion. NO_X and SO_X emissions were higher due to higher fuel nitrogen and sulfur concentrations. Waste oil from automotive use showed higher inorganic levels than crankcase oil used for truck engine lubrication. Both burner types discharged high levels of metallic species, but the air atomizing unit had much higher stack emission levels than did the vaporizing pot system. Also, particulate loading levels were an order of magnitude higher for the air atomizing burner than for the vaporizing pot burner when firing the waste oils. However, the vaporizing pot burner generated a waste residue containing the majority of its elemental emissions. Elements which exceeded threshold limit values for one or both heaters were cadmium, chromium, cobalt, copper, iron, lead, nickel, phosphorus, and zinc. However, the nickel and much of chromium appeared to be a sampling artifact caused by the stainless steel sampling system.     

Formaldehyde Concentrations in Wisconsin Mobile Homes

Mobile homes utilize a class of prefabricate construction techniques which rely greatly upon the use of particle board and hardwood plywood paneling for structural components. This has resulted In household sources which may emit formaldehyde into the home, since urea-formaldehyde resins are used as the bonding agent in most pressed wood stocks. A series of 137 mobile home households was investigated to determine indoor formaldehyde exposure concentrations. Homes were selected based on the estimated age of the construction components. Homes were studied serially for a nine-month period, with formaldehyde samples obtained on a monthly basis using a modified NIOSH chromotropic acid procedure. Formaldehyde concentrations were found to range from less than 0.10 ppm to 2.84 ppm. The median exposure concentration was 0.39 ppm. Analysis of variance was performed on each home to discern visit and room measurement effects. Eighty-nine percent of the homes exhibited no measurement placement effects, while only 10 percent failed to demonstrate between-visit variance effects. Regression models were constructed to predict household formaldehyde concentrations. Concentrations exhibited an inverse relationship with the age of the construction materials. A weighted least squares regression model of log of home age predicting temperature-corrected log formaldehyde explained 82 percent of the formaldehyde variation.     

Evaluation of Selected Gaseous Halocarbons for Use in source Test Performance Audits

A repository of 38 gaseous organic compounds in compressed gas cylinders has been established by EPA. This repository was established to provide standards for source test performance audits, that is, quantitative quality assurance tests. Among these compounds are ten halogenated organic species, which are the focus of this paper.

Stability studies of all ten compounds have been performed to determine the feasibility of using them as performance audit standards. Results indicate that all of the halocarbons tested are adequately stable to be used as reliable audit standards.

Subsequent to completion of stability studies, four of the ten halocarbons were used in source test performance audits. Results are available at this time for two of the four compounds; the results show agreement within 10% of the concentrations previously established by Research Triangle Institute.     

Dry FGD at United Power Association’s Stanton Station

The United Power Association’s dry FGD system at Stanton, North Dakota was the first utility-operated lime spray dryer to be put into service in the United States. At 60 MW in size, it utilizes a single spray dryer vessel with three rotary atomizers and a ten-compartment fabric filter. It is currently operating at better than expected efficiency and Is meeting state and federal air quality requirements. Start-up and operation have shown that certain areas of design and operating conditions are critical to reliable operation. Flue gas, slurry, and water distribution and mixing must be carefully controlled if reliable, long term operation is to be achieved. Likewise, water chemistry Is Important in the reagent preparation equipment. Start-up of the system was accomplished In a step-wise fashion to bring the baghouse on line first, followed by the spray dryer. The spray dryer was operated at gradually lower outlet temperatures until design conditions were met. Measures taken since start-up to ensure reliable operation, and operation over an eighteen month period are discussed. Both particulate and SO₂ emission performance are evaluated.