Stationary Source Control Techniques Document for Fine Particulate Matter EPA CONTRACT NO. 68-D-98-026 WORK ASSIGNMENT NO. 0-08 Prepared for: Mr. Kenneth Woodard Integrated Policy and Strategies Group (MD-15) Air Quality Strategies and Standards Division U.S. Environmental Protection Agency Research Triangle Park, North Carolina 27711 October 1998 Submitted by: EC/R Incorporated Timberlyne Center 1129 Weaver Dairy Road Chapel Hill, North Carolina 27514 Disclaimer This report has been reviewed by the Office of Air Quality Planning and Standards, U.S. Environmental Protection Agency, and has been approved for publication. Mention of trade names or commercial products is not intended to constitute endorsement or recommendation for use. Copies Copies of this document are available through the Library Services Office (MD-35), U.S. Environmental Protection Agency, Research Triangle Park, NC 27711; or from the National Technical Information Service, 5285 Port Royal Road, Springfield, VA 22161 (for a fee). This document can also be found on the Internet at the U.S. Environmental Protection Agency website (http:\\www.epa.gov/ttn/oarpg). ii CONTENTS TABLES .................................................................... ix FIGURES ................................................................... xi 1 INTRODUCTION .....................................................1-1 1.1 PURPOSE OF THIS DOCUMENT ..................................1-1 1.2 OTHER RESOURCES ............................................1-1 1.3 ORGANIZATION ...............................................1-1 1.4 REFERENCES ..................................................1-3 2 BACKGROUND ......................................................2-1 2.1 TRENDS IN AMBIENT PARTICULATE MATTER CONCENTRATIONS AND PARTICULATE MATTER EMISSIONS .........................2-1 2.2 PROJECTIONS FOR FUTURE CONTROL PROGRAMS AND EMISSIONS ....................................................2-2 2.3 SOURCES OF PM10 AND PM2.5 EMISSIONS .........................2-4 2.3.1 Point Sources ..............................................2-4 2.3.2 Area Sources ..............................................2-4 2.4 CHARACTERIZATION OF PM2.5 CONCENTRATIONS ................2-5 2.4 REFERENCES ..................................................2-8 3 MEASUREMENT .....................................................3-1 3.1 LIST OF EPA PM MASS MEASUREMENT TEST METHODS ............3-1 3.2 EPA STATIONARY (POINT) SOURCE PM MASS MEASUREMENT TEST METHODS ................................................3-3 3.2.1 EPA Test Method 5 for Total PM Mass ..........................3-3 3.2.2 EPA Test Method 5 Variations: 5A - 5H .........................3-6 3.2.3 EPA Test Methods for PM10 from Stationary Sources ...............3-7 3.2.3.1 Method 201: Determination of PM10 Emissions--Exhaust Gas Recycle Procedure ....................................3-8 3.2.3.2 Methods 201A: Determination of PM10 Emissions--Constant Sampling Rate Procedure ...............................3-8 3.2.4 EPA Test Method 17: Determination of PM Emissions from Stationary Sources-- In-Stack Filtration Method ............................3-8 3.2.5 Method 202 for Condensible PM Measurement ....................3-9 3.2.6 EPA Test Method 9: Visual Determination of the Opacity of Emissions from Stationary Sources, and Alternate Method 1 for the Use of Remote Lidar .............3-9 3.2.7 Performance Specifications for Continuous Emissions iii CONTENTS (continued) Monitoring Systems (CEM) Used to Monitor Opacity ........3-10 3.3 OTHER STATIONARY (POINT) SOURCE PM MASS MEASUREMENT TEST METHODS ................................3-10 3.4 FUGITIVE PM MEASUREMENT METHODS ........................3-11 3.5 PARTICLE SIZE ANALYSIS .....................................3-14 3.5.1 Cascade Impactors ........................................3-14 3.5.2 Sampling Cyclones .........................................3-15 3.5.3 Real-Time Size Distribution Measurement ........................3-15 3.5.4 Size Distribution of Bulk Samples ..............................3-16 3.6 SPECIATION ..................................................3-17 3.6.1 EPA Test Method 29 for Metals and PM ........................3-17 3.6.2 EPA Office of Solid Waste Test Method 0010 (SW-846)41 ..........3-18 3.6.3 Spectrometry .............................................3-19 3.6.3.1 Atomic Absorption Spectrometry ........................3-19 3.6.3.2 Optical Emission Spectrometry ..........................3-19 3.6.3.3 Mass Spectrometry ..................................3-19 3.6.3.4 Neutron Activation Analysis ............................3-20 3.6.3.5 X-Ray Fluorescence Spectrometry .......................3-20 3.6.4 Electrochemical ...........................................3-20 3.6.5 Chemical ................................................3-21 3.7 REFERENCES FOR SECTION 3 ..................................3-21 4 FUEL SUBSTITUTION AND SOURCE REDUCTION APPROACHES FOR PARTICULATE MATTER ...............................................4-1 4.1 FUEL SUBSTITUTION ...........................................4-1 4.1.1 Applicability ...............................................4-1 4.1.2 Emission Reductions with Fuel Switching .........................4-2 4.1.3 Costs ....................................................4-5 4.1.4 Other Impacts .............................................4-6 4.2 PROCESS MODIFICATION/OPTIMIZATION ........................4-7 4.3 REFERENCES FOR SECTION 4 ...................................4-9 5 EXHAUST GAS CLEANING SYSTEMS FOR STATIONARY SOURCES ........5-1 5.1 PRETREATMENT ............................................. 5.1-1 5.1.1 Precollection Devices ...................................... 5.1-1 5.1.1.1 Settling Chambers .................................. 5.1-1 5.1.1.2 Elutriators ........................................ 5.1-4 5.1.1.3 Momentum Separators ............................... 5.1-4 5.1.1.4 Mechanically-Aided Separators ........................ 5.1-4 iv CONTENTS (continued) 5.1.1.5 Cyclones ......................................... 5.1-8 5.1.2 Collection Efficiency of Precollectors ......................... 5.1-12 5.1.2.1 Gravity Settling .................................... 5.1-12 5.1.2.2 Momentum Separators .............................. 5.1-12 5.1.2.3 Mechanically-Aided Separators ....................... 5.1-12 5.1.2.4 Cyclones ........................................ 5.1-16 5.1.3 Applicability ............................................ 5.1-20 5.1.4 Costs of Precollectors .................................... 5.1-22 5.1.4.1 Capital Costs of Cyclones ........................... 5.1-22 5.1.4.2 Annual Costs of Cyclones ........................... 5.1-24 5.1.5 Energy and Other Secondary Environmental Impacts of Precollectors . 5.1-27 5.1.6 Flue Gas Conditioning .................................... 5.1-27 5.1.6.1 Sulfur Trioxide Conditioning .......................... 5.1-28 5.1.6.2 Ammonia Conditioning .............................. 5.1-29 5.1.6.3 Ammonium Compound Conditioning ................... 5.1-30 5.1.6.4 Organic Amine Conditioning .......................... 5.1-30 5.1.6.5 Alkali Conditioning ................................. 5.1-31 5.1.7 Costs of Flue Gas Conditioning ............................. 5.1-31 5.1.8 Energy and Other Secondary Environmental Impacts of Flue Gas Conditioning ............................................ 5.1-32 5.1.9 References for Section 5.1 ................................. 5.1-34 5.2 ELECTROSTATIC PRECIPITATORS ............................. 5.2-1 5.2.1 Particle Collection ........................................ 5.2-1 5.2.1.1 Electric Field ...................................... 5.2-1 5.2.1.2 Corona Generation .................................. 5.2-3 5.2.1.3 Particle Charging ................................... 5.2-3 5.2.1.4 Particle Collection .................................. 5.2-4 5.2.2 Penetration Mechanisms .................................... 5.2-5 5.2.2.1 Back Corona ...................................... 5.2-5 5.2.2.2 Dust Reentrainment ................................. 5.2-5 5.2.2.3 Dust Sneakage ..................................... 5.2-6 5.2.3 Types of Electrostatic Precipitators ............................ 5.2-6 5.2.3.1 Dry ESPs ......................................... 5.2-6 5.2.3.2 Wet ESPs ........................................ 5.2-6 5.2.3.3 Wire-Plate ESPs ................................... 5.2-7 5.2.3.4 Wire-Pipe ESPs .................................... 5.2-9 5.2.3.5 Other ESP Designs ................................ 5.2-11 5.2.4 Collection Efficiency ...................................... 5.2-15 v CONTENTS (continued) 5.2.5 Applicability ............................................ 5.2-16 5.2.6 Costs of Electrostatic Precipitators ........................... 5.2-20 5.2.6.1 Capital Costs ..................................... 5.2-20 5.2.6.2 Annual Costs ..................................... 5.2-22 5.2.7 Energy and Other Secondary Environmental Impacts ............. 5.2-24 5.2.8 References for Section 5.2 ................................. 5.2-28 5.3 FABRIC FILTERS ............................................. 5.3-1 5.3.1 Particle Collection and Penetration Mechanisms .................. 5.3-1 5.3.2 Types of Fabric Filters ..................................... 5.3-6 5.3.2.1 Shaker-Cleaned Fabric Filters ......................... 5.3-6 5.3.2.2 Reverse-Air Cleaned Fabric Filter ...................... 5.3-9 5.3.2.3 Pulse-Jet Cleaned Fabric Filter ........................ 5.3-12 5.3.2.4 Other Fabric Filter Designs ..........................