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EPA-450/3-81-002
January 1981
Air
&EPA
AMMONIUM NITRATE
Ammonium Nitrate AP-42
Section 6.8
Reference Number
1
Manufacturing
Industry - Technical
Document
Note: This is a reference cited in AP 42, Compilation of Air Pollutant Emission Factors, Volume I Stationary
Point and Area Sources. AP42 is located on the EPA web site at www.epa.gov/ttn/chief/ap42/
The file name refers to the reference number, the AP42 chapter and section. The file name
"ref02_c01s02.pdf" would mean the reference is from AP42 chapter 1 section 2. The reference may be
from a previous version of the section and no longer cited. The primary source should always be checked.
EPA-450/3-81-002
Ammonium Nitrate
Manufacturing
Industry - Technical
Document
This report has been reviewed by the Emission Standards and Engineering
Division, Office of Air Ouality Planning and Standards, Office of Air, Noise,
and Radiation, Environmental Protection Agency, and approved for puhlication.
Mention of company or product names does not constitute endorsement by EPA.
Copies may be obtained, for a fee, from the National Technical Information
Service, 5285 Port Royal Poad, Springfield, VA. 22161.
TABLE OF CONTENTS
Chapter
1.0
2.0
.......... ..
..
..
The Ammonium Nitrate Industry
2.1 Industry Structure
End
Uses.
2.2 Ammonium Nitrate Products and
2.3 References .
.......
...
Environmental Impacts
6.1 Air Pollution Impact
6.2 Water Pollution Impact
6.3 Solid Waste Impact
6.4 Energy Impact
6.5 Other Impacts
6.6 References
1-1
1-1
1-1
2-1
2-1
2-4
2-8
3-1
3-1
3-9
3-49
4-1
4-1
4-4
4-28
4-35
4-43
5-1
5-1
5-11
5-20
5-28
5-36
6-1
6-1
6-6
6-6
6-6
6-7
6-9
7-1
7-1
7-28
7-29
Appendix A
AppendixB
A-l
B-1
...
.......
ii
LIST OF TABLES
Page
Table
1-1
.........
1-3
1-2
1-4
2-1
2-2
2-2
2-5
2-6
3-1
3-2
3-2
3-10
3-3
3-4
3-20
3-22
3-22
3-7
3-24
3-8
3-29
3-9
3-10
3-34
3-11
3-35
3-12
3-41
3-13
3-44
2-3
3-5
3-6
iii
....
3-33
3-14
3-45
4-1
4-3
4-2
4-29
4-3
4-36
5-1
5-2
5-2
5-10
5-3
5-12
5-4
5-15
5-5
5-17
5-18
5-22
5-23
5-24
5-25
5-26
5-27
5-29
5-6
5-7a
5-7b
5-7c
5-8a
5-8b
5-8c
5-9a
iv
5-9b
5-30
5-9c
5-31
5-10
5-33
5-11
Emission Factors
5-34
5-12
5-35
6-1
6-2
6-4
6-3
6-5
6-4
6-8
7-1
7-2
7-2
Emission Factors
7-3
7-3
7-4
7-4
7-7
7-5a
6-2
7-5b
......
Fac; 1i ty. . . . . . . . . . . . . . . . . . . .
7-8
7-11
7-5c
7-5d
7-15
7-18
7-6
7-7
7-8
7-9
7-10
7-11
7-12
7-19
7-20
7-21
7-23
7-25
7-27
vi
LIST OF FIGURES
Figure
Page
3-1
3-2
3-3
3-3
3-5
3-4
...
3-6
. . . .
3-7
3-5
3-12
3-6
3-14
3-7
3-15
3-8
3-16
3-9
Spinning bucket
3-10
3-11
3-12
3-36
3-13
3-39
4-1
4-5
4-2
4-7
4-3
4-9
4-4
Tray-type scrubber.
4-5
4-12
4-6
4-13
.....
3-17
3-26
....
...........
vii
3-30
4-10
....
....
....
4-7
4-8
4-9
4-18
4-10
4-20
4-11
4-12
4-13
.................
4-24
4-14
Fabric filter.
4-26
4-15
4-16
4-33
4-17
4-34
4-40
4-18
4-14
4-17
..
4-23
...
5-1
5-2
5-3
..
5-6
5-4
5-7
5-5
5-8
7-1
7-10
7-13
7-2
viii
5-4
5-5
PURPOSE
The purpose of this document is to present information on the
emission levels, control techniques and costs associated with the
control of particulate emission sources and facilities in the ammonium
nitrate (AN) solids producing industry. The industry, emission sources
and existing control techniques are described and discussed. Control of
solution formation processes and emissions are not discussed, although
uncontrolled emissions data are presented.
12 SUMr4ARY
1.2.1 Industry Structure
The ammonium nitrate industry produces AN in both solid and solution
form. Solids are primarily manufactured in three sizes: high density
prills, low density pri11s and granules. High density prills and granules
are used as fertil izer, while low density prill s are used as fertil izer
or -i~--~~pl~i~;;-:~-Ammoni~-~-~i-t~;-t~--~~l~-t i~~~d_-~-;;-~sed-~--i~-~t 1,i; e;" 0 r
are concentrated for use in solids formation processes. There are
66 plants in the United States producing either AN solution alone or
both solution and solids. In 1980, ammonium nitrate production is
expected to be 10.08 Tg (11.10 million tons).
1.2.2 Processes and Emissions
The production of AN can be divided into several steps or unit
processes. Unit processes in the ammonium nitrate industry include AN
solution synthesis, solution concentration, solids formation (prilling
and granulation), solids finishing, solids screening, solids coating,
and bagging and/or bulk shipping. Uncontrolled AN particulate emission
rates from these unit processes range from 0.03 g/kg (0.06 lb/ton) of AN
produced for the concentration process to 147.2 g/kg (294.6 lb/ton) of
AN produced for a solids producing process (granulation). The most
1-1
1-2
TABLE 1-1.
Model
Plant
Number
H 1-3
Control
Alternative
High Density
Pri 11 ing
1 (ELOC)
2
3
4
4a
.......
w
L 1-3
1 (flOC)
2
3
Prill Tower
0
0
Granulation
1 (ELOC)
2
X (Option 1)
X (Option 2)
X (Option 3)
X
X
X
X
Prill Tower
Predryer, dryer
and cool er
0
0
X (Option 1)
X (Option 2)
Granulator
G 1-3
Cooler
X
X
X
Cooler
*Options 1, 2, and 3 correspond to different control devices and different levels of control for the
prill towers as explained in Chapter 5.
0
X
- Optional Control
TABLE 1-2.
Production
Capac1ty
My/Day
(Tons/Day)
Control Alternatives
Control Alternatives
4a
4a
.......
-Po
If-I
363
(400)
1.40
(2.80)
0.75
(1.50)
0.30
(0.60)
0.10
(0.20)
0.10
(0.20)
3.77
(3.42)
3.84
(3.58)
3.31
(3.00)
8.36
(7.58)
2.61
(2.37)
H-2
726
(800)
1.40
(2.80)
0.75
(1. 50)
0.30
(0.60)
0.10
(0.20)
0.10
(0.20)
3.12
(2.83)
3.25
(2.95)
2.73
(2.48)
7.44
(6.75)
2.25
(2.04)
H-3
1089
(1200)
1.40
(2.80)
0.75
(1. 50)
0.30
(0.60)
0.10
(0.20)
0.10
(0.20)
2.87
(2.60)
2.97
(2.69)
2.58
(2.34)
7.22
(6.55)
2.03
(1.84 )
L-l
181
(200)
2.80
(5.60)
0.85
(1. 70)
0.40
(0.80)
0.20
(0.40)
2.88
(2.61)
3.65
(3.31)
6.14
(5.57)
11.29
(10.24)
L-2
363
(400)
2.80
(5.60)
0.85
(1. 70)
0.40
(0.80)
0.20
(0.40)
2.08
(1.89)
2.60
(2.36)
4.35
(3.95)
9.47
(8.59)
L-3
816
(900)
2.80
(5.60)
0.85
(1.70)
0.40
(0.80)
0.20
(0 .40)
1.64
(1.49)
2.05
(1.86)
3.46
(3.14)
7.97
(7.23)
G-l
363
(400)
0.95
(1.90)
0.30
(0.60)
-6. lOb
(-5.53)
G-2
726
(800)
(1. 90)
0.95
0.30
(0.60)
6-3
1089
(1200)
0.95
(1.90 )
0.30
(0.60)
_6.25 b
(-5.67)
-6.25 b
(-5.67)
-6.25 b
(-5.67)
Granulation Plants
-6. lOb
(-5.53)
_6.lO b
(-5.53)
INDUSTRY STRUCTURE
Ammonium nitrate, or Norway saltpeter (NH 4 N0 3), is a hygroscopic
colorless solid which is produced from ammonia and nitric acid. Ammonium
nitrate is an oxidant containing a high proportion of nitrogen (33.5 percent
by weight), which makes it desirable for manufacture of explosives and
for use as a nitrogen fertilizer.
During World War II, the ammonium nitrate industry (SIC 28731) was
greatly expanded by the U.S. Government in order to manufacture munitions.
Following the war, the federal government sold the ammonium nitrate
plants to private industries who began marketing ammonium nitrate as a
fertilizer. Early product drawbacks and consumer reluctance were soon
overcome and ammonium nitrate developed into a major fertilizer compound.
Presently in the United States, 41 companies are operating 66 ammonium
nitrate plants. Total 1980 production capacity for the industry is
estimated to be 10.08 Tg (11,101,000 tons) of ammonium nitrate. Table 2-1
contains a listing of ammonium nitrate plants, their location, the type
of product they manufacture, their production capacity, and the year
they began production.
Historically, the Southeast has shown the greatest growth in production
capacity, while the Northeast has shown the greatest decline. At present
the largest ammonium nitrate producing area lies in the central and
southeastern part of the country. The top six AN producing states,
Kansas, Missouri, Oklahoma, Louisiana, Mississippi and Georgia, account
for 47 percent of total U. S. ammonium nitrate production capacity.l
2-1
TABLE 2-1.
Plant Location
COJl11lny Name
~1~ ~roducts
A~1HONIUM
and
C~~.
Annual
Capacity
(10 3 Mg)
Fonn of ANa
~oiut,ons.
Inc.
Oate on Stream
I1U
prills
1956
Helena. AR
Geismar. LA
Omaha. NB
91
365
102
Solutions
Solutions
Solutions
1967
1967
1956
Hanni ba1. MO
'ISO
HO & LO prills
1966
Benson. A:Z.
112
LO prill s
1945
Woodward. 0tC
105
Solutions
1978
Calumet Nitrogen
HalllllOnd IN
50
NIA
Odessa. TX
75
Solutions. (captive
NIA
for nitrogen solutions)
CF Industries. Inc.
Donaldsonville. LA
Fremont. !'fB
Orlean. NY
Terre Haute. IN
203
Tunis. NCb
:363
Tyner. TN
:!13
30
64
145
Solutions
Solutions
Solutions
Solutions. LO
prill s
Solutions. HO
pri 11 s
Solutions. HO
pri 11 s
1978
1966
1967
1964
1969
1962
Cheyenne, WY
66
Solutions. HO
pri 11 s
1965
Augusta. Ga
539
Solutions, LO
& HO prill s
1963
Beatrice. NB
157
Granular
1966
Seneca. IL
179
HO &LO pri11s
1967
Escambia Chemicals
Pace. FL
HD prills
1980
Esmark. tnc.
Estecn Gen. Chems. Corp.
Beaumont. TX
lB1
Solutions. HD
pri 11s
1967
Oodge City. KS
Lawrence. KS
73
417
Solutions
Solutions. HO
pri 11 s
1975
1954
Clinton. IA
132
Solutions. HO
LO pri 11 s
1963
Goodpasture. Inc.
Oi.itt. TX
Solutions
1971
w.
Wilmington. Ne
'197
Solutions. LO
pri 11 s
1963
Pittsburg. KS
3B7
LO prills
1940
Bessemer, AL
Carthage. MO
Donora. PA
Hercules. CA
23
14
'136
'126
1955
1966
1969
NIA
louisiana. MO
454
Grains
Grains
lO pri1ls
Solutions. LO
pri 11 s
Solutions. LO
pri lls
Marseilles. Il
126
Solutions. HD
pri 11 s
1964
'3ainbridge. GA
Nortl: Bend. OH
Savannah. GA
95
229
54
Solutions
S.,lutions
Solutions. LO
pri 11 s
Solutions
1965
1965
1957
Solutions. HO
prills
1951
Illinois
~itrogen
Corp.
90
&
2B
Tampa. Fl
~ississippi
Che.. Co.
47
Yazoo City. MS
2-2
562
1961
1960
TABLE 2-1.
(continued)
Company Name
Plant Location
Annual
capacitr
(10 3 Hg
Monsanto Co.
E1 Do rado, AR
Luling, LA
227
181
HI) pri 11 s
HD !o LO prills
1949
Nitram, Inc.
Tampa, FL
272
Solutions, LD
prills
1963
N-Ren Corporation
Carlsbad, NM
E. Dubuque, IL
Pine Bend. MN
87
209
1976
NIA
1962
Pryor. OK
139
LD prills
Solutions
Solutions, HI)
& LO prill s
Solutions,
granular
B3
Fol'lll of AHa
Date on Stream
1954
1967
Hanford, CA
20
Solutions
1965
Finley, WA
40
Solutions
1963
Beatrice, NB
Etter, TX
68
163
Solutions,
LD prills
1965
1950
Reichhold Chemicals
St. Helens, OR
22
Solutions
1968
J. R. Simp10t Co.
Pocatello. ID
18
Solutions
1974
Standard Oil of CA
Chevron Chem. Co.
Fort Madison, IA
172
1961
Kennewick, WA
214
1960
Richmond. CA
68
Solutions.
granular
Solutions,
granular
Solutions
Lima, OH
58
Solutions
1956
39
Solutions
1972
Port Neal. IA
"130
Solutions, HD
prills
1967
Joplin, MO
Tamaqua, PA
146
14
HI)
!o LO prills
Crystal
1958
1956
Brea. CA
113
Solutions. HD
pri1ls
1955
U. S. Anny
Kingsport. TN
MIA
MIA
1967
U. S. Steel Corp.
Cherokee, AL
136
1962
Crystal City. MO
223
Tyler Corp.
Atlas Powder Corp., subs.
NIA
Geneva, UT
91
Solutions, HD
pri 11s
Solutions, LD
pri lls
LD prills
a Centro. CA
Hellll, CA
4D
4D
Solutions
Solutions
1968
1976
Williams Co.
Agrico Chem. Co.
Verdigris. Olt
478
Solutions
1975
2-3
10,081
1954
1957
Year
Capacity
(103 Mg)
Production
(10 3 Mg)
Capacity
utilization
(percent)
1961
Z,8SJ
4,017
71.7700
1962
2,981
4,239
70.3232
1963
3,336
4,720
70.6780
1.964
3,867
5,3n
71.9174
1965
4,203
6,013
69.8986
1966
4,467
7,071
63.1735
1967
5,137
7,617
67.4412
1968
5,4-4S
7,804
69.8104
1969
5,089
8,157
62.3881
1970
5,641
8,025
70.2929
1971
6,025
8,124
74.1630
1972
6,164
7,888
78.1440
1.973
6,251
7,843
79.7016
1974
6,549
7,637
87.0630
1975
6,n1
7,995
84.6904
1.976
5,353
8,250
n.0061
19n
6.n1
8,317
81.4116
1978
6,645
8,478
78.3793
1.9i9
7,074-
9,315
75.9420
2-5
TABLE 2-3.
Number of
plants
Product
Estima ted
capacity
(10 Mg)
producti~n
Prills
Low density
10
1,276
High density
12
1,396
1,880
29
4,552
Granul es
611
Grains
37
Crystals
14
38
5,314
Total Sol id
2-6
inroads into the high density prill market. This is partly due to the
fact that granules have more abrasion resistance and a higher crushing
strength than pril~s.
Within the United States, ammonium nitrate competes with a number
of other nitrogenous fertilizers. The major competitors are anhydrous
ammonia, aqueous ammonia, nitrogen solutions, urea and ammonium sulfate.
Since 1974, the demand for ammonium nitrate fertilizers has been decreasing,
particularly for solid ammonium nitrate fertilizers. In 1979, ammonium
nitrate accounted for 11 percent of all nitrogen consumed in the United
States as fertilizer. 4 The increasing use of urea fertilizer is one
reason for the decline. However, in contrast to the decreasing demand
for solid ammonium nitrate fertilizers, ammonium nitrate explosives
demand has risen steadily.3 Currently there are no economically viable
alternatives to ammonium nitrate for use in explosives.
2-7
2.3 REFERENCES
1.
2.
3.
Reference 1, p. 14.
4.
Reference 1, p. 12.
2-8
INTRODUCTION
This chapter describes uncontrolled emissions from the ammonium
nitrate (AN) processing industry. Section 3.1 presents the basic AN
process chemistry, a manufacturing overview and an emissions overview.
Section 3.2 describes each process and presents its emissions.
3.1.1 Process Chemistry
Ammonium nitrate is produced as an aqueous solution by the neutralization
of nitric acid with ammonia.) The reaction is represented by the equation:
_0'
_.
decomposition
__
~.
__
' _ _ ' __
<01(
3-1
III
IV
V
Morphology
cub i c
o tetragonal
y rhombic
13 rhombic
a tetragonal
E
Process Overview
The process for manufa~turing ammonium nitrate (AN) contains up to
seven major unit operation~ The basic arrangement of these operations
is shown in Figure 3-1.\ These major operating steps are:
(1) Solution form~on or synthesis
(2) Solution concentration
(3) Solids formation
(4) Solids finishing
(5) Solids screening
(6) Solids coating
(7) Bagging and/or bulk shipping
3.1.~
3-2
SOLIDS
FORMATION
NITRII
ACID
BUlK
OFFSIZE RECYCLE
!..oJ
I
!..oJ
SOLUTIONS
Figure 3-1.
SHIPPING
3-4
AMMot~IA
7:---
NITRIC 1 __
ACID C
W
I
U1
'OrTIONAL
Figure 3-2.
ADDITIVE'
AMMONIA
NITRIC
ACID
SOLUTION
FORMATION
I-
SOLUTiON
CONCENTRATION
I-I~
PRILLING
r--.
PREDRYING
DRYING
r-.
~-
OFFSIZE RECYCLE
I
0'1
BAGGING
14-
STORAGE
f4-
COATING'
SCREENING
,
BULK
SHIPPING
Figure 3-3.
COOLING
f----e-o
AMMONIA~
.-1
COATINO
)-
W
I
......
i
""'OPTIONAL
Figure 3-4.
i OVERSIZE!
R~CYClE
BAGGING
(~otary
3-8
3-9
Emission Source
w
I
Ammonium Nftrate l
Part iculate
g/kg (lb/ton)
Solution formation
lIeutra 1tzer
c!vaporators/concentrators
2.6
0.03-0.07
(5.3)
(0.06-0.14)
Solids formation
low density prill tower
high density prl1l tower
cI rllll granul ator
\Ian granulator
0.39
1.6
147.2
1.34
~O. 78)
3.2J
(294.6
(2.68)
IInmoniab
g/kg (1b/ton)
18.0
(36.0)C
0.066-4.2 (0.13-8.3)
0.13
28.6
29.7
0.07
(0.26)
f57.2J
59.5
CO.1S)
I-'
Solids finishing
to predryer
1.0 dryer
LD cooler
lID cooler
Rotary drllll granulator cooler
Pan granulator precooler
Pan granulator cooler
10.1-37.3
11.4-93.7
12.3-37.8
0.83
7.5-8.6
18
0.25
120.2-74.6)
22.8-187.4)
24.5-75.7)
(1.66)
(15-17.3)
(36)
(0.49)
0-0.29
0-1.3
0-0.29
0-0.03
0-1.2
0
0
rOOS81
0-2.6)
0-0.58)
0.05)
0-2.3)
0
0
afterward. Ammonia and nitric acid emissions are also presented in this
chapter; but they also are not discussed further in this document.
3.2.1 Neutralization
The reaction between nitric acid and ammonia, an exothermic acidbase neutralization, is carried out in a reactor or neutralizer. A 55
percent nitric acid stream is used in the reaction to produce a 61
percent ammonium nitrate solution. The heat generated in this reaction
is used to drive off a portion of the remaining water, further concentrating
the solution to 83 percent ammonium nitrate. The reactor, where neutralization is actually accomplished, can be a one or two-stage unit. In a
two-stage operation an excess of nitric acid is fed to the first stage
reactor. The reaction products from the first stage flow to a second
reactor where additional ammonia is introduced to insure that all of the
nitric acid reacts. 9
A single-stage reactor (Figure 3-5) may operate with excess ammonia
(NH ), excess nitric acid (HN0 ) or under neutral concentrations. Most
3
3
plants today operate the neutralizer with excess ammonia. Reactors are
operated under pressure, at atmospheric pressure or under a vacuum.
There are several types of single-stage neutralizers used in the industry;
these include thermosyphon, forced circulation, tank type units and a
proprfetary system developed by Mississippi Chemical Company.
Emissions occur when steam is liberated during the course of the
exothermic neutralization reaction. Emissions of ammonium nitrate and
ammo~ia or nitric acid occur as this steam is vented from the neutralizer
vesse\? ,Ammonia emissions are a result of excess ammonia in th~ ne~trali
zation and nitric acid emission are a result of excess _--;.nitric acid. EPA
test results of an atmospheric neutralizer operating under excess ammonia
are reported in Table 3-2. The ammonium nitrate emissions were measured
to be 2.6 g/kg (5.3 lb/ton) of ammonium nitrate produced. Testing
details can be found in Appendix A.
3.2.2 Evaporation/Concentration
The 83 percent AN solution produced in the neutralizer is concentrated
further by heating the solution in an evaporator. This step yields a
... ~._~ ..
3-11
CHEMICAL
STEAM
t.l1$T ElIt.lIHATOR
Nil
..----.
NEUTRALIZER
i--_--I(""',r-------
a 3 -,.
A H TO
j)ROCESS
VAPOR! ZED
NH3 ------~---~
- - -
TAUK
-
FE~D
---------~
-- - W(AK
llOUOR
RECYCLE
(OPTIONAU
Figure 3-5.
Single stage
3-12
neutralize~
3-13
AIR A.L'tD
WATER VAPOR
t
ENTRAINMENT
SEPARATOR
IJNDERFLOl-l
WEI .-::t=:::r-",
FEED
DISTRIBUTORS
AN SOLUTION
BLOloJER
AMBIENT
AIR
STEM1
w---STEA~ f
AIR SWEPT
FALLING FILM
EVAPORATOR
AIR
HEATER
...-Jf-_ _
PACKED
SECTION -+---T'
(OPTIONAL)
CONDENSATE
-CONDENSATE
HEATED
-AIR
TED
SOLUTION
CONCENl'R..~
AN
Figure 3-6.
=:
<
/\
=:
:<
~!=:
<
:z:
<
=
~
C
In
....-
.....
~
-----------------t-~--~r.'\1.:=..
1
c..
~.
l:~
,...,.
I
M
<1J
:;:,
0'1
....u...
3-15
HEADTANK
CONTAINING
MELT
MULTIPLE
SPRAY HEADS
3-16
MaT FROM ..
~_....,
HEADTAMK
---
..,
ROTATION
HEAD TANK
SPINNING
BUCKET
PRILL
TOWER
Figure 3-9.
Spinning bucket.
3-17
3-18
Prll 1 Tower
de'iign capacity
Mg/day (Tons/day)
Plant
......
Temperature
AN prills
K
(oF)
372
(210)
397
(255)
358
(185)
389
(240)
12.55
(2.23)
389
(240)
4.48
(0.795)
372
(210)
4.48
(.795)
372
(210)
--
--
--
--
10,336
(365,000)
2.06
(6.76)
67.1
(220)
6,286
(222,000)
3.14
(336)
29.9
(98)
3,766
(133,000)
2.01
58.1
(625)
61
(200)
16,254
(574,000)
4.66
(15,31 )
(400)
37.2
(400)
36.6
(120)
6,343
(224,000)
2.84
(9.33)
(750)
45
(484)
42.7 b
(140)
4,663
(200,000)
2.10
--
383
(230)
(790)
298.9
--
364
(195)
(452)
544
(600)
41
(441 )
--
--
83.6
(900)
838c
(922)c
33.4
(360)
363
(400)
31.2
998
(t ,100)
363
680
(320,000) 0.51
9,061
44.8
(147)
aThis tower r.an prvuuce both flO and lD prills - data shown are for HD prill production.
bReported as "free fall" height.
cReported as production capacity.
717
Pressure head
at droplet
device
kPa (psig)
--
42
Droplet
fonnation
technique
2.86
(625)
Tower
air velocity
Meters/s
(fps)
(254,930)
567
46.9 b
(154 )
24.4 b
(80)
51.8 h
(170)
Tower
3airflow (actual)
m /min
(cfm)
7,219
Tower
cross-sectional
Tower height
area
meters 2 (feet 2) Meters (feet)
(3,217)
--
---
14.94
(2.65)
--
TABLE 3-4.
Plant
w
I
Prill Tower
Des ign Capaci ty
Mg/day (tons/day)
Tower
Cross-Sectional
Area
Meters 2 (feet2)
Tower Height
Meters (feet)
Tower
A!rflow (Actual)
m /min
(cfm)
Tower
Air Velocity
Meters/s (fps)
Droplet
Formation
Technique
Pressure Head
at Droplet
Device
kPa (psig)
181
(200)
--
--
--
--
--
223
(245)
18.2
(196)
1.699
(60.000)
1.56
Hb
525
(576)
8i.6
(900)
8.673
(305.000)
1. 72
(5.65)
410
(450)
18.6
(200)
42.7 d
(140)
51.8 d
(170)
36.6d
(120)
2.832
(100.000)
2.54
514
(564)
41
(441 )
--
4.248
(150.000)
1.73
273
(300)
65.4
(704)
54.9
(l80)
5.437
(192.000)
1.39
726
(800)
182.3
(1962)
67.07
(220)
7.796
(275.320)
0.71
N
0
--
--
Temperature
AN prills
K
(oF)
--
----
355
(180)
350
(170)
366
(200)
366
(200)
350
(170)
to melt temperature. The fume may recombine upon exiting the tower to
form sub-micron AN crysta1s. 12
~a rti cul ate emi ss i on rates from pri 11 towers may be affected by the
following parameters:
(1) Tower airflow
(2) Spray melt temperature
(3) Condition of spray device orifices and type of spray device
(4) Ambient air temperature
(5) Crystal state changes of solid pri11s~
The effect of these parameters on emissions are discussed in the following
paragraphs.
\, Tower airflow affects emissions because it determines the air
velocity in the tower. Increasing tower airflow increases tower velocity
thus increasing entrainment of particles'~ Prill tower emissions may be
very sensitive to tower velocity. For example, one study reports that a
change in velocity from 1 m/sec to 3 m/sec increases emissions by a
factor of 14. 13
( Melt temperature is another significant factor that affects emissions.
As the temperature increases, vapor pressure increases, with a corresponding
increase in the amount of fume generated.~~e spray melt temperature
depends on specific plant operating practice and whether the product is
low or high density prills~ Tables 3-5 and 3-6 summarize melt conditions
for low and high density pp6duction. (on the average, the melt spray in
high density towers is 24 K (45F) hotter than low density spray melt)
Therefore, it is expected that fume emissions would be greater in high
density towers than low density towers)
The condition of the orifices in the spray device can also affect
emissions. Orifices should be round and clean to produce round, correctly
sized prills. If a hole is partially plugged it can produce prills that
are too small, called micro-prills; but more often it will spray in a
manner that produces only fi ne dust. These fi nes can be entrai ned by
the tower airstream and increase particulate emissions. Furthermore, if
a hole is partially plugged so that it sprays at an angle, the sprays
3-21
TABLE 3- 5.
f1EL T STREAM CHARACTERI STI CS FOR LO\~ DENS ITY PRI LL PRODUCTI ON 14
Plant
Temperature
Percent by Weight
Ammonium Nitrate
% H2O
NA
95.0
5.0
K (300F)
K (305 oF)
K (330F)
K (315F)
96.5
3.5
422
425
439
430
96.5
97.0
96.0
3.5
3.0
4.0
416 K (290F)
96.0
4.0
426 K (305F)
96.2
3.8
H
J
Average
NA-Not Available
TABLE 3-6.
Temperature
% ANa
98.4
97.7
97.7
0.5
450 K (350F)
450 K (350F)
453 K (356F)
450 K (350F)
99.0
0.5
455 K (360F)
455 K (360F)
99.8
99.9
458 K (365F)
458 K (365 P F)
99.9
99.0
0.2
O. 1
O. 1
0.2
Average
450 K (350F)
98.9
0.3
Plant
A
G
3-22
14
%H0a
2
0.3
0.2
may impinge on one another, creating fine droplets which form ammonium
nitrate dust and increase emissions. 15 Spinning buckets tend to have
fewer problems with orifice plugging than spray Plates.) However, spray
plates can be vibrated to aid droplet formation and decrease micro-prill
formation. 16
l_Ambient air is used to cool prills. Changes in ambient temperature
affect operation and production parameters, which may affect prill tower
emissions. As the air temperature increases, a greater airflow is
required to cool the prills. The required summer airflow rate is approximately
40 percent greater than the airflow used during winter operation. If
the airflow rate must be increased because of ambient conditions, emissions
will increase due to increased entrainment of microprill~ Higher
ambient air temperatures also cause AN fuming to increase because cooling
is slower at the prill surface. 10
Emissions are also affected by the transition of the prills between
crystal states. A rapid transition in crystal state can cause the prill
to disintegrate. The resulting dust can become entrained in the prill
tower airflow, thus increasing emissions. low density prills are more
sensitive to crystal changes than high density prills, and have a greater
tendency to break up into dust because of their larger void spacing.
Emissions data on high and low density prill towers from EPA and
industry tests are reported in Table 3-7. Uncontrolled ammonium nitrate
emissions from high density prill towers range from 0.81 to 2.74 g/kg
(1.63 to 5.48 lb/ton) of AN produced. Industry and EPA test data on
emission quantities indicate that uncontrolled ammonium nitrate emissions
from low density prill towers range from 0.21 to 0.69 g/kg (0.42 to 1.38
lb/ton) of AN produced. However, industry and EPA data may not be
directly comparable because of differences in sampling and analytical
procedures.
3.2.4 Granulation
3.2.4.1 Drum Granulation. The drum granulator consists of a
rotating horizontal cylinder, either 3.7 or 4.3 m (12 or 14 ft) in
diameter, which is divided by a retaining dam into two sections, the
3-23
TABLE 3-7.
Plant
Product
Ammonium Nitrate C
g/kg
(lb/ton)
High Density
Prills
1.60
(3.20)
High Density
Pri11s
2.74
(5.48)
High Density
Pri 11s
1.16
(2.33)
High Density
Pril1s
1.28
(2.55)
High Density
Pri 11s
0.81
(1.63)
High Density
Pri 11s
1.93
(3.86)
Low Density
Pri 11s
0.21
(0.42)
Low Density
Pri 11s
0.22
(0.45)
Low Density
Pri 11s
0.69
(1.38)
Low Density
Pri 11s
0.60
(1.20)
Low Density
Pril1s
0.47
(0.93)
Low Density
Pril1s
0.49
(0.98)
Zb
Low Density
Prill s
0.39
(0.78)
Ammonia d
g/kg
(lb/ton)
28.6
( 57.2)
0.1.3
(0.26)
3-25
ROTATING
DRUM
AMMONIUM
NITRATE
SPRAY
RETAINING
DAM
W
I
BED OF AMMONIUM
NITRATE GRANUU:S
CONCENTRATED
AMMONIUM
NITRATE
SOLUTION
'"
COOLING
AIR
Figure 3-10.
3-27
3-28
TARI.E 3-8.
Plant
Capacity
Mg/day
Tons/day
Ammonium Nitrate C
Particulate
Ammonia d
, blton
g/kg
lb/ton g/kg
Drum Granulation
Sa
381
420
147.2
295
Kb
249
275
152
305
Kb
352
388
138
277
Pan Granulation
Da
325
358
1. 34
2.68
3-29
29.7
59.5
0.07
0.15
AREA COVERED
BY SOWTION SPRAYS
LARGE GRANULES
LEAVE PAN HERE
Figure 3-11.
3-30
conveyor belt and are removed for further processing. The pan granulator
yields a product which is less spherical and somewhat softer than granules
produced in a rotary drum. 30 Pan granulation also tends to have a
larger recycle to product ratio than drum granulators because almost all
the required bed cooling is accomplished by the cooled recycle particles.
Recycled material consists of undersized and oversized granules.
Undersized granules are used as seed particles and the oversized material
is either dissolved and used in solution formation or crushed and used
as seed. The amount of crushed material used as seed is held to a
minimum since this practice can lead to formation of agglomerates and
weak granules.
Operational parameters which are critical to product quality include
the concentration and temperature of the feed melt, the slope and
rotational speed of the pan, the location of the sprays, and the amount,
size and temperature of the recycle material. 31
Emissions are affected by the following:
(1) Airflow rates over the pan
(2) Rotational speed of the pan
(3) Bed temperature
(4) AN melt spray
(5) Crystal state changes of granules
An increase in the airflow rate can affect emissions by entraining
more fine particles and fume. However, there is very little airflow
over the pan; consequently, entrainment of fine spray or seed granules
is less than that encountered in drum granulation. Operating data
indicate that less than 5 percent by weight of the product is entrained. 24
The rotational speed of the pan can also affect emissions. A
higher rotational speed increases attrition of the granules, thus increasing
emissions.
The temperature of the bed affects granule temperature. If bed
temperature increases significantly, granules will turn to dust and
increase emissions.
3-31
3-32
!'I~nt
"
N
N
w
I
w
w
k
k
C
H
J
L
L
Q
F
Z
Facility
HIgh DensIty Rotary
DrllJ1 Cooler
High Dens Ity Rotary
DrllJ1 Cooler
HIgh Dens Ity Rotary
Drlln Cooler
HIgh DensIty Rotary
DrllJ1 Cooler
HIgh Density Rotary
Drum Cooler
High DensIty
Fluidized Bed Cooler
HIgh Dens Ity
Fluidized Bed Cooler
Rotary Drum Granulator
Rotary Drlln Cooler
Rotary Drlln Granulator
Rotary Drlln Cooler
Rotary Dr... Granulator
Rotary Drlln Cooler
Rotary Drum Granulator
Fluidized 8ed Cooler
!'an Granulator
Rotary Drlln Precooler
Pan Granulator
Rotary Drlln Cooler
Low DensIty
Drum Cooler
Low Density
Drum Cooler
Low Density
Drum Cooler
Low DensIty
Drum Cooler
Low Density
Drum Cooler
Low DensIty
Drum Cooler
Low Density
8ed Cooler
low Density
Bed Cooler
ProductIon capaclt~
My/day (tons/day
AIrflow
scm/Kg (scf/ton)
545 (600)
1496 (48.000)
283 (50)
339 (150)
372 (210)
313 (105)
294 (324)
3281 (105.286)
300 (80)
354 (177)
389 (240)
316 (110)
458 (504)
2811
(90.186)
291 (65)
339 (151)
357 (184)
331 (137)
318 (350)
4535 (145.536)
283 (50)
365 (198)
397 (256)
311 (100)
363 (400)
2333 (74.845)
283 (50)
372 (210)
305 (90)
363 (400)
6065 (194.593)
283 (50)
372 (210)
305 (90)
872 (960)
1223 (39.241)
280 (45)
294 (70)
363 (194)
324 (124)
454 (500)
1800 (57.670)
330 (135)
307 (93)
277 (305)
2150 (68,930)
332 (138)
324 (124)
JOO (81)
272 (JOO)
1940 (62.050)
282 (48)
308 (95)
333 (140)
303 (86)
363 (400)
2770 (88.720)
299 (79)
(102)
333 (140)
J05 (90)
AIr Temperature K~
Inlet
OU e
320 (353)
3200 (102.400)
314 (346)
1610 (51.610)
Rotary
194 (214)
1620 (51.900)
281 (47)
328 (130)
345 (162)
306 (91 )
Rotary
457 (504)
2700 (86.380)
303 (85)
317 (111)
334 (142)
308 (95)
Rotary
453 (499)
1440 (46.150)
289 (60)
316 (110)
333 (140)
304 (88)
Rotary
409 (451)
1740 (55.850)
278 (40)
316 (110)
322 (120)
304 (88)
Rotary
409 (451)
4150 (133.100)
278 (40)
316 (110)
322 (120)
J04 (88)
Rotary
272 (300)
2250 (72.000)
294 PO)
325 (125)
347 (165)
316 (110)
Fluidized
222 (245)
3320 (106.330)
291 (65)
308 (95)
333 (140)
308 (95)
Fluidized
582 (641)
4281 (137.281)
Prill Moisture
wt percent H2O
Inlet
Outlet
Plant
Capaci ty,
tlg/day (lPD)
194
(214)
331
(137)
350
(170)
378
(220)
343
(158)
1560
(49.840)
222
(245)
353
(175)
344
(160)
3.5
2.6
20
350
(170)
350
(170)
3310
(106,000)
457
(504)
345
(162)
344
(159 )
2.5
1.5
10
336
(145)
345
(161)
2570
(82.380)
453
(499)
366
(200)
355
(180)
3.0
1.8
20
366
(200)
344
(161)
1130
(36,060)
409
(451 )
350
(170)
366
(145)
2.5
1.4
30
355
( 180)
322
(120)
1400
(45,000)
409
(451)
350
(170)
336
(145)
2.5
1.4
30
355
(180)
322
(120)
1790
(57.450)
272
(300)
350
(170)
339
(150)
3.5
2.5-3.0
13
366
(200)
339
(150)
2250
(72.000)
479
(528)
3263
(104.649)
w
I
w
33
._~~11
bFluidized bed
Prill Residence
Time. Minutes
Air T~erature K ~
In et
Out et
Plant
Capacf t},
Hg/day (HO)
-----
194
(214)
350
(170)
345
(162)
222
(245)
344
(160)
333
(140)
2.6
1.6
II
457
(504)
344
, (159)
334
(142)
1.5
453
(499)
355
(180)
333
(140)
409
(451)
336
(145)
409
(451)
FD
w
I
w
lt1
----
-~---
370
(206)
345
(161)
1450
(46,410)
20
333
(140)
333
(140)
3480
(111,300)
0.3
10
330
(135)
330
(139)
' 2800
1(89.600)
1.8
0.4
20
366
(200)
333
(140)
322
(120)
1.4
0.4
30
355
(180)
322
(120)
335
(145)
322
(120)
1.4
0.4
30
355
(180)
322
(120)
4240
(136.000)
272
(300)
339
(150)
316
(110)
2.8
0.9
13-23
353
(175)
314
(l05)
2250
;(72.000)
479
(528)
----a
----
34
1080
(34,620)
1990
,(63.830)
!.
2942
(94,324)
COOLER
SHEl.l.
LIFTING
FUGHTS
SHEl.l.
...- - -
L~e~
SUPPORTING
ROLLERS
ENOV1EW
AIR
OUTLET
COOLER
SHELL
CHILLER
AIR
INLET
DISCHARGE
FAN
AIR
DISCHARGE
HOOC
\.
SH EU.-SU PPORTlNG
ROOL~S
COOLED SOLIDS
DISCHARGE
SJCEVIEW
Figure 3-12.
--_._--------.,~,.-.,.,
~_._.-.
3-37
The airflow rate through the drum affects emissions, also. Higher
airflow rates can increase the amount of fines entrained in the air
stream.
(pri 11 and granul e temperature control is necessary to control
emissions. Changes in specific volume of the solid accompany changes in
crystal structure, which is a function of the solid temperat~ Changes
in specific volume may contribute to solid AN disintegration. With low
density prills especially, the change in specific volume increases
emissions through the creation of additional fines. 34 Also, the bed
temperature in the rotary drum cooler can affect emissions indirectly.
Higher bed temperatures require increased airflow rates to cool the
prills. And, as discussed above, higher airflow rates can cause greater
emissions.
Fluidized bed cooling units are also used on drum granulated and
prilled products. A fluidized bed cooler consists of a long narrow
vessel separated into two parts by a horizontal perforated plate (the
bed plate). Conditioned air is blown up through the bed plate to fluidize
the prills or granules in the upper half of the vessel. Hot prills or
granules drop onto the inclined end of the long plate, and displace the
fluidized particles along the bed causing the cooled material to spill
over the opposite end into the outlet chute, as shown in Figure 3_13. 35
The advantages of a fluidized bed cooler are that the capital cost,
size, and weight are lower than for a rotary drum; also, no special
foundations are needed and there is no product abrasion on moving parts.
An additional advantage is that the residence time in the unit is much
shorter than for a comparable rotary unit. It is also reported that the
flow of the fluidizing air can be adjusted so that fines are left in the
product or removed for collection and treatment. 36
Of the two AN plants constructed during the last ten years, both
have employed fluidized bed coolers in their processes. However, there
is insufficient information to conclude that this is an industry trend.
3.2.5.2 High Density Prill Cooling. Because of low moisture
content, high density prills only require cooling when they exit the
3-38
COOLING AIR
EXHAUST
HOT PRILL
INLET
W
J
W
\0
0,
""J!ll!tl~.r&~tg~~~t~~~\~lltrjm~p-t~~.,f{~
~~
:~
:~. '= CC '- <1.....-
(L
_-:.
.....J~(
COOL PRILL
OUTLET
LPERFORATED
PLATE BED
Figure 3-13.
r------
COOLING AIR
INLET
prill tower. The pri11s are usually belt conveyed from the prill tower,
at temperatures of 358 to 389 K (185 to 240F), to a rotary drum cooler.
Internal flights in the cooler lift the prills and cause them to fall
through a countercurrent airflow. The pri11s have a residence time of
8 minutes to approximately 1 hour in the rotary drum cooler depending on
design. 37 Prills are usually cooled to between 305 and 331 K (90 and
137F) and have a moisture content between 0.2 and 0.5 percent by
weight (Table 3_9).37 Airflow rates are reported between 1,496 and
4,535 scm!Mg (48,000 and 145,536 scf/ton) of AN produced. Some plants
report varying the airflow through the cooler to maintain product
outlet temperature at desired levels, while others report varying product
throughput rate to obtain desired product outlet temperature. 38,39,40
The cooling air gains 50 to 88 K (90 to 160F) as it passes through the
cooler. 37 EPA emissions data for a high density prill rotary drum
cooler are presented in Table 3-12. The results of EPA testing indicate
that ammonium nitrate is emitted at a rate of 0.8 g/kg (1.6 1b/ton) of
AN produced.
Fluidized bed coolers are used at two high density prill plants.
Inlet cooling air is reportedly chilled to 280 K (45F) at one plant and
to about 283 K (50F) at the other. One of these fluidized bed coolers,
which operates with an airflow of 6065 scm/Mg (194,593 scf/ton) of AN
produced, reportedly lowers prill temperature from 372 K (210F) to
305 K (90F). No emissions data are available for these units.
3.2.5.3 Granulated product cooling. Both rotary drum and fluidized
bed coolers are employed to cool granulated ammonium nitrate, but rotary
drums are most commonly used. The units operate identically to coolers
in high density pri11ing plants.
Emissions data from EPA testing of two drum granulator coolers and
one pan granulator precooler and cooler are presented in Table 3-12.
Ammonium nitrate emissions from the (drum granulator) coolers are
reported to be 7.5 g/kg (15 lb/ton) and 8.6 g/kg (17.3 1b/ton) of AN
produced. Ammonium nitrate emissions from the finishing equipment for
the pan granulator were found to be 18.0 g/kg (36.0 1b/ton) of AN produced
3-40
TABLE 3-12.
Plant
:=acil1ty
Ammonium nitrgte
particulate
(ib/ton)
g/kg
41
Ammoniac
gjkg
(ib/ton)
0.8
( 1.6 )
0.02
7.5
(15.0 )
8.6
(17.3 )
1.18
Pan granulator
Rotary drum precooler
18.0
(36.0 )
Pan granulator
Rotary drum cooler
( 0.49)
12.3
(24.5 )
Ld
19.2
(38.4 )
Ld
35.5
(70.5 )
37.8
(75.7 )
0.25
3-41
0.29
( 0.05)
( 2.35)
( 0.59)
for the precooler and 0.25 g/kg (0.49 lb/ton) of AN produced for the
cooler. A discussion of the testing can be found in Appendix A.
Operating information on three rotary drum coolers and one fluidized
bed cooler is presented in Table 3-9. In rotary drum coolers, the
granule temperature decreases an average of 25 K (46F). Reported
airflows are 1800 scmft~g (57,670 scf/ton), 1940 scm/Mg (62,050) and 2150
scm!Mg (68,930 scf/ton) of AN produced. For the fluidized bed cooler,
inlet air is cooled to an average temperature of 299 K (78F). The
fluidized bed cooler operates with an airflow of 2770 scm/Mg (88,720
scf/ton) of AN produced and lowers the ammonium nitrate granule temperature
from 333 K (140F) to 305 K (90F). The temperature of the cooling air
increases approximately 13 K (23F). Residence time of the granules in
this cooler is approximately one minute.
3.2.5.4 Low density prill predrying, drying, and cooling. Low
density prills initially have a higher water content than high density
prills. To remove this water, low density prills are dried in three
steps: predrying, drying and cooling. Although cooling is not usually
associated with the removal of moisture, ammonium nitrate coolers do
achieve a small amount of final water removal. These steps are normally
conducted in three separate rotary drums, although one plant (Plant F)
reports the use of three separate fluidized beds. Tables 3-9, 3-10 and
3-11 summarize available information on the operation of coolers, predryers,
and dryers, respectively.
Industry reports that the key parameters monitored to control
predryer, dryer or cooler operations are prill temperature and prill
moisture into and out of the units, and air temperature into and out of
the units. 42 ,43 Plants can control either the airflow rate or the air
temperature to control prill temperature and moisture. Fluidized bed
units generally control airflow rate and rotary drum units generally
I:ontrol air temperature. 44 ,42 The quantitative effect of these parameters
on uncontrolled emissions is not known. However, changes in these and
other parameters can lead to increased emissions, as discussed in Section
3.2.5.1.
3-42
3-43
TABLE 3-13.
Plant
Ammonium Nitrate
particulate b
g/kg
(lb/ton)
Ammoniac
g/kg
(lb/ton)
10.1
( 20.2 )
zd
37.3
( 74.6 )
0.29
Le1
3.2
6.4 )
L~
4.1
8.2 )
a
( 0.58
3-44
Plant
Ammonium nitrgte
particulate
g/kg
(1 b/ton)
Ammonia e
g/kg
(lb/ton)
11.4
( 22.8 )
Zd
93.7.
( 187.4 )
1.3
Le1
22.9
( 45.7 )
Le2
7.8
( 15.6 )
2.6
3-45
contain between 0.13 and 0.4 percent (average 0.21 percent) moisture by
weight. 45 The average cooler is fed low density prills at 333 K (141F)
and cools the prills to an average of 307 K (93F) (Table 3-9). Residence
time in the cooler varies between 10 and 30 minutes. 45 Reported airflows
range between 1440 and 4281 dscm/Mg (46,150 and 137,281 dscf/ton) of AN
produced and are changed depending on the desired product outlet temperature,
inlet air temperature and product throughput rate. Test results on
coolers are presented in Table 3-12. Results of EPA test results show
uncontrolled AN emissions from a low density rotary drum cooler of 12.3
g/kg (24.5 lb/ton) of AN produced and from a low density fluidized bed
cooler of 37.8 g/kg (75.7 lb/ton) of AN produced.
3.2.6 Screening
Screening operations separate offsize ammonium nitrate solids from
the properly sized product. In low and high density prilling plants,
offsize material from the screens is redissolved in water or a weak
solution of ammonium nitrate, then recycled to the solution formation
process. In granulation plants, undersized and oversized granules (the
oversized are first crushed) from the screens are returned to the granulator
as seed material or returned to the solution formation process.
Shaking and vibrating screens are most commonly used in the ammonium
nitrate manufacturing industry. Shaking screens consist of a rectangular
frame with perforated plate or wire cloth screening surfaces, usually
suspended by rods or cables and inclined at an angle of about 15 degrees. 46
Vi brati ng screens have one or more decks, usually pl anar. The screen
forms the floor of a box which is vibrated mechanically or electrically.
The ,a:onium nitrate particles vibrate normal to the screen surface
.~issions are generated by the attrition of the ammonium nitrate
solids against the screens and against one another. Therefore, almost
all screening operations used in the ammonium nitrate manufacturing
industry are enclosed or have a cover over the uppermost screen. The
screening equipment is located inside a building and emissions are
ducted from the proces~ Results of the survey conducted during this
program indicate that this operation is a small emission source, and in
most cases no visible emissions were observed.
3-46
3-47
3-48
3.3
REFERENCES
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
3-49
13.
14.
15.
Shearon, W. H. and W. B. Dunwoody. Ammonium Nitrate: A StaffIndustry Collaborative Report. Industrial and Engineering Chemistry.
45(3): p. 501. March 1953.
16.
17.
18.
19.
Reference 18, p. 2.
20.
21.
22.
Reference 20, p. 2.
23.
24.
25.
26.
27.
28.
29.
30.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
3-51
December 16,
December 16,
43.
44.
45. Memo from Bowen, M. L., Radian Corporation, to file. December 18,
1980. Residence time and prill moisture for low density coolers.
46.
47.
48.
49.
Reference 6, p. 4.
3-52
4.1
4-2
TABLE 4-1.
Process
Fat Illty
.j::o.
Number of Sources
Included In Survey
20
12 a
18
Drum Granulator
6c
Pan Granulatcr
Solids Finistl!!!L
Predryer, Dryer
or cooler
mrous
FIl ter
76d
Wet Scrubbers
Entrainment
Cyclone
Venturi
Other Controls
Tray
Mechanical
Other b None
Fabric
Filter
Dry Cyclone
12
37
12
w
aEleven of ttese scrubbers are fibrous filters and one Is a wetted mesh pad.
Includes knockout chambers, spray towers, etc.
cTwo of the drum granulators have two entrainment scrubbers each.
d
Total number of solids finishing processes with available data. Some will have more than one control device or may be connected In series to a
stngle control device.
b
No. Info.
4-4
AMMONIUM NITRATE
SOLUTION
BYPASS
--t--h
EXHAUST
COLLECTION
HOOD
LIQUOR
IN
CONTROL
DEVICE
...
~--,..-_
Figure 4-1.
~--t..
LIQUOR
OUT
the amount of air requlrlng treatment, thus reducing the size of the
prill tower control apparatus. The major portion of the prill tower
airflow bypasses the collection hood and is vented to the atmosphere
untreated. Any of the following particulate scrubbers can be used in
conjunction with fume collection hoods.
4.2.2 Wet Scrubbing
Awet scrubber is a device in which a particle laden gas stream is
brought into contact with a liquid for the purpose of transferring
particulates from the gas to the liquid stream. There are many different
types of scrubbers and many different techniques to bring about the
gas/liquid contact. Consequently, wet scrubbers exhibit a broad range
of costs, collection efficiencies and power requirements.
The following subsections briefly describe the types of scrubbers
and typical operating parameters encountered in the ammonium nitrate
industry. In the sections below, the cut diameter is used to describe
and compare the performance of various scrubbers. The cut diameter of a
scrubber is the diameter of the particle that the scrubber will collect
at 50 percent efficiency. For example, a scrubber with a cut diameter
of 2 microns will remove particles of 2 microns in diameter at 50 percent
efficiency.
4.2.2.1 Wetted Fibrous Filter Scrubber. The wetted fibrous filter
scrubber is typically used in conjunction with a collection hood, but it
can also be used to control the entire exhaust flow.
This scrubber consists of two series of filter elements separated
by an atomizing spray chamber (see Figure 4-2). Each filter element,
made of compressed glass fibers, is irrigated to remove captured particles.
The exhaust stream first encounters a set of elements of relatively low
fiber density, designated IIspray catcher" elements. These elements
collect the large, insoluble particulates (larger than 3 microns) that
may clog the second set of filter elements. According to the manufacturer's
literature, the dominant collection mechanism for these elements is
inertial impaction. 9 The pressure drop across the IIspray catcher" elements
is 0.25 to 0.50 kPa{l to 2 in. W.G.).
4-6
HIGH EFFICIENCY
ELEMENTS
ATOMIZING
SPRAYS
SPRAY CATCH ER
ELEMENTS
EXHAUST FROM
COLLECTION
HOOD
.--._~--
SCRUBBER
SOLUTION
TANK
FIBER
PACKING
GAS FLOW
SPRAY CATCH ER
ELEMENTS
HIGH EFFICIENCY
ELEMENT
Figure 4-2.
The remaining particulates in the gas stream flow into the spray
chamber where some of them impinge on the water droplets. The particle
laden droplets are then removed from the gas stream by the second set of
filter elements, which are designated as "high efficiency" elements.
These high efficiency elements contain fibers that are compressed to a
greater density than the spray catcher elements. The pressure drop
across these elements is about 1 to 5 kPa (4 to 20 in. W.G.) for prill
tower app1 ications. The manufacturer's 1iterature states that the
dominant collection mechanism for these elements is Brownian movement of
the particles. Brownian movement causes the particles to collide with
the glass fiber mat where they are collected. 12 A collection efficiency
of 95 to 99.5 percent is reported for particles under 3 microns in
diameter, as well as 100 percent collection efficiency for particles
larger than 3 microns. (See Figure 4-3).
The major factor affecting performance of the wetted fibrous filter
scrubber is airflow rate. As stated earlier, the two filters have
different particle collection mechanisms and capabilities. Because of
these differences, the effect on collection efficiency of changes in gas
airflow, particle concentration or particle size is reduced. A decrease
in airflow lowers the collection efficiency of the "spray catcher"
elements which depend on particle impaction, but increases the time
allowed for Brownian movement and, thus, increases the collection
efficiency of the "high efficiency" elements. Higher airflows increase
the inertial impaction of particulates on the "spray catcher" elements,
while reducing the time allowed for Brownian movement on the "high
efficiency" elements. These counter-balancing trends result in negligible
collection efficiency shifts with changes in airflow. The same is also
true for particle size or concentration shifts. 13
4.2.2.2 Tray-Type Scrubbers. A tray-type scrubber is shown in
Figure 4-4. It consists of a vertical tm'ler containing one or more
transversely mounted trays. Particulate laden gas enters the tower
bottom and bubbles up through valves, perforations or other types of
4-8
too
99L~
cst
..
>-
:t
95
z
......
.....
U
t-f
h_
I!..
l1.J
900_
z:
a
t-f
t-
u
......
.....J
...J
a
-!='a
I
\0
80--
70 ,
0.025
0.1
0.3
0.5
Figure 4-3.
11m
CLEAN GAS
OUTLET
r--_~r---
DIRTYGAS<?
INLET
-
i2:L1QUOR
INLET
.......,..
TRAYS
- - - - . SUMP
LIQUOR
OUTLET
Figure 4-4.
Tray-type scrubber.
4-10
openings in each tray before exiting through the top of the tower.
Usually scrubbing liquid is introduced at the top plate, where it flows
across, over a retaining dam, and through a downcomer to reach the plate
below.
Tray scrubbers do not exhibit the same removal efficiency for all
particle sizes. They show a sharp efficiency drop at a specific particle
size, which is detenmined primarily by the diameter of the plate perforations
used. The cut diameter for a well designed tray scrubber is 2-3 microns.
The liquid-to-air ratio for these devices ranges from 670 to 2010 liters/1000
m3 (5 to 15 gal/1000 ft 3 ).15
The major factor affecting efficiency for a tray scrubber is pressure
drop. Generally, higher pressure drops result in greater removal
efficiencies. The number of trays, the size of the orifices in the
tray, and the velocity of the gas stream through the scrubber control
the pressure drop of the scrubber.
Manufacturers' perfonmance curves show an increase in particulate
removal with the addition of tower trays. Figure 4-5 illustrates this
effect for a tray scrubber used in the ammonium nitrate industry for a
variety of particle sizes. The efficiency of the vertical axis, tenmed
standard efficiency, is for a standard 0.37 kPa (1.5 in W.G.) pressure
drop per tray.
Increasing the pressure drop across each tray through the use of
smaller orifices also increases removal efficiencies. Figure 4-6
illustrates this effect. For any given scrubber efficiency, the efficiency
at a higher pressure drop can be read.
A higher liquid-to-gas ratio can usually increase particulate
removal. However, an optimum liquid flow rate is usually Maintained,
which insures adequate liquor for particulate removal without blocking
the airflow through the tray orifices.
4.2.2.3 Spray Tower Scrubbers. Spray tower scrubbers (Figure 4-7)
typically consist of a vertical or horizontal tower containing banks of
spray-nozzles. Either countercurrent, concurrent or crossflow spray
configurations are used to spray droplets into the gas stream.
4-11
100
99
98
97
96
>.
r::
OJ
.,..
u
.,..
95
94
IfIf-
.t::o
W
"t:S
93
s...
r::
rd
+J
Vl
92
91
90
89
88
87
86
0
10
100
r-
-------------------------------------:;~=-~
98
t!J
:3:
96
....c
III
94
>.
u
c:
....
.,..
''..--
QI
92
90
I~ - - - -
"t:J
.p.
I
l.---'
l..
ld
"t:J
C
08
VI
06
84
02
80 I
90
IB
91
92
/
93
94
95
96
97
Figure 4-6.
98
99
100
iI
II
),
l.l
><
;:><
7<
7<;;
...
INLET
>
LIOUOR OUTLET
Figure 4-7.
4-14
Particles in the gas stream impinge on the liquid droplets, then are
collected and removed from the bottom of the tower. Droplet properties
are defined by the nozzle configuration, the type of liquid being atomized,
and the pressure at the nozzle. Nozzle pressure is typically 790 to
1,480 kPa (100 to 200 psig) but can be as high as 2,860 kPa (400 psig)
to remove submicron particles. 17 ,18
Pressure drops across these scrubbers typically range from 0.120.50 kPa (0.5-2 in. W.G.), with gas velocities of 0.37 to 1.5 m/sec (1.5
to 5.0 ft/sec). The liquid-to-gas (L/G) ratio used in spray towers is
generally 400 to 2674 liters/1000 m3 (3 to 20 gal/1000 ft 3).18,19 No
performance curves are available for these scrubbers.
Factors reported to affect spray tower performance include droplet
size, relative velocity between droplets and gas airflow, and the liquidto-gas ratio. Large droplets provide less total surface area for impaction,
thus decreasing the spray tower's particulate removal efficiency. On
the other hand, small droplets increase particulate removal efficiency,
since a larger total surface area is available for particle capture.
The relative velocity between droplets and gas airflow also determines
removal efficiency. Large droplets have a higher relative velocity and
improved chances of particle-droplet collisions because of the droplet's
larger terminal settling velocity. Smaller droplets have a lower relative
droplet-to-gas velocity, and, if too small, will be entrained in the
rising gas stream. Therefore, an optimum droplet size can be found to
enhance spray tower efficiency, depending on the particle size distribution
and the flow rate of the gas stream. One optimum droplet size reported
is in the range of 500-1,000 microns for particle sizes ranging from 210 microns. 19 Spray towers are capable of handling large gas airflows
if the droplet size and pressure are adjusted accordingly.
The liquid-to-gas ratio also impacts tower performance. It must be
high enough to insure effective particulate capture by the water droplets,
but not so high that it hinders the flow of gas through the spray tower.
4-15
4-16
TOP vIEW
DIRTY
GAS INLET
CLEAN
GAS OUTLET
LIQUOR
INLET - - - - \
. .
':->'.'\2:'-:"
.
I
. . .'....
\
FLOODED
ELBOW
'
CYCLONIC
SEPARATOR
,\.
\'
'
" . . '
,.,., \
SIDE VIEW
LIQUOR
OUTLET
Figure 4-8.
99.9
995~
99.0
p~W.G.
30"
97
95
>u
z
w
(3
.pa
I
......
00
90
80
u:
U.
-'
70
>
a
~
w
a:
60
.2
.3
.4
.5
.6.7
.8.9 1.0
Figure 4-9.
duct (see Figure 4-10). The airflow atomizes some of the liquid into
droplets; these act as a particle collecting and mass transfer surface.
Particle collection results from both inertial impaction of the particles
in the gas stream on the liquid surface and by impingement of the particles
on the atomized droplets. 26 The particle laden droplets are removed
from the gas stream by gravity and a set of spinner vanes. The spinner
vanes force the droplets to contact the liquid surface and the sides
of the device where they flow down to the sump.
The cut diameter for this type of entrainment scrubber ranges from
0.08 to 0.3 microns. The pressure drop ranges from 1-4 kPa (4-16 in
W.G.).27 Figure 4-11 presents the collection efficiency curves for this
scrubber as a function of particle size and pressure drop.
The most important factor determining entrainment scrubber performance
is pressure drop. Pressure drop may be adjusted by changing the liquid
level in the sump.28 Too low a pressure drop reduces impaction which
decreases the scrubber collection efficiency. An excessive pressure
drop reduces collection efficiency because of insufficient 1iquid to gas
contact. Pressure drop is affected by gas airflow, but in entrainment
scrubbers it is also affected by gas velocity. Entrainment scrubbers
depend on the velocity of the inlet air to atomize the scrubber liquid.
Therefore, even modest turndowns or reductions in air velocity will
reduce the scrubber's collection efficiency. Entrainment scrubbers used
in the ammonium nitrate industry handle the turndown problem by adjusting
the gas nozzle, which directs the gas airflow into the liquid, to accomodate
changes in the inlet air velocity so that collection efficiency will not
be affected. 27
4.2.2.6 Mechanically Aided Scrubbers. Mechanically aided scrubbers
rely on fan blades for particle collection. Scrubbing liquid is typically
introduced at the hub of the rotating fan blades. Particles in the gas
stream are captured as they impinge on the blades, and on the liquid
droplets atomized by the fan blades. Some liquid runs over the blades,
washing them of collected particles. This liquid atomizes as it leaves
4-19
OUTLET
SPINNER
VANES
INLET---....
LIQUOR
INLET ---II"
LIQUOR
OUTLET
Figure 4-10.
H.80
l;
is
~\
I H .9
I ~.OQ
~I
~i
$1
~I
H.OO
glCS'
u
9!.OO
,tclCO
I
;._o.._J::._-:1~
+-
-+
2.0
5:0
:::' IQ.CO
,a:o
Figure 4-11.
the fan wheel and is recaptured by the fan housing, which drains into a
sump. Figure 4-12 shows an example of a mechanical centrifugal scrubber.
Pressure drops for these scrubbers are low {0.25-1.5 kPa (1-6 in.
W.G.)) and have little effect on removal efficiency, because the fan
blades primarily atomize the scrubber liquor instead of increasing the
gas flow rate and also serve as a collection device. 30 ,31 Mechanical
centrifugal scrubbers generally have a cut diameter below 1 micron and
1iquid-to-gas ratios of 2680 to 5360 1iters/1000 m3 {20 - 30 gal/1000 ft 3).3l
No performance curves for these scrubbers are available.
One factor affecting performance of this device is the amount of
liquid on the fan blade. If too little liquid is used, the particles in
the gas stream will pass on through the device. Too much liquid increases
the amount of wastewater to be handled, but does not significantly
increase performance. Changes in gas flow do not significantly affect
scrubber performance. However, higher fan velocities generally cause
greater impingement of particles on the fan blades, increasing particulate
removal. 32
4.2.2.7 Wet Cyclones. Wet cyclones, usually cylindrical in shape,
impart a rotational motion to the incoming gas stream by tangentially
introducing the gas stream into the scrubber, or by directing the gas
stream against stationary swirl vanes (Figure 4-13). Liquid is sprayed
through the rotating gas stream either outward from a central manifold,
or inward from the collector wall. Particles in the swirling gas stream
impact on the liquid droplets. The centrifugal force and high velocity
of the gas stream carry the particle laden droplet out to the cyclone
wall, where a continuous water film washes it down the wall and out of
the system.
Wet cyclones generally operate at 0.50-1.5 kPa pressure drops
(2-6 in. W.G.).8 This pressure loss is directly proportional to the gas
stream flow rate. Wet cyclone scrubbers are designed for cut diameters
between 2 and 3 microns s with liquid-to-gas ratios of 268 to 1340 liters/1000
m3 (2-10 gal/10DD ft 3).33 No efficiency curves for these scrubbers are
available.
4-22
WATER
SPRAYS
Figure 4-12.
4-23
GAS
/OUTLET
GAS
INLET~
LIQUID
SPRAYS
~L1QUID
INLET
LIQUID
OUTLET
Figure 4-13.
Since it directly influences pressure drop the gas flow rate is the
most important factor affecting the performance of a ~et cyclone. If
the gas flow rate is lowered, scrubber efficiency will be reduced.
4.2.3 Fabric Filters
Fabric filters (baghouses) are high efficiency collection devices
used quite extensively in the ammonium nitrate industry for control in
bagging and coating operations. An average removal efficiency for a
fabric filter is 99 percent. 34 Figure 4-14 depicts a typical fabric
filter system. In the type of design shown, the airstream enters the
baghouse and is pulled up into fabric sleeves located throughout the
baghouse. The air pulled through these fabric sleeves is exhausted to
the atmosphere, while dust remains trapped in the weave of the fabric,
forming a layer of dust on the bag. The pressure drop through the bag
increases as this dust layer builds up. The dust is eventually removed
from the bag by one of several bag cleaning methods.
An important operating principle for fabric filters is that effective
filtering of the dusty airstream is accomplished, not only by the fabric,
but also by the dust layer which forms on the fabric. This dust layer
bridges the gaps between adjacent fibers and increases the chances of
impaction and interception of small particles. For this reason, too
frequent cleaning can actually decrease efficiency by not allowing a
dust layer to accumulate between cleaning cycles.
Materials available for bag construction are numerous. They include
cotton, Teflon R, coated glass, orlon, nylon, dacron and wool. The type
of material selected depends upon many factors, including temperature,
frequency of cleaning, ease of removing particles, resistance to chemical
attack, and abrasion characteristics of the collected particles.
Factors affecting baghouse performance include air-to-cloth ratio,
type of fabric used, method and interval of cleaning, pressure drop, and
the properties of the exhaust being cleaned. Air-to-cloth ratio is
dimensionally equivalent to a velocity; and it indicates the average
face velocity of the gas stream through the effective area of the fabric.
4-25
BRANCH
HEADER
CLEAN AIR
OUTLET
NOZZLE
BAFFLE
PLATE
PYRAMrOAL OR
TROUGH HOPPERS
ACCESS
DOOR
Figure 4-14.
4-26
Fabric fi1ter. 35
4-27
MgO. The emission rates measured from all samples were considered
normal and showed no change.
These emissions tests were conducted by using a test method other
than the EPA method ("modified" Method 5 or AN-MOD 5) and should only be
used as an indication of possible performance. Regardless of the potential
emissions reductions possible with the above modifications, the study
concluded that control equipment would still be necessary to reduce
emissions on high density prill tower operations to meet state air
emission regulations.
4.3
4-28
TABLE 4-2.
Uncontrolled Emissions
g/kg (lb/ton)
Ariiliionlum
AnInonia Nitrate
Controlled Emissions
g/kg (lbC:)
nium
Control Device Armionia Nitrate
Percent of
Airflow to
Device
Percent of
Emissions to
Control Device
100
100
Plant
Type of Plant
Aa
28.80
(57.60)
1.60
(3.20)
Gb
High Density
Prill ing
NA
2.74
(5.48)
Collection Hood
Wetted Fibrous
Fi 1ter Scrubber
NA
0.40
(0.81)
Hb
High Density
Pril1ing
NA
1.16
(2.33)
NA
0.51
(1.02)
33
NA
III
Hi gil Dens i ty
Pri 11 ing
NA
1.28
(2.55)
Collection Hood
Vetted Fibrous
Ffl tel' Scrubber
NA
0.16
(0.32)
21
84
pb
High Density
Prill ing
NA
1.93
(3.86)
Collection Hood
Vetted Fibrous
Filter Scrubber
NA
0.24
(0.48)
25
89
Zb
Hi gh Dens i ty
Pri 11 ing
NA
NA
Collection Hood
Wetted Fibrous
Filter Scrubber
NA
0.03
(0.07)
NA
NA
Ob
Hi gil Dens i ty
Prill ing
NA
0.82
(1.63)
Collection Hood
Wetted Fibrous
Fi 1tel' Scrubber
NA
0.29
(0.57)
25
67
Jb
Low Density
Pri 11 ing
NA
0.22
(0.45)
NA
0.11
(0.21 )
DNA
100
Zb
Low Density
Prill ing
NA
NA
Collection Hood
Wetted Fibrous
Fi 1tel' Scrubber
NA
0.06
(0.13)
NA
NA
Za
Low Density
Pri 11 ing
0.13
(0.26)
0.39
(0.78)
Collection Hood
Wetted Fibrous
Fll ter Scrubber
0.07
(0.14)
0.25
(0.49)
17
42
aa
Drum Granulator
30
(60)
147
(295)
Entra inment
Scrubbers
0.09
(0.18)
0.22
(0.43)
DNA
100
Eb
Drutll Granulator
NA
NA
Entrainment
Scrubber
DNA
100
Da
Pan Granulator
0.61
(1.23)
0.02 e
(0.04)
DNA
100
0.07
(1.15)
1.34
(2.68)
4.70
(9.40)
NA
Variable Throat
Venturi Scrubber
0.85
(1.69)
4-29
88
4-30
3
III
t:
~}
0
$...
.,...u
$...
QJ
...,
QJ
.p
I
W
E
.,...m
C
UJ
.u
.,...
...,
$...
a.
1
.9
.8
.7
.6
.5
~}
+
.4
.3
.2
.1,
.1
1 2
10
20 30
50
70
90
99
pressure drop and results of EPA testing show that emissions were reduced
from 147.2 g/kg (294.6 lb/ton) to 0.22 g/kg (0.43 lb/ton).45,46 Figure
4-16 presents the particle size characteristics of emissions from the
rotary drum granulator. The EPA test also reports that visible emissions
from the scrubber ranged from 10-20 percent opacity.47
4.3.4 Pan Granulators
There is only one pan granulator in operation in the U. S. and it
uses a venturi scrubber with a pressure drop of 6.75 kPa (27 in. W.G.)
for emission control. 7 EPA tests measured uncontrolled AN particulate
emission from the pan granulator at 1.34 g/kg (2.68 1b/ton). Measured
outlet emissions from the venturi scrubber include both evaporator and
pan granulator emissions, so actual controlled emissions for the pan
granulator alone are not available. However, controlled emissions from
the pan granulator can be estimated based upon its proportion of the
inlet emissions. The estimated controlled emission rate is 0.02 g/kg
(O.041b/ton).48 Controlled visible emissions ranged from 5 to 15
percent opacity.49
4.3.5 Solids Finishing Processes
Solids finishing equipment includes rotary drum predryers, dryers,
coolers and fluid bed coolers. These units are discussed together
because of their similarities in operation and emissions. As shown in
Figure 4-17, particle sizes for uncontrolled emissions from various
types of solids finishing equipment are similar. Each of these facilities
have emissions with 99.7 percent of the particles greater than one micron.
Presently, wet cyclones are the most common wet scrubber used for
solids finishing equipment. The designs for these scrubbers are varied,
but all report pressure drops between 0.5-1.5 kPa (2-6 in. W.G.). Other
wet scrubbers used to control emissions are mechanical scrubbers,
entrainment scrubbers, spray towers and tray scrubbers. Of the wet
scrubbers used to control these emoiss;ons, all report removal efficiencies
greater than 95 percent for particles greater than 5 microns in size.
4-32
11'I
C
s..
u
.,...
::E
......
+::>
I
W
W
s..
f1 f
---
Run 1 0
Run 2 6.
Run 3 0
- --
QJ
.f-J
QJ
Itl
.,...
0
QJ
'''''
.f-J
s..
Itl
CL.
.2
. I,
.01
'I
'I
.1.2.51
10
50
80
90
95
98
99.9
99.99
.......
I/)
c:::
.....u
:E
......~
CIJ
~
ItJ
.9
.8 .
.f-J
.J::>
I
.J::>
'0-
CIJ
u
'0-
+J
s-
ItS
D.
.7
.6
.5
.4 .
.3
.2
.1
..
>
.01
.1.2.5 1 2
Figure 4-17.
5 10
50
80
90
Weight Percent less Than Stated Size
95
E
B
D
C
C
C
4-35
TABLE 4-3.
Plant
-Pred2erl
tOil
Lb
1
Lb
ns
fact I Itt
Control
DevIce
Pressure Prof'
Itra(ln. W.G.)
Ih1controlled
(lb/ton)
MissIons "'kg
IlROnt.
f.monla
NItrate
Controlled
MIssIons 9/kl fIb/ton)
JiiiiiiOii ..
rerCf'n(
"-nla
Ouctty
Bttrtte
..
tt
Spray Tower
0.5-1.25 (2-5)
Wet Cyclone
0.75-1.5 (3-6)
l~
Tray Scrubber
Tray Scrubber
3.2 (6.4)
4.1 (8.2)
37.3 (74.6)
D.29 (0.58)
0.13 (0.26)
0.12 (0.25)
0.03 (0.06)
0.18 (0.36)e
0.2'
IlrxeDi
.011 ns Ity
Lb1
Spray Tower
0.5-1.25 (2-5)
Lb2
W.t Cyclon.
0.15-1.5 (3-6)
Zb
Tray Scrubber
Tra.y Scrubber
22.8 (45.7)
7.8 (15.6)
1.3 (2.6)
'13.7 (187.4)
0.18 (0.37)
0.1 (0.2)
0.03 (0.06)
0.47 (0.94)'
0.2'
0.075 (0.15)
Coolers
gJiDens t ty
.J:a
I
w
en
Srray Chamber
1.0 (4.0)
0.5-0.75 (2-3)
h
G
Wetted Mesh
Pad
Zh
Wet Cyclone
0~D3
0.83 j f .61i.)
(0.05)
0.01 (0.02)
0.15 (0.3)
0.003 (0.007)
0.31 (0.60 d
Lb
1
Lb
2
Zh
Z
Spray Tower
0.5-1.25 (2-5)
Wet Cyclone
0.75-1.5 (3-6
lIet Cyclone
19.2 (38.4)
35.2 (70.5)
0.29 (0.58)
37.8 (75.7)
Ent ralrlllent
Scrubber
3.3 (13.1)
1.18 (2.35)
8.6 (17.3)
IIet Cyclooe
1.4 (5.6)
Dr.. GranulatIon
0.02(0.03)
0.16 (0.32)
0.65 (1.3)
0.07 (0.14)d
0.03 (0.07),
Pan GranulatIon
0
18.0 (36.0)
the precooler at this phnt operates like the cooler at other plants.
dComblned emIssions from a precooler and cooler. Precooler emissions are vented to the
scrut>her while cooler emissions are vented directly to the atmosphere.
eScrublK'r controls predryer and dryer emIssions. (In the EPA test. 28% by n~ss of emlssloos
are from the predrYf'r.)
fOpacity reading Is from the scrubher that controls the predryer and dryer.
gPhnt L has tlIO solids fInIshing trains.
0.12 (0.23)
0-10
computation of emissions since the emission rates were similar for all
three runs. Due to particle collection problems, particle size data
were invalid.
4.4.2 Low Density Prill Towers
EPA also tested one low density prill tower (Plant Z). This tower
is equipped with a collection device and wetted fibrous filter scrubber
to reduce emissions. The prill tower operating parameters at this
plant, such as melt temperature, airflow, and prill temperature, are
similar to other plants in the industry. Therefore, the tower operation
can be considered representative of other low density plants. The
collection device design used is proprietary, but functions similarly
to others in the industry. This collection device captures 17 percent
of the tower airflow and ducts it to a 3.5 kPa (14 in. W.G.) pressure
drop wetted fibrous filter scrubber. 4l
EPA measured uncontrolled emissions of 0.39 g/kg (0.78 lb/ton) from
this tower. These emissions contained both bypass emissions (0.22 g/kg
(0.45 lb/ton)) and scrubber inlet emissions (0.16 g/kg (0.33 lb/ton)).
The wetted fibrous filter scrubber reduced emissions collected by the
collection device to 0.02 g/kg (0.04 lb/ton). When combined with
bypass emissions, the total controlled emissions were 0.24 g/kg (0.48
lb/ton).42
The wetted fibrous filter scrubber removed 88 percent of the mass
emissions received at its inlet. This value is less than the lowest
removal efficiency reported by the manufacturer in Figure 4-3 (95 percent).
The lower than expected removal efficiency is probably due to low particulate
loadings (0.16 9/k9 (0.33 lb/ton)). Also, particle sizes measured at
the scrubber inlet indicate that approximately 50 percent of the particles
were less than 1.2 microns (Figure 4-15). Even though the 88 percent
removal efficiency is lower than expected, the scrubber is still effective
in controlling AN emissions.
The total emissions reduction, including the bypass emissions, was
only 38.5 percent. This low overall emissions reduction was probably
due to the fact that the collection device only collected 41 percent of
the uncontrolled emissions.
4-37
4-38
..
:~.'
--.
flow rates, these too were believed to be low by 10-15 percent. Therefore,
the calculated efficiencies were expected to be lower than actual efficiencies.
4.4.4 Solids Finishing
EPA tested the uncontrolled and controlled emissions for four
solids finishing processes. The facilities tested included a high
density prill rotary drum cooler (Plant A), a pan granulator rotary drum
precooler (Plant D), a drum granulator rotary drum cooler (Plant E), and
a low density prill rotary drum predryer and dryer (Plant Z). As stated
in Section 4.3.5, these processes are considered together because of
similarities in operation and emissions. The particle size data from
each of these facilities are also similar, as can be seen in Figure 4-17
and Figures A-ll and A-12 in Appendix A.
Figure 4-18 presents the controlled emissions from each of these
solids finishing facilities. All of the scrubbers reduced the emissions
effectively because of the large size of the particles. Each scrubber,
except the one at Plant A, had approximately 98 percent removal efficiency.
The scrubber at Plant A had a 91 percent removal efficiency, which could
be attributed to a low particulate loading. Even though its scrubber
achieved a 99.5 percent removal efficiency, the controlled emissions for
the predryer and dryer at Plant Z were much higher than the other facilities.
The uncontrolled emissions for the predryer and dryer were also higher
than the other solids finishing facilities possibly due to higher airflows;
this may account for the higher controlled emissions.
At Plant A, a 1.0 kPa (4.0 in. W.G.) pressure drop spray chamber,
followed by a cyclone separator, is used to control cooler emissions. 52
The scrubber reduced emissions from 0.8 g/kg (1.6 lb/ton) to 0.075 g/kg
(0.15 lb/ton),53 for a removal efficiency of 91 percent. Plant A reported
no irregularities in operation or problems in sampling during the test.
Particle size data were not available due to particulate collection
problems.
At Plant 0, a 1.4 kPa (5.6 in. W.G.) pressure drop spray scrubber
is used to control precooler emissions. 54 The precooler at this plant
operates like coolers at other facilities, since it follows the solids
4-39
lb/toll
gnq
.f:a
.15
.30
.14
.28
.13
.26
.12
.24
.11
.22
.10
.20
.O!J
.18
.08
.16
.07
.14
.06
.12
.05
.10
.04
.08
.03
.06
l.391b/ton
t1.30 Ib/toll
1.21 Ib/ton
.f:a
Plant
A
FactI fty
Cooler
Product
High Oensity Prill
Ai'-flow Rate
48,000
0-
Ell
Precooler
Granul e-Piln
Cooler
Granule-Drum
Predryer-Dryer
low Density Prill
102,400
68,930
206,990
~cf/ton
aOnl y two test runs were accepted and both had the same emission rate.
Figure 4-18.
4-41
4-42
4.5 REFERENCES
1.
Memo from Bowen, M., Radian Corporation, to file. September 30; 1979.
Summary of scrubber pressure drops reported by industry.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Reference 9, p. 7.
13.
14.
15.
Atlanta, Van
17.
18.
Reference 8, p. 193.
19.
20.
21.
22.
23.
Reference 8, p. 201.
24.
Reference 20, p. 8.
25.
26.
27.
Reference 6, p. 3.
28.
29.
Reference 6, p. 5.
30.
4-44
Chemical Engineering.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Reference 2, p. 13.
40.
Reference 2, p. 49.
41.
42.
43.
44.
45.
46.
47.
48.
49.
Reference 7, p. 40.
4-45
50.
5l.
52.
Reference 2, p. 55.
53.
Reference 2, p. 21.
54.
Reference 7, p. 54.
55.
56.
57.
58.
4-46
MODEL PLANTS
The model ammonium nitrate plants developed for this study are
presented in Table 5-1. The rationale for selection of the model plants
is discussed in Section 5.1.1. Process flowsheets and parameters for
the model plants are presented in Section 5.1.2 and Section 5.1.3,
res pect ive ly.
5.1.1 Rationale for Selection of Model Plants
Major solid production techniques currently in use in this industry
are high density prilling, low density prilling and granulation. The
emission sources included in a model high density prilling plant are the
prill tower and cooler. Model low density prilling plant emission
sources are the prill tower, predryer, dryer and cooler. Model granulation
plants have two sources of emissions, granulators and coolers. Model
plant production capacities range from 181 to 816 Mg/day (200 to 900
TPD) for low density prilling, and from 363 to 1089 Mg/day (400 to 1200
TPD) for both high density prilling and granulation plant';.
Plant sizes were selected from the distribution of existing plant
capacities to represent existing plants, as well as those expected to be
constructed, modified or expanded in the near future. The data used to
determine plant sizes, operating parameters and emissions levels were
5-1
H-3
363 (400)
726 (800)
1089 (1200)
l-l
L-2
L-3
181 (200)
363 (400)
816 (900)
G-l
6-2
G-3
Granulation
Granulation
Granulation
H-2
01
Capacity
Mg/Day (TPD)
11-1
Process
363 (400)
726 (800)
1089 (1200)
Emission Sources
Prill Tower, Rotary Drum Cooler
Prill Tower, Rotary Drum Cooler
Prill Tower, Rotary Drum Cooler
Prill Tower. Rotary Drum Predryer, Dryer, and Cooler
Prill Tower. Rotary Drum Predryer, Dryer, and Cooler
Prill Tower. Rotary Drum Predryer, Dryer, and Cooler
Rotary Drum Granulator, Rotary Drum Cooler
Rotary Drum Granulator. Rotary Drum Cooler
Rotary Drum Granulator. Rotary Drum Cooler
obtained from an industry survey, source testing and available 1iterature. l ,2,3
The mode1 plants represent plants of small, medium and large capacities.
Although AN plants exist with greater capacities than the largest selected
for modeling, their capacities were developed incrementally over several
years; therefore, no model plants were chosen to represent those capacities.
A few plants have prill towers producing both high and low density
pri11s. However, there was insufficient information available to determine
what the d~vision of operating hours or production would be between
products. Therefore, it was assumed that each model plant would produce
a specific product only.
5. 1.2 Process Flow Sheets
Process flow sheets for each of the model plants selected are
presented in Figures 5-1 to 5-5. Figure 5-1 represents the high density
pri1ling process. Figure 5-2 represents the low density prilling process,
and Figures 5-3 to 5-5 represent the granulation process. These flow
sheets present only the solids formation and finishing part of the plant
downstream of the solution process. The process equipment and parameters
shown for all the model plants are typical of the current industry
practice and are based on a survey of the industry.
All sizes of prilling plants have flow sheets similar to the one
shown. Rotary drum granulators usually come in a fixed size, 400 TPD.
For plants with larger capacities, companies build multiple, parallel
400 TPD trains, as shown in Figures 5-3 to 5-5.
In each of the model plants, gaseous ammonia and a 56 percent
nitric acid solution (by weight) are combined in a neutralizer to form
an 83 percent solution of ammonium nitrate. This solution is then
concentrated to a 96.5 to 99+ percent melt. Solids are then formed by
prilling or granulation. After the formation process, the solids are
dried, if needed, and cooled. The product may also be coated to prevent
caking. The solids are then either bagged or bulk shipped. Additional
process parameters are discussed in the following section.
5-3
o
~
CONTROL
EQUIPMENT
-I
SCLUTION
FORMATION &
CONCENTRATION
99.8% AN MELT
0.2%H20
SOLUTION
AIR1
r::~~~~~S
CONTROL
EQUIPMENT
~.;;o H 20
cj
63 C
J'%~,o
PRILL
TOWER
1130 C SOUD AN
0.2% H 20
COOLER
43CSOUDAN
0.2% H 20 ...
SCREENS
0.2% H 20
COATER
1.5%
rV
Ul
I
43 C
COATING
REFRIGERATED
AIR AT 18 C
.p.
SOUDAN
OFFSIZE RECYCLE
iEXHAUST
STREAM
27" C <
0.8% H 20<
BAGGING
1-4--
Figure 5-1.
BUl.K
LOADING~
BULK
STORAGE
I-+-
..
CD
0)
~
1
SOLUTION
FORMATION &
CONCENTRATION
"
96.5%ANME~
PRILL
TOWER
AIR;!
oj
CONTROL
DEVICE
CONTROL
DeVICE
2.2% H20
71 C SOLID AN
2% H 20
71 C SOLiD AN
2.5% H 20
0'1
~IHROL
~:VICE
~30C
40C
60 C
0'1
2.2% H20
2.2% H20
60 C SOLID AN _
0.5% H20.
DRYER
COOLER
)..,
,.L
AIR IN
93C
AIR IN
71C
35 C
0.2% H 20
SOLID AN
rV
AIR IN
21C
OFFSIZE RECYCLE
If
38C
J>2.2% H20
SCREENS
i
EXHAUST STREAM
270
~~
27"C ,
0.8% H20 )
0.80~
BAGGED
PRODUCT
BAGGING
._--'
BULK
LOADING
Figure 5-2.
BULK
...
STORAGE
1.5%COATING
I COATER ~
C0
MAKEUP
--------~k-J-,--1-,I
I--t-,-t-l--:) SCRUBBER
/"
...-
SCRUBBER
unulD
STORAGE
TJ\NK
<.T1
I
65% AN
WATER
CD
,
REFRIGERATED
AIRAT 10" C
W
CONTROL
EQUIPMENT
r;:2"C
~2.~~io H 20
DRUM
GRANULATOR
~I-
165% AN
0'1
49" C
c(
~
0
SOLUTION
FORMATION &
CONCENTRATION
OJ
ANSOUD
46C
d1.8% H20
CRUSHER
I..
SCREENS
J
COOLER
35" C
99.8% AN
i
27"C
~oH20
COATER
OVERSIZE
(\.1
REFRIGERATED
AIR AT 10" C
UNDERSiZE
-ANSOUD
27"C ,
EXHAUST STREAM
0.8% H 2
<t
BAGGING
Figure 5-3.
BULK
I-~ BULK
STORAGE
LOADING
o
- j.
~{
.
.--
,1__
I.e -
",MAKE.UP
WATER
-...------.
REFRIGERATED
AIR AT 10'e
tl5%AN
CONTROL
EQUIPMENT
ocmmnJJ
LIQUOR
STORAGE
TANK
U1
I
OVERSIZE
UNDERSIZE
CONTROL
DEVICE
REFRIGERATED
AIR AT 10' C
BAGGING
I I I
......
SOLUTION
FORMATION &
CONCENTRATION
l,;HU~Nt:H
BAGGING
EMISSION
POINT
MAKE-UP
WATER
~~
65% AN
REFRIGERATED
AIR AT 10'C
CONTROL
EQUIPMENT
1.8% H 20
UNDERSIZE
Figure 5-4.
REFRIGERATED
AIRAT 10' C
~BULK
STORAGE
BULK
LOADING
(9
(2)
"0
,,'0
AHGOLID
1CflU8_
LIQlJOA
STORAGE
TANK
REFRtGER4T1ED
......
AIAAT10C
(i)
<9
U1
I
00
L_
"'0
NlSOlIO
IIULK
ftEFRIGERATED
AIR AT 1Q"C
o
<9
"'0
ANSOUD
lXHAUSTOTREAM
ANSOUD
REFRIGERATED
AlftATlOC
Figure 5-5.
5-9
TABLE 5-2.
Plant Size
Mg/Cfay fpD
lJ1
I
AmmoniitGg/yr lO"'TP'f
Nitric Ac;L
Gg/yr 10"'fPY
Coating A~
Gg/yr 10 TPY
363
400
24.0
26.5
88.8
97.9
3.6
4.0
726
800
47.9
52.8
177.7
195.9
7.2
7.9
1089
1200
71.9
79.3
266.5
293.8
10.8
11.9
......
aBased on plant production capacity and 7728 operating hours per year.
b56 percent nitric acid in water.
5-11
TABLE 5-3.
State
Opacity
(percent)
Alabama
Arizona
Arkansas b
Cali forn1a c
F1 or1d.
Georgia
I1linois d
...
,J
20
40
20
20
20
20
30
40
40
20
20
20
40
20
20
Indiana
Iowa
Kansas
Loui siana
mnnesota
Mississippi
MI ssourl
Nebraska
New Mexico
North Carolina
Oklahoma
Tennessee
Texas
Utah
Washington
20
20
20
20
20
20
Wyoming
20
Gral~sl
ft
Gral:Js/
m
0.69
0.3
0.69
0.3
0.25
0.69
0.58
0.1
0.23
NITRATE PLANTS
Allowahle parti- Allowable part1- Allowable parti- A1101~able particulate emissions culate emissions culate emissions culate emissions
in kg/hr for
in lb/hr fo~
in lb/hr fo,
1n kg/hr fora
Process weight regulation
200 ton/day
1200 ton/day
1089 Mg/day
181 Mg/daya
P~JO ton/hr
P)30 ton/hr
Process
Process
Process
Process
3.59(P)O.62
4.10(P)0.67
0.0722(P)0.78
0.3
N~MONIUM
3.59(P)O.62
3.59(P)O.62
2.54(P)O.534
4.10(P)O.67
4.10(P)0.67
4.10(P)0.67
4.10(P)O.67
3.59(P)0.62
4.10(P)0.67
4.10(P)0.67
4.10(P)0.67
4.10(P)0.67
9.377(P)0.3067
4.10(P)0.67
3.59(P)0.62
3.12(P)0.985
17.3l(P)O.16
13.37
(55.0(P)0.1l )-40 16.97
1.29(P)0.43
120.26
26.74
17.31(P)0.16
13.37
17.31(P)O.16
13.37
24.8(P)0.16
7.88
(55.0(P)O.1I)-40 16.97
(55.0(P)O.11)_40 16.97
(55.0(P)0.1l )-40 16.97
(55.0(P)0.11 )-40 16.97
17.31{P)0.16
13.37
(55.0(P)0.11)_40 16.97
(55.0(P)0.11)_40 16.97
(55.0(P)0.11)_40 16.97
(55.0(P)0.11)_40 16.97
17.96
(55.0(P)0.11)_40 16.97
17.31 (p)0.16 13.39
25.4(P)0.287
25.18
6.079
7.72
54.68
12.14
6.079
6.079
3.58
7.72
7.72
7.72
7.72
6.079
7.72
7.72
7.72
7.72
8.17
7.72
6.079
11.45
32.37
44.58
259.91
13.15
32.37
32.37
20.52
44.58
44.58
44.58
44.58
32.37
44.58
44.58
44.58
44.58
31.13
44.58
32.37
78.06
14.72
20.27
118.18
5.97
14.72
14.72
9.33
20.27
20.27
20.27
20.27
14.72
20.27
20.27
20.27
20.27
14.15
20.27
14.72
35.49
6.079
32.37
14.72
Under Development
Under Development
3.59(P)0.62
17.31(P)0.16
13.37
5-13
5-14
TABLE 5-4.
PLANT SIZE
(200 TPO)
.1Sf 1'fg/0
(400 TPO)
362 MglO
(800 TPO)
STATE
lb/ton
g/kg
lb/ton
g/kg
lb/ton
Alabama
1.604
.802
1.233
.616
.910
Arizona
2.031
1.018
1.620
.810
7.035
Arkansas a
f4.071
fOS9 MglO
lb/ton
g/kg
.455
.647
.323
1.227
.613
.892
.-W6
2.502
glkg
9.433
4.716
6.323
3.161
5.004
Ca 1ifornia
1.307
.65l5
.793
.397
.466
.233
.343
'72
florida
1.604
.saz
1.233
.616
.910
.455
.647
.323
Georgia
.910
.455
.647
.323
1.604
.8OZ
1.233
.616
Illinois
.946
.473
.685
.343
.496
.248
.410
.205
Indiana
2.037
1.018
1.620
.810
1.227
.613
.892
.446
Iowa
2.037
1.018
1.620
.810
1.227
.613
.892
.446
Kansas
2.037
1.018
1.620
.810
1.277
.613
.892
.446
Louisiana
2.037
1.018
1.620
.810
1.277
.613
.892
.446
:-1innesota
1.604
.S02
1.233
.616
.910
.45~
.647
.323
Mi ssouri
2.037
1.018
1.620
.810
1.227
.613
.892
.~6
Mississippi
2.037
1.018
1.620
.810
.227
.613
.892
.446
~ellraska
2.037
1.018
1.620
.810
1.227
.613
.892
.446
Nelw Mexico
2.037
1.018
1.620
.810
1.227
.613
.892
.446
North Carolina
2.156
1.078
1.333
.667
.825
.413
.623
.312
Oklahoma
2.037
1.018
1.620
.810
1.227
.613
.392
.446
Tennessee
2.037
1.018
1.620
.810
1.227
.613
.892
.446
Texas
3.022
1.511
2.991
2.085
1.042
1.561
.780
Wyoming
1.604
.802
1.233
.6i6
.910
.455
.547
.323
Straight Average
1.882
.941
1.498
.749
1.108
.554
.816
.408
TOTAL
Weighted Average
1.884
.942
1.480
.74
1.089
.544
.795
.398
i .894
.941
1.490
.745
1.094
.547
.797
.398
i" OW~r
Density Prill
'Nei ghted
Average
1.797
.m
1.375
.688
1.015
.507
.741
.370
GRANULATION
Weignted Average
2.32
2.017
1.009
1.475
.737
1.086
.543
1.49
1. 16
aArkansas not included in averages oecause l!!Irissions are for entire plants. not single soun:es.
5-15
5-16
TABLE 5-5.
Proces,;
No. of
Faef 1Hfes
Uncontrolled Emfssfons
Nftrate g/kg (lb/ton)
EPA
Industry
Amn~nfum
WFFS"
Entrafnment
Cyclone
Venturf
Tray
Type
Mechanfcal
Othera
None
Solfds Formatfon
Hf gh Dens tty
Prf 11 Tower
20
1.6
(3.2)
0.82 - 2.7.4
(1.63 - 5.48)
11
18
0.39
(0.78)
0.21 - 0.69
(0.42 - 1.38)
!J
12
Drum
Granulator!.
147.2
(294.6)
138 - 152
(277 - 305)
Pan
Granulator
1.34
(2.68)
No Data
37
12
Solfds
Ffnfsl~
Predryers,
Dryers,
Cooler
U1
I
~
uP
D.83-18
( 1.66-36)
3.2 - 35.2
(6.4 - 70.5)
-...J
Includes smog towers, knockout chambers, spray towers.'.fnternal controls, or wetted mesh pads.
Total nultber of solfds ffnishing processes with avaflable data. Some wfll have more than one control device or may be connected fn serfes to a
sfngle control device.
WFFS = Wetted Ffbrous Fflter Scrubber
a.
b.
No.
Info.
TABLE 5-6.
Emission
source
Existing control
equipment
High density
prill tower
Two-tray Scrubber
6P = 2.7 kPa (11" W.G.)
1.4
0.7
Low density
prill tower
None
1.4
0.7
Granulator
Entrainment Scrubber
6P = 3.5 kPa (14" W.G.)
0.5
0.25
Solids finish;ng
Tray Scrubber
6P = 0.75 kPa (3" W.G.)
1.4
0.7
5-18
ELOC
1blton
ELOC
g/kg
tower would be 1.55 g/kg (3.l lb/ton), based upon the EPA test. With
this level of uncontrolled emissions, a high density prill tower requires
a low efficiency control device to meet the chosen emission level.
5.2.2.2 Low Density Prill Towers. Industry data summarized in
Table 5-5 indicate that uncontrolled emissions for low density prill
towers range from 0.21 to 0.69 g/kg (0.42 to 1.38 lb/ton) and that the
majority of low density prill towers are uncontrolled. It is expected
that new low density prill towers would have the same range of uncontrolled
emissions and would be capable of meeting the applicable SIP's. The
existing level of control chosen, 0.7 g/kg (1.4 lb/ton), represents the
allowable SIP level for an average sized source. It is assumed that a
new low density prill tower would not require any control equipment to
achieve this emission level.
5.2.2.3 Granulators. Results of an EPA test show uncontrolled AN
emissions of 147.2 g/kg (294.6 1b/ton) for granulators. A comparison of
uncontrolled emissions from granulators and even the most lenient SIP's
indicates that removal efficiencies of greater than 99 percent would be
required. In addition, process economics dictate the use of a control
device to recover the large amounts of pr~duct that would otherwise be
lost. A survey of industry indicated that all existing granulators
utilize wet scrubbers to control emissions. With these considerations
in mind, it is unlikely that a new granulator will be built without some
type of control device.
The existing level of control for granulators was set at 0.25 g/kg
(0.5 lb/ton), based on an EPA test of a typical granulator scrubber
(Table 5-6). This degree of control is greater than required by most
SIP's; however, it is typical of existing industry practice.
5.2.2.4 Solids Finishing. Solids finishing includes granulator
coolers, high density prill coolers, and low density predryers, dryers,
and coolers. Rotary drum coolers, dryers and predryers have the same
configuration no matter where they are applied. However, uncontrolled
emissions from these rotary units do vary by the type of product handled.
5-19
.., .'
--
All rotary coolers, dryers and predryers installed in the past ten years
have been equipped with some form of control device. Wet scrubbers are
the predominate control device in the industry. Three fluid bed coolers,
one fluid bed dryer and one fluid bed predryer have been constructed
over the last 11 years. Two of the three fluid bed coolers are uncontrolled.
Uncontrolled emissions for solids finishing operations are reported
by industry to vary from 3.2 to 35.2 g/kg (6.4 to 70.5 lb/ton) and have
been measured by EPA from 0.83 to 18 g/kg (1.66 to 36 lb/ton). With
these high emissions levels, the majority of solids finishing operations
would require some form of control to meet SIP's. Table 5-5 indicates
that the majority of solids finishing operations are controlled. For
the purpose of this analysis it was assumed that all sol ids finishing
operations would have an existing level of control of 0.7 g/kg (1.4
lb/ton) based upon the average SIP's (Table 5-6). In addition, it was
assumed that, based upon an average of EPA tests, the uncontrolled
emissions for a typical solids finishing operation would be 5.4 g/kg
(10.8 lb/ton). With this level of uncontrolled emissions, any solids
finishing operation would require a moderately efficient scrubber to
meet the chosen emission level.
5.3 CONTROL OPTIONS
This section presents an analysis of the individual emission sources
requiring control. Discharge parameters from these sources are presented
for the various model plants, and control equipment is selected to
reduce emissions over the existing level of control. High density and
low density prill towers are discussed in Sections 5.3.1 and 5.3.2,
respectively. Section 5.3.3 discusses granulators, and Section 5.3.4
discusses solids finishing equipment.
5.3.1 High Density Prill Towers
The high density prill tower is usually controlled to meet state
implementation plan (SIP) emission levels. A tray scrubber was chosen
for the existing control device, as shown in Table 5-6. To meet a more
stringent limitation, a fume collection hood, followed by a wetted
fibrous filter scrubber, was selected (Option 1). Only the portion of
5-20
the tower airflow having the most concentrated emissions is treated with
the control device in this system. Another option selected was using
the wetted fibrous filter scrubber to control the full tower airflow
(Option 2). A third option was also selected and is the same as Option
2, except that the net tower airflow is reduced through the use of
process modifications (Option 3). One plant in the industry operates in
such a manner. This plant was originally designed to operate in the
conventional manner, with full airflow. By modifying the process to
handle a reduced airflow, the size and cost of control equipment were
greatly reduced. Discharge parameters for high density prilling plants
are presented in Tables 5-7a to 5-7c.
Control equipment is located on top of the prill tower in all cases
except the full airflow case (Option 2). A scrubber that could handle
the full tower airflow would be too large to fit on top of the prill
tower. Therefore, the scrubber is located at ground level and tower
emissions are ducted down to it.
5.3.2 Low Density Prill Towers
The low density prill tower is typically uncontrolled. Therefore,
no control was selected for the existing case. One system for controlling
particulate emissions from low density prill towers includes a fume
collection hood, followed by a wetted fibrous filter scrubber (Option
1). With this system a selected portion of tower airflow emissions
bypasses the control device. Another option chosen involves using the
wetted fibrous filter scrubber to control the full tower airflow (Option 2).
The discharge parameters for low density prilling plants are presented
in Tables 5-8a to 5-8c.
The control equipment is located on top of the prill tower for all
cases except the full airflow case for the same reasons as discussed
above in 5.3.1.
5.3.3 Granulators
The granulator control device is the same for all control alternatives.
All granulators in the industry are currently controlled with the same
type of device (an entrainment scrubber), and if properly installed and
5-21
Part Iculate
Emission Rate
grains/s grams/s
I
N
N
Stack
Diameter
feet meters
Stack
Temperature
iF
K
Total Air
Flow Rat~
scfm SEd M m n
Air Velocity
nr Stack
fts IIleters/s
Type of
Discharge
Level of
Control
Type of
Control
Prill Tower
Stack
Existing
Tray
Scrubber
11" liP
45,4
2.94
203,0
61.87
3(15,0
3(11.52
43.9
13.37
Option I
Bypass
14.47
0,94
191.0
58.22
31114.5
31111,37
43.3
13.21
1.73
0.11
220.0
67,06
4.0
1.22
877.92
41.1
12.53
0,21
60.0
18.29
21116,0
2'1.83
45.7
13.93
0.21
222.0
67.67
4.5
1.37
100 310.62
39.000 1.104.48
41.0
12.50
2.94
60.0
18.29
3.0
0,91
115 318.94
20.000
566.40
47.2
14.39
0.21
60.0
18.29
3.0
0.91
115 318,94
20,000
566.40
47.2
14.39
Collectloc
Hood/WFFS
14" liP
U1
Height of
Discharge
feet meters
Eml ss Ion
Source
Option 2
Cooler
Stack
Existing
Tray
Scrubber
Cooler
Stack
Option 1
Entrainment
Option 3
45.4
3.24
31,000
a20 percent of the airflow goes through collection hood; 87 percent of the emissions goes throu9h collection hood.
bWetted fibrous filter scrubber.
cReduced flow -- 25 percent of baseline.
E,"hs Ion
Source
Type of
Discharge
Level of
Control
Type of
Control
Prf 11 Tower
Stack
Ex fs tlng
Tray
Scrubber
II" "P
90.7
Optfon 1
Bypass
Dlschar~e
Stack
Dfameter
feet meters
Stack
Temperature
of
Total Afr
Flow Rate
scfm std M3fiiiTii
Afr Velocl ty
~er Stack
ft s meters!s
feet
me ers
5.88
205.0
62.48
4~6.0
4~1.83
45.7
13.93
28.93
1.88
195.0
59.44
3@6.0
3l!l1.83
48.8
14.86
3.47
0.23
224.0
68.28
5.5
1.68
62,000 1,755.84
43.5
13.26
0.42
60.0
18.29
4(\16.0
4l!l1.83
45.7
13.93
0.42
225.0
68.58
6.0
1.83
100 310.62
78,000 2,208.96
46.0
14.02
5.88
80.0
24.38
5.0
1.52
115 318.94
40,000 1,132.80
33.97
10.35
0.42
80.0
24.38
5.0
1.52
115
318.94
40,000 1,132.80
33.97
10.35
Collectloc
Hood/WFFS
14" liP
U1
I
N
eN
HeIght of
Prfll Tower
Stack
Option 2
Prfll Tower
Stack
Optfon 3
Cooler
Stack
Existing
Tray
Scrubber
Cooler
Stack
Option 1
Entrafnment
Scrubber
13" liP
90.7
6.48
a20 percent of the afrflow goes through collectfon hood; 87 percent of the emfssion goes through hood.
bwetted ffbrous fflter scrubber.
cRcduced flow - 25 percent of baseline.
TABLE 5-7c.
Emission
Source
Type of
Discharge
level of
Control
Type of
Control
Prill Tower
Stack
Exlstin9
Tray
Scrubber
11" t.P
Option 1
Bypass
Part iculate
miss ion Ra te
gralnsJs gramsJs
Stack
Temperature
iF
Total Air
Flow Rat~
scfm Std M m n
rr
Air Velocity
Stack
Hi meters/s
205.0
62.48
6416.0
6tl1.83
45.7
13.93
43.41
2.81
195.0
59.44
5i16.0
5(i11.83
43.9
13.37
Collect ion
lIood/WFFSb
14" t.P
5.20
0.34
222.0
67.67
2(i14.5
2(i11.37
2,633.76
48.8
14.86
9.72
0.63
60.0
18.29
6(i16.0
6(i11.83
45.7
13.93
9.72
0.63
223.0
67.97
2tl5.0
2(i11.52
3,285.12
49.3
15.01
136.1
8.82
90.0
27.43
6.0
1.83
115
318.94
60,000
1,699.20
35.4
10.79
24.3
1.58
90.0 27.43
6.0
1.83
115
318.94
60,000
1,699.20
35.4
10.79
Option 2
Prll1 Tower
Stack
Option 3
Cooler
Stack
EXisting
Tray
Scrubber
Cooler
Stack
Option 1
Entrainment
Scrubber
13" t.p
Stack
Diameter
feet meters
8.82
Stack
Prill Tower
\Ieight of
Discharge
feet meters
136.1
93,000
01
I
N
.J:a
a20 percent of the airflow goes through collection hood; 87 percent of the emission goes through collection hood.
bWetted fibrous filter scrubber.
cReduced flow -- 25 percent of baseline.
TABLE 5-8a.
Emlnlon
Source
Prill Tower
Prill Tower
Type of
Ot scharge
Level of
Control
Stack
hlsting
SLack
Option 1 Bypass
Type of
Control
Unl~"ntt'o11e<f
Co I It'd i "C
Hood/WFFS
14" l'i P
If
Prill Tower
Stack
I'reclryer
Stack
Existing Tray
Scrubber
Stack
Option 1 Entrainment
wet sc rubber
13"61'
Dryer
Stack
E~1sting
Dryer
Stack
Cooler
Stack
Cooler
Stack
!')
U1
Particulate
emission ratll
grailiSl'
grains/s
22.7
1.47
lIelyht of
cll~dldr~1l
Stack
diameter
meters
feet
Stack
temperature
OF
Total Air
All' velocity
flow rate ~
per stack
scfm
Std M1m n ft/s meters/s
feet
meters
lR9.0
57.61
3@ 3.5 3@ 1.07
100
310.62 76,000
2152.32
43.9
13.31l
57.30
3@ 3.0 3@ 0.91
100
310.62 61.000
1727.52
4B.0
14.62
15,000
424.80
35.4
10.79
7.23
0.87
0.47
IAB.O
0.06
218.0
66.45
3.0
0.91
1.62
0.11
6U.0
18.29
6.0
1.83
100
310.62 76,000
2152.32
44.8
13.66
1.47
50.0
15.24
2.0
0.61
135
330.04 10,000
283.20
53.0
16.15
0.11
50.0
15.24
2.0
0.61
135
330.04 10,000
283.20
53.0
16.15
1.47
50.0
15.24
2.0
0.61
135
330.04 10,000
283.20
53.0
16.15
0.11
50.0 15.24
2.0
0.61
135
330.04 10,000
283.20
53.0
16.15
'l2.7
1.62
Tray
Scrubber
Option 1 Entra i nment
wet scrubber
13"6 P
22.7
Existing Tray
Scrubber
Option 1 Entrainment
wet scrubber
13"6 P
22.7
1.62
1.62
1.47
50.0
15.24
2.0
0.61
115
318.94 10,000
283.20
53.0
16.15
0.11
50.0
15.24
2.0
0.61
115
318.94 10,000
283.20
53.0
16.15
a20 percent of the total airflow goes through collection device; 60 perceot of the emissions go through collection device.
bWetted Fibrous Filter Scrubber
TABLE 5-8b.
Emission
Source
Pri 11 Tower
Type of
01 scharge
level of
Control
Stack
Existing Uncontrolled
Type of
Control
Option 1 Bypass
Collection
Hood/WFFSb
14" AP
U1
I
N
Prill Tower
Stack
Predryer
Stack
Existing
Predryer
Stack
Dryer
Stack
Dryer
Stack
0"1
Particulate
emission rate
grains/s gramsls
Stack
diameter
feet Pieters
Stack
temperature
OF
K
Total Air
flow rate 3
scfm Std H /mtn
Ai r velocHy
per stack
ft/s meters Is
45.4
2.94
3@1.52, 100
43.0
13.11
14.47
0.94
3'1.37
42.6
13.00
1.73
0.11
220.0 67.U6
849.60
39.8
12.13
3.24
Tray
45.4
Scrubber
Option 1 Entrainment
~. 24
wet scrubber
13" A P
Tray
Scrubber
Option 1 Ent ra i nment
wet scrubber
45.4
Tray
Scrubber
Option 1 Ent ra i nlllent
wet scrubber
13".0. P
45.4
Existing
lIeight of
discharge
feet meters
3.24
100
30,000
4.0
1.22
0.21
?,.1.R3
100
44.8
13.66
2.94
60.0 18.29
3.0
0.91
135
330.04
20,000
566.40
47.2
14.39
0.21
60.0 18.29
3.0
0.91
135
330.04
20,000
566.40
47.2
14.39
2.94
60.0 18.29
3.0
0.91
135
330.04
20,000
566.40
47.2
14.39
0.21
0.91
135
330.04
20,000
566.40
47.2
14.39
2.94
60.0 18.29
3.0
0.91
115
318.94
20,000
566.40
47.2
14.39
0.21
60.0 18.29
3.0
0.91
115
318.94
20.000
566.40
47.2
14.39
13" A P
Cooler
Stack
Cooler
Stack
---------
Existing
3.24
--_.
a 20 percent of total airflow goes through collection hood; 80 percent of emission goes through collection hood.
bWetted fibrous filter scrubber.
TABLE 5-8c.
Emission
Source
Prill Tower
Level of
Control
Stack
Option 1
Type of
Control
Particulate
eml ss Ion rate
gralns/s
grams!s
Type of
01 scharge .
Bypass
Collection
Hood/WFFS
Itelght of
di scharge
feet
meters
Stack
diameter
feet
meters
Stack
t elllpe ra tu re
OF
K
Total Air
flow rate 3
scfm
Std H /mln
Air velocity
stack
ftls meters Is
6.62
195.0
59.44
4@6.0
4@1.83
100
310.62
342,000 9,685.44
50.4
15.37
2.11
195.0 59.44
3@6.0
3@1.83
100
310.62
274,000
7,759.68
53.9
16.43
3.90
0.25
225.0
68,58
6.0
1.83
68,000
1,925.76
40.1
12.22
32.6
14" I~ I'
01
I
N
.....
Prlll Tower
Stacks
7.29
0.47
60.0 18.29
4@6.0 4@1.,1l3
100
310.62
342,000 9,685.44
SO. 4
15.37
Pred rye r
Stack
6.62
RO.O 24.38
5.0
1.52
135
330.04
45,000 1,274.40
38.2
11.64
Predryer
Stack
102.1
Tray
Scrubber
7.29
Option 1 Entrall1nent
wet scrubber
13"6 P
0.47
80.0 24.38
5.0
1.52
135
330.04
45,000 1,274.40
38.2
11.64
Dryer
Stack
6.62
80.0 24.38
5.0
1. 52
135
330.04
45,000
1,274.40
38.2
11.64
Dryer
Stack
102.1
Tray
Scrubber
Option 1 Entrainment
7.29
wet scrubber
13"6P
0.47
80.0 24.38
5.0
1.52
135
330.04
45,000 1,274.40
38.2
11.64
Cooler
Stack
Existing
Tray
Scrubber
6.62
80.0 24.38
5.0
1.52
115
318.94
45,000 1,274.40
30.2
11.64
Cooler
Stack
0.47
80.0 24.38
5.0
1.52
115
318.94
45,000 1,274.40
38.2
11.64
Existing
Existing
102.1
7.29
a 20 percent of total airflow goes through collection device; 80 percent of the emissions goes through collection device.
bWctted fibrous fll ter scrubber.
5-28
1TI
I
N
\JJ
Type of
01 scharge
level of
Control
Type of
Control
Entrainment
Existing Scrubber
& Option 1 14"AP
Granulator
Stack
Cooler
Stack
Existing
Cooler
Stack
Option 1
Tray
Scrubber
Entrainment
Scrubber
13" AP
Particulate
emission rate
gralns/s gramsls
Itelght of
discharge
feet meters
Stack
Stack
diameter
temperature
K
feet meters OF
Total Air
flow rate 3
scfm Std M/mln
Air velocity
per stack
ftls meters Is
16.2
1.05
~.O
27. 43
6.0
1.83
23.6
7.19
45.4
2.94
60.0
18.29
3.0
0.91
566.40
47.2
14.39
0.21:
81.0
1e. 29
3.0
0.91
566.40
47.2
14.39
3.24
Emission
Source
Type of
DlsChlll'lI11
Granl/lator Stack
level of
Type of
Control
Control
Existing
& Option 1
Cooler
Stack
Existing
Cooler
Stack
Option 1
Entrillnment
Scrubber
Tray
Scrubber
Entrainment
Scrubber
lIeight of
discharge
feet
meters
Stack
diameter
feet
Stack
temperature
meters
tiF
Total Air
Air velocity
flow rate :h--.- --J!!! stack
seflll Std M/m1n HIs meters!s
32.4
2.10
2@
90.0
2@
27.43
2@
6.0
2@
1083
110
23.6 7.19
90.7
5.88
2f!l
60.0
2@
60.0
2@
18.29
2@
18.29
2@
3.0
2@
3.0
2@
0.91
2@
0.91
115
47.2 14.39
115
47.2 14.39
14" 6 P
13"6 P
CJ1
Particulate
emission rate
grains/s
grams!s
6.48
0.42
Emission
Source
Granulator
U1
I
W
-'
Type of
Di scharge
Stack
Level of
Control
Existing
& Option 1
Cooler
Stack
Existing
Cooler
Stack
Option 1
Tyre of
Control
Entra lnRlent
Scrubber
Hill!. P
Tray
Scrubber
Entra i nment
~5t,*~er
Particulate
emfssion rate
grains/s
grams/s
48.6
136.1
9.72
3.15
8.82
0.63
/leight of
discharge
feet
meters
3@
~O.O
3l!l
60.0
3@
60.0
Stack
diameter
meters
feet
Stack
temperature
of
Total Air
flow rate .
selin Std
A1mrn
Air velocity
per stack
1tls meters/s
3@
6.0
3@
1.83
3,398.40 23.6
7.19
27.. 43
3@
18.29
3@
18.29
3@
3.0
3@
3.0
3l!l
0.91
3@
0.91
115 318.94
60,000
1,699.20 47.2
14.39
318.94
60,000
1,699.20 47.2
14.39
3@
115
5-32
:
... '-.
TABLE 5-10.
Prill Tower
1 (existing)
o
o
2
3
4
4a
Cooler
o
X
X
X
X
X (option 1)
X (option 2)
X (option 3)
Prill Tower
1 (existing)
o
o
2
3
4
X (option 1)
X (option 2)
X
X
X
GRANULATION PROCESS
Alternative
Number
1 (existing)
2
Granu1 ator
Cooler
O-X*
O-X*
X - Optional Control
*Granulators existing and option control are the same.
5-33
TABLE 5-1l.
EMISSION FACTORS
Uncontro lied
kg/Hg (lbs/ton)
Exlstlnll Control
Ex tstlnq
kg/My ( Ibs/ton)
Controlled
kg/My (lbs/ton)
0.1
1.55
(1.4)
(3.1)
None
Two-Tray Scrubber
2.15 kPa (II" W.G.) AP
0.1
0.1
(1.4)
(1.4)
01
I
.J:>o
Granulators
Option 1
CollectIon Hood/WFFS'
3.5 kPa (14" W.G.) AP
0.25
(0.5)
Optlan 2
WFrs
3.5 kPa (14" W.G.) AP
Option 15
CollectIon Hood/WFFS
3.5 kPa (14" W.G.) AP
5
Optlan 2 and 3
WFrS
3.5 kPa (14" W.G.) AP
0.05
(0.1)
0.25
(0.5)
0.05
(0.1 )
145
(290)
EntraInment Scru~Ler
3.5 kPa (14" W.G.) AP
0.25
(0.5)
Sallie
0.25
(0.5)
5.4*
(10.8) *
Tray Scrubber
.15 kPa (3" W.G.) AP
0.7
(1.4)
EntraInment Scrubber
3.25 kPa (13" W.G.) AP
0.05
(0.1 )
So lids Flnlsh!.!!9.
Predryers, Dryer, Cooler
aWetted Fibrous filter Scrubber
*Averaye of EPA test data
TABLE 5-12.
Process
Capacity
Mg/Day
(TPO)
Prill Tower or
Granulator
Predryer, Dryer or
Cooler
H1-1
High Density
Pri11ing
363 (400)
Tray Scrubber
Tray SCrubber
Hl-2
Hi gh Dens i ty
Pri11ing
363 (400)
Tray SCrubber
Entrainment Scrubber
Hl-3
High Density
Pri 11 ing
363 (400)
Collection Hood/WFFS a
(Op.1)
Entrainment Scrubber
Hl-4
High .Density
?ri11ing
363 (400)
Entrainment Scrubber
Hl-4a
High Density
Pri 11 ing
363 (400)
Entrainment Scrubber
tiZ-1 through
HZ-4a
High Density
Pri 11 ing
726
H3-1 through
H3-4a
High Density
?ri11ing
1089 (1200)
Ll-l
Low Density
Pri 11 in9
181 (200)
None
Tray SCrubber
Ll-2
Low Density
Pri 11 in9
181 (200)
None
Entrainment Scrubber
Ll-3
Low Density
Prill ing
181 (200)
Entrainment Scrubber
Ll-4
181 (200)
Collection Hond/WFFS a
(Op.l)
Full F10wWFFS a
(Op.Z)
U-1 through
U-4
Low Density
Prill ing
363 (400)
L3-1 :hrough
L3-4
Low Density
Prilling
816 (900)
61-1
Granulation
363 (400)
Entrainment Scrubber
Tray Scrubber
Gl-2
Granulation
363 (400)
Entrainment Scrubber
Entrainment Scrubber
61-1 and
GZ-2
Granulation
726
63-1 and
G3-2
Granulation
(800)
(800)
1089 (1ZOO)
Entrainment Scrubber
5-35
5.5 REFERENCES
1.
2.
3.
4.
5.
5-36
6-1
TABLE o-l.
Hodel
Plant
Number
H-I-3
Control
Alternative
Iii gh Oens tty
Prill i ng
1 (lOC)
2
3
4
4a
Prill Tower
Cooler
0
0
X (Option 1)
X (Option 2)
X (Option 3)
0
X
X
X
X
Prill Tower
L 1-3
Ol
I
1 (lOC)
2
3
4
0
0
X (Option 1)
X (Option 2)
8
(2.
.50
0.60
0.20)
(0.20)
g/kg
(1. 30~
0.65
1.10
1.30
1.30
2 2O
f2.60
(2.60)
0
46
79
93
93
Predryer, dryer
and cooler
0
X
X
X
~5.601
1.70
2.80
0.85
0.40
0.20
0.80
(0.40)
0.95
0.30
9
(1.
(0.60
1.95
2.40
2.60)
P l
9
4.80
(5.20)
0
70
86
93
Granulator
G 1-3
(iranul a t ion
1 (ELOC)
0
X
Cooler
0
X
0.65
(1.30)
BErni ssion f.lctors reflect total emissions. Inel udi ng hypa ss emi ssions when applicable.
bThis option is for a reduced flow wetted fibrous filter scrubber, no reduction in emissions are credited.
impacts will be changed.
o-
X - Optional Control
0
68
6-3
TABLE 6-2.
Hodel Plant
Number
Hodel
Plant
H-l
Hi gh Dens Ity
Prilllng
363
(400)
76 (84)
129 (142)
152 (167)
152 (167)
H-2
726
(800)
152 (167)
258 (284)
305 (335)
305 (335)
11-3
1089
(1200)
228 (251)
387 (426)
456 (502)
456 (502)
181
(200)
114 (126)
140 (155)
152 (167)
1.-2
363
(400)
228 (251)
281 (309)
304 (335)
L-3
816
(900)
512 (565)
631 (696)
683 (753)
363
(400)
76 (84)
G-2
726
(800)
152 (167)
G-3
1089
(1200)
L-1
m
Control Alternative
3
Plant Capacfty
My/Day
(TPO)
G-l
Granulator
228 (251)
4a
TABLE 6-3.
Model Plant
O'l
Control
Alternative
Power Plant
Particulate Emissions
Over flOC 2
10- 2 g/kg
10- lh/ton
AN Particulate
Emissions Reduction
FrlJll1 noc
g/kg
lblton
Percent Impact of
Secondar.v Emissions
Over AN Emissions
Reduction
Power Plant NO
Emissions Over E~OC
g/kg
lh/ton
H-l
2
3a
4a
4a
0.45
-0.80
1.11
-0.65
0.91
-1.60
2.22
-1.30
0.65
1.1
1.3
1.3
1.3
2.2
2.6
2.6
0.7
-0.7
0.8
-0.5
0.02
-0.03
0.05
-0.03
0.04
-0.07
0.10
-0.06
0.02
-0.03
0.04
-0.02
0.04
-0.07
0.09
-0.05
H-2
2a
3
:1
0.33
-0.68
1.14
-0.49
0.67
-1.36
2.29
-0.98
0.65
1.1
1.3
1.3
1.3
2.2
2.6
2.6
0.5
-0.6
0.9
-0.4
0.01
-0.03
0.05
-0.02
0.03
-0.06
0.10
-0.04
0.01
-0.03
0.04
-0.02
0.03
-0.06
0.09
-0.04
1f-3
2a
3
4a
4a
0.39
-0.67
1.20
-0.50
0.78
-1.34
2.40
-1.00
0.65
1.1
1.3
1.3
1.3
2.2
2.6
2.6
0.6
-0.6
0.9
-0.4
0.01
-0.03
0.05
-0.02
0.03
-0.06
0.10
-0.04
0.01
-0.03
0.05
-0.02
0.03
-0.06
0.10
-0.04
l-I
2
3
4
1.07
1.68
3.59
2.15
3.37
7.18
1.95
2.4
2.6
3.9
4.8
5.2
0.5
0.7
1.4
0.04
0.07
0.15
0.09
0.15
0.31
0.04
0.07
0.14
0.09
0.14
0.29
l-2
2
3
4
1.06
1.66
3.57
2.12
3.33
7.14
1.95
2.4
2.6
3.9
4.8
5.2
0.5
0.7
1.4
0.04
0.07
0.15
0.09
0.14
0.31
0.04
0.07
0.14
0.09
0.14
0.29
l-3
2
3
4
1.06
1. 70
3.50
2.13
3.41
7.01
1.95
2.4
2.6
3.9
4.8
5.2
0.5
0.7
1.3
0.04
0.07
0.15
0.09
0.15
0.31
0.04
0.07
0.14
0.09
0.14
0.29
G-l
0.35
0.70
0.65
1.3
0.5
0.01
0.03
0.01
0.03
G-2
0.35
0.70
0.65
1.3
0.5
0.01
0.03
0.01
0.03
G-3
0.35
0.70
0.65
1.3
0.5
0.01
0.03
0.01
0.03
I
U'1
a The power plant e",issions (secondary emissions) are less than the ElOC for this alternative because the control equipment for this
al ternative requiJ"es less energy than the control equipment for the flOC.
Table 6-3 also presents the increases in S02 and NO x power plant
emissions for each type of model plant. Alternative 4 for Model Plant L-l
causes the largest increase in these emissions. In this case t the power
plant would generate an increase in S02 and NOx emissions of 0.150 g/kg
(0.313 lb/ton) and 0.145 g/kg (0.291 lb/ton) of AN produced t respectively.
The assumptions and calculations used in developing these air quality
impacts can be found in Reference 1.
6.1.3 Summary of Air Quality Impacts
The primary air pollutant emissions from affected facilities in the
AN industry are AN particulates. The major benefit of implementing the
control alternatives is a reduction of particulate emissions, and thus a
potential lessening of health and environmental hazards. The largest
reduction in AN particulate emissions which would result from applying
the control alternatives would be 683 Mg/year (753 TPY) for Alternative 4
of Model Plant L-3. The corresponding increase in power plant emissions
would be 9.20 Mg/year (lO.14 TPY), which is only a 1.3 percent impact on
the particulate emission reduction. Therefore t the potential secondary
air emissions are not considered significant.
6.2 WATER POLLUTION IMPACT
There would be no adverse water pollution impact due to the implementation of the proposed control alternatives. Water used in the wet
scrubbers to control particulate emissions is usually recycled to the
solution concentration process for complete recovery of the ammonium
nitrate.
6.3 SOLID WASTE IMPACT
There would be no solid waste impact due to the application of the
control alternatives, since the collected AN emissions are dissolved in
the scrubber liquor and recycled to solution formation.
6.4 ENERGY IMPACT
The energy impact of the control alternatives is less than seven
percent of the energy needed for the process equipment. The process
equipment energy includes energy needs from solution formation through
the finishing of the final product. 2
6-6
6-7
Model
Plant
Control
Alternative
4a
17.58
20.23
12.88
24.05
13.80
2.52
-4.45
6.14
-3.56
11-2
1
2
3
4
4a
32.22
35.94
24.69
44.90
26.76
33.99
37.92
26.05
47.37
28.23
3.72
-7.53
12.68
-5.46
H-3
1
2
3
4
4a
47.20
53.68
36.09
67.11
38.88
49.80
56.63
38.07
70.80
41.02
-11.11
1
2
3
4
7.30
10.28
11.96
17 .22
7.70
10.85
12.62
18.17
2.98
4.66
9.92
L-2
1
2
3
4
14.50
20.37
23.71
34.26
15.30
21.50
25.01
36.14
5.87
9.21
19.76
L-3
1
2
3
4
32.69
45.93
53.92
76.33
34.48
48.45
56.89
80.52
13.24
21.24
43.64
G_l b
1
2
4.73
6.68
4.99
7.05
1.95
1
2
9.46
13.35
9.98
14.08
3.89
1
2
14.19
20.03
14.97
21.13
5.84
1
2
3
Energy Requirements
Over ELOC
t09 8tu/yr
TJ/yr
16.66
19.18
12.21
22.80
13.08
H-l
0'\
L-l
00
G_2 b
G_3 b
6.48
19.91
-8.32
544
544
544
544
544
574
574
574
574
574
0.5
-0.8
1.1
-0.7
1086
1086
1086
1086
1086
1146
1146
1146
1146
1146
0.3
-0.7
1.2
-0.5
1630
1630
1630
1630
1630
1720
1720
1720
1720
1720
0.4
-0.7
1.2
-0.5
271
271
271
271
286
286
286
286
1.1
1.7
3.7
544
544
544
544
574
574
574
574
1.1
1.7
3.6
13.97
22.41
46.04
1223
1223
1223
1223
1290
1290
1290
1290
1.1
1.7
3.6
2.06
578
578
610
610
0.3
4.10
1153
1153
1216
1216
0.3
1731
1731
1826
1826
0.3
2.66
-4.69
6.48
-3.78
3.93
-7.94
13.38
-5.76
6.83
-11.72
21.00
-8.78
3.14
4.91
10.46
6.20
9.71
20.85
6.16
alncludes energy needed for solution formation through finishing of the final product.
control equipment for the granulator is considered in the plant ener9Y requirements. not in the
control equipment energy reqUirements.
bThe
6.6
REF ERENC ES
1.
2.
6-9
New York,
7-1
"--J
Process
IH gh
Capacity
Mg/Day (TPD)
H-l
H-2
H-3
363 (400)
726 (800)
1089 (1200)
L-l
L-2
L-J
181 (200)
363 (400)
816 (900)
G-l
G-2
G-3
Granulation
Granulatfon
Granulation
363 (400)
726 (800)
1089 (1200)
TABLE 7-2.
Uncontro11 ed
kg/Hg (Ibs/ton)
EMISSION FACTORS
Exlstlnll r:ontrol
Ex Istfnll
kg/Mg ( Ibs/ton)
Controlled
kg/Mg (Jbs/ton)
Solids formation
Low Density Prill Towers
0.7
1.55
(1.4)
(3.1 )
None
Two-Tray Scrubber
2.75 kP. (II" W.G.) AP
0.7
0.7
(1.4 )
(1.4)
-..J
I
Granulators
Option 1
Co llect Ion lIood/WFFS
3.5 kPa (14- W.G.) AP
0.25
(0.5)
Optlvn 2
WFFS
3.5 kPa (14- W.G.) AP
0.05
(0.1)
Option IS
Collection Hood/WFFS
3.5 kP. (14- W.G.) AP
5
Opt IVn 2 and 3
WFFS
3.5 kPa (14- W.G.) AP
0.25
(0.5)
0.05
(0.1)
145
(290)
Entrainment Scrubber
3.5 kPa (14- W.G.) AP
0.25
(0.5)
Same
0.25
(0.5)
5.4
(10.8)
Tray Scrubber
.75 kPa (3- W.G.) AP
0.7
(1. 4)
Entrainment Scrubber
3.25 kPa (13- W.G.) AP
0.05
(o.ll
Solids Finishing
Predryers, Dryer, Cooler
aWetted Fibrous FIlter Scrubber
Average of EPA test data
TABLE 7-3.
PI"OCl!SS
Capacity
Mg/Day
(TPD)
Pri 11 Tower or
Granulator
Predryer. Dryer or
Cooler
Hl-1
High DeIlsity
Pri 11 ing
363 (400)
Tray Scrubber
Tray Scrubber
Hl-2
High Density
Pri 11 i",
363 (400)
Trly Scrubber
Entraillllent Scrubber
Hl-3
Hi gh DeJlSity
Pri11fng
363 (400)
Entrainment Scrubber
Hl-4
High Density
PrflHng
363 (400)
Hl-4a
Hi gil Density
Prini",
363 (400)
Collection Hood/WFFSa
(Op.l)
Full Flow WFFS a
(Op.2)
Reduced Flow WFFS a
(Dp.3)
H2-1 through
H2-4a
High Density
Prilling
726 (800)
H3-1 through
H3-4a
Higil Density
PrilHng
1089 (1200)
Ll-l
1.ow Density
Prfl1ing
181 (200)
None
Tray Scrubber
1.1-2
1.ow Density
Prllling
181 (ZOO)
None
Entrainment Scrubber
1.1-3
1.ow Density
Pri11ing
181 (200)
Collection HoDd/WFFSa
(Op.l)
Entrainment Scrubber
1.1-4
1.ow Qnsity
Prilltng
181 (200)
Entrainment Scrubber
1.Z-1 through
L2-4
1.ow Density
Printng
363 (400)
Same controls
IS
LJ-l through
L3-4
1.ow Density
PrilHng
816 (900)
Same controls
IS
Gl-1
Granulation
363 (400)
Entrlinment Scrubber
Tray Scrubber
&1-2
GrallUlltfon
363 (400)
Entrainment Scrubber
Entrainment Scrubber
Gl-l and
GZ-2
Gr.-litton
726 (BOO)
Same controls
GJ-l and
&3-2
GranullUan
1089 (1200)
7-4
IS
Entrainmp.~t
Scrubber
Entrainment Scrubber
7-5
7-6
TABLE 7-4.
7-7
TABLE 7-5a.
I.
Control Device
Stacks
CONTROL OPTION I
Control Device
Stack
Bypass Stacks
7-8
III.
CONTROL OPTION 2
Control Device
Downcomer
Stacks
CONTROL OPTION 3
Control Device
Stack
Recirculation Pump and Motor
7-9
I.
II.
STACKS
WFFS
n.....---STACKS
FANS
FANS-~~m~n;:3r-- DU.CTING
SPRAY
COLLECTION
HOOD
SPRAY
CONVEYING
CONVEYING
IV.
I---.L..lr--~r--
DOWNCOMER
SPRAY
STACKS
CONVEYING
CONVEYING
WFFS
Figure 7-1.
DUCTING
TABLE 7-5b.
I.
t~JOR
Stacks
II.
CONTROL OPTION I
Control Device
Stack
Bypass Stacks
III.
CONTROL OPTION 2
Control Device
Downcomer
7-11
Stacks
high, 55
2.4 m3/min (620 gpm), 299 kPa (100 ft. of
water), 30 kw (40 bhp)
7-12
I.
EXISTING UNCONTROLLED
II.
~-, I r-----STACKS
STACKS
SPRAY
COLLECTION
HOOD
CONVEYING
CONVEYING
DOWNCOMER
CONVEYING
FANS
Figure 7-2.
TABLE 7-5c.
Control Device
Stack
7-14
TABLE 7-5d.
I.
Control Device
Stack
II.
OPTION CONTROL
Control Device
Stack
7-15
7-16
7-17
TABLE 7-6.
0.67 Q
0.51 Q
3.08 Q
7-18
TABLE 7-7.
Plant Type
High Density
Pri 11 ing
Source of
Emissions
Cooler
Cooler
Prill Tower
Prill Tower
Prill Tower
Prill Tower
Low Density
Prill ing
Predryer
Predryer
Dryer
Dryer
Cooler
Cooler
Prill Tower
Prill Tower
Prill Tower
Granulation
Cooler
Cooler
Granulator
Major Equip.b
ment Cost
24.000
38.000
215.000
124.000
60.000
71,000
340.000
352.000
184.000
219.000
1.040.000
1.090.000
558.000
940.000
2.900,000
158.000
249.000
767.000
25.000
38.000
25.000
38.000
35,000
37.000
124.000
61.000
71.000
61.000
71.000
59,000
69,000
148,000
350,000
187.000
217,000
187.000
217,000
181.000
210,000
454,000
1,080,000
564.000
943,000
2,910,000
26,000
39,000
57,000
63,000
72,000
122,000
192,000
221,000
374,000
Control Equipment
7-19
Total Instal1edc
Cost
TABLE 7-8.
Total
Equipment
Cost
Tota1 d
Installed
Cost
400,000
411,000
423,000
1,010,000
320,000
657,000
669,000
721,000
1,800,000
564,000
896,000
900,000
1,050,000
2,680,000
794,000
188,000
219,000
363,000
664,000
327,000
356,000
559,000
1,150,000
668,000
696,000
1,060,000
2,220,000
183,000
193,000
366,000
386,000
549,000
579,000
1,230,000
1,270,000
1,300,000
3,110,000
986,000
2,020,000
2,060,000
2,220,000
5,560,000
1,740,000
2,760,000
2,770,000
3,230,000
8,140,000
2,450,000
580,000
675,000
1,120,000
2,050,000
1,010,000
1,100,000
1,720,000
3,550,000
2,060,000
2,140,000
3,260,000
6,860,000
565,000
594,000
1,130,000
1,190,000
1,700,000
1,780,000
P1ant a
No.
Hl
H2
H3
Ll
LZ
Gl
GZ
GJ
Reg. b
Alt.
1
2
3
4
4a
1
2
3
4
4a
1
2
3
4
4a
1
2
3
4
1
2
3
4
1
2
3
4
1
2
1
2
1
2
Cue
Hl-1
Hl-2
Hl-3
Hl-4
Hl-4a
H2-1
H2-2
H2-3
H2-4
H2-4a
H3-1
H3-2
H3-3
H3-4
H3-4a
Ll-1
Ll-2
Ll-3
11-4
L2-1
LZ-2
L2-3
LZ-4
L3-1
U-2
L3-3
L3-4
G1-1
Gl-2
GZ-1
GZ-2
GJ-1
GJ-Z
Difference in
Total Instilled
Cost for
Alternative Relathe to ELDC'" %
3.3
5.7
153
-20
2.0
9.9
175
-14
0.4
17
195
-11
16
93
253
B.9
70
251
3.9
58
233
5.1
5.3
4.7
Emission Reductions e
Achieved by Control
Alternative
M91yr
{ton/yr!
n6
715
799
856
801
801
1,297
1,448
1,553
1,600
1,600
1,945
2,173
2,330
2,400
2,400
824
938
964
976
1,547
1,874
1,927
1,951
3,707
4,218
4,336
4,390
17 ,464
17,531
34,927
35,061
52,391
52,593
883
1,430
1,597
1,713
1,764
1,764
2,144
2,396
2,569
2,647
2,647
908
1,034
1,063
1,076
1,816
2,067
2,125
2,151
4,086
4,652
4,782
4,841
19,250
19,333
38,500
38,665
57,750
57,969
649
725
7-20
883
Emissions for
Al ternative
Relative to
ELOC'" %
12
20
24
24
12
20
24
24
12
20
24
24
14
17
19
14
17
19
14
17
19
0.4
0.4
0.4
Electricity
$.04/kwh
Operating Labor
$17.45/hr 14
Operating Hours
Process Equipment
7,728 hours/year
Scrubbers
7,728 hours/year
Each scrubber requires one eighth of
an operator while in operation 15
5.5 percent of capital investment lS
Maintenance
Capi ta1 Charges
Administrative Overhead
Recovery Credit
$SS/Mg ($SO/ton)
7-21
7-22
TABLE 7-10.
Plant Type
Hi gh Dens i ty
Prilling
Source of
Emissions
Cooler
Cooler
Prill Tower
?ri 11 Tower
Prill Tower
Prill Tower
Low Density
Pri 11 ing
Predyer
Predryer
Dryer
Dryer
Cooler
Cooler
Prill Tower
Pri 11 Tower
Prill Tower
Granulation
Cooler
Cooler
Granulator
Control Equipment
ELOC' Tray Scrubber
Entrainment Scrubber
ELOC Two-Tray Scrubber
Collection Hood/WFFS e
(Op.l)
Full Flow WFFS e
(Dp.2)
Reduced Flow WFFS e
(Op.3)
Entrainment Scrubber
ELOC Entrainment Scrubber
Total Annual b
Cost
6,200
22,600
118,000
30,800
72,000
97,000
405,000
331,000
41 ,000
63,000
400,000
323,000
150,000
924,000
914,000
35,900
254,000
244,000
5,700
21.800
5.700
21.800
5,700
21,000
4,400
32.000
72,000
96,000
72,000
96.000
70,000
93,000
123,000
331,000
41.000
62.000
41,000
62.000
40,000
59.000
123,000
329,000
151,000
927.000
923,000
5.900
22,000
43.500
73.000
97.000
158.000
43,000
63.000
-775,OOOd
7-23
7-24
TABLE 7-11.
P1ant a
No.
HI
Reg. b
Alt.
1
2
3
4
4a
H2
1
2
3
4
4a
H3
1
2
3
4
4a
Ll
L2
L3
Gl
G2
63
1
2
3
4
1
2
3
4
1
Z
3
4
1
2
1
2
1
2
Case
H1-1
Hl-2
Hl-3
Hl-4
Hl-4a
H2-1
H2-2
H2-3
H2-4
H2-4a
H3-1
H3-2
H3-3
H3-4
H3-4a
Ll-l
Ll-2
Ll-3
Ll-4
L2-1
L2-2
LZ-3
L2-4
l3-1
L3-Z
L3-3
l3-4
Gl-1
Gl-2
G2-1
GZ-2
G3-1
G3-2
..
476.000
502.000
428.000
1.020.000
350.000
BOO.OOO
840.000
724,000
1.830.000
612,000
1,110,000
1,160,000
1.030.000
2.660,000
844,000
214.000
263,000
410,000
711.000
335,000
406.000
614.000
1.210,000
637,000
768,000
1,150,000
2.330.000
Z31.000
254.000
462.000
508,000
693,000
762.000
440,000
462,000
386,000
976,000
306,000
729,000
760,000
638,000
1,740.000
525.000
1.010,000
1.040,000
903,000
2.530,000
713.000
168,000
213,000
359,000
659,000
244,000
303,000
507,000
1,110,000
433,000
536.000
906.000
2.090.000
-732,000
-712,000
-1.460,000
-1,420,000
-2.200,000
-2,140,000
Effect on Coste
of Product
(including recovery
credit)
cost'
Effectiveness
(including recovery
credi t)
SiMg
S/to"
S/Mg
S/ton
3.77
3.84
3.31
8.36
2.61
3.12
3.25
2.73
7.44
2.25
2.87
2.97
2.58
7.22
2.03
2.88
3.65
6.14
11.29
2.08
2.60
4.35
9.47
1.64
Z.05
3.46
7.97
-6.25
-6.10
-6.25
-6.10
-6.25
-6.10
3.42
3.58
3.00
7.58
2.37
2.83
2.95
2.48
6.75
2.04
2.60
2.69
2.34
6.55
1.84
2.61
3.31
5.57
10.24
1.89
2.36
3.95
8.59
1.49
1.B6
3.14
7.23
-5.67
-5.53
-5.67
-5.53
-5.67
-5.53
679
637
497
1224
381
562
525
411
1087
327
517
478
387
1055
297
204
227
372
676
148
162
616
578
451
1110
346
510
476
372
986
297
469
434
351
957
259
185
206
338
513
134
147
239
514
106
115
189
433
-38
-37
-38
-37
38
-37
Z63
567
117
127
209
477
-42
-41
-42
-41
-42
-4",
In Table 7-9.
7-25
Cost Effectiveness
Relative to ElOC*
(including recovery
credit)
S/Mg
S/ton
287
-422
3516
-880
262
-383
3190
-798
205
-355
3337
-674
186
-322
3027
-611
131
-306
3331
-605
119
-278
3022
-590
394
1358
3222
357
1232
2923
259
938
2849
235
851
2585
201
749
2420
182
680
2195
266
241
266
241
266
241
Cx
alternative x.
CE = Net annualized cost to remove a quantity of pollutant (P E) to
meet the specified existing level of control.
Cost effectiveness values indicate that Alternative 3, Alternative 1,
and Alternative 2 are the most cost effective alternatives for high
density pril1ing, low density pril1ing and granulation plants, respectively.
7.1.2.6 Base Cost of Facility. To provide a perspective in which
control costs can be viewed, capital and annual cost for the entire
ammonium nitrate plants are presented. Table 7-12 provides the base
capital and annual cost of ammonium nitrate plants for the range of
plant sizes investigated. All costs are installed costs, and all facilities
are uncontrolled.
Capital costs of the plants were based upon plant costs obtained
from published sources and cost estimating manuals. 22 ,23 These costs
are for the entire plant, which include solution formation, concentration,
and solids formation equipment. Costs are given for various model plant
sizes, but no differentiation is made between low density pril1ing, high
density prilling and drum granulation.
The average total capital investment for new ammonium nitrate
plants ranged from $3.54 million for a 181 Mg/day (200 TPD) facility to
$9.48 million for a 1089 Mg/day (1200 TPO) facility.
The annual cost for ammonium nitrate plants was based upon information
obtained from an economic analysis of water pollution regulations. 24
This economic analysis presents annual costs as percentages of annual
sales. From this source it was determined that a small 181 Mg/day (200
TPD) facility spends 99 percent of the sales value of the product on
annual expenses. For a large 1089 Mg/day (1200 TPD) plant, operating
costs amount to 74 percent of the sales value of the product. The
annual cost for operation of the ammonium nitrate plants ranges from
$5.80 million for a 181 Mg/day (200 TPD) facility to $26.00 million for
a 1089 Mg/day (1200 TPD) facility.
7-26
TABLE 7-12.
Plant Size
Mg/Day (TPD)
Annua 1 Cos t
$ Millions
181 (200)
2.95 - 4.13
3.54
5.80
363 (400)
4.01 - 5.90
4.96
10.90
726 (800)
6.12 - 9.09
7.61
19.40
816 (900)
6.72 - 9.68
7.95
21.10
1089 (1200)
7.39 - 11.60
9.48
26.00
7-27
7-28
7.3 REFERENCES
1.
Letter from Kahn, P. A., Peter A. Kahn and Co., to Brown, P., GCA
Corporation. October 30, 1979. p. 1. Cost of Monsanto EnviroChern Mist Eliminator.
2.
3.
4.
Te1econ. Brown, P., GCA Corporation, with Ewach, J., Koch Engineering.
May 7, 1979. Cost and operation of two-tray scrubber.
5.
6.
7.
8.
Reference 7, p. 4-53.
9.
Reference 7, P. 4-61.
10.
11.
Reference 7, p. 4-73.
12.
Economic Indicators.
1980.
13.
April 21,
June 4, 1980.
15.
16.
17. Memo from Apple, C., Radian Corporation, to file. September 19,
1980. 6 p. Capital and Annual Costs of control devices.
18.
19. Memo from Apple, C., Radian Corporation, to file. June 20, 1980.
3 p. Determination of recovery credits for ammonium nitrate
facilities.
20.
Memo from Apple, C., Radian Corporation, to file. June 20, 1980.
3 p. Survey of industry to characterize scrubber liquor concentration.
21.
22.
23.
24.
David, M.l., J.M. Malk and C.C. Jones. (Development Planning and
Research Associates, Inc.) Economic Impact of Costs of Proposed
Effluent Limitation Guidelines for the Fertilizer Industry.
(Prepared for U.S. Environmental Protection Agency.) Washington,
D.C. Publication No. EPA-230/1-73-010. October 1973. p. 11-14.
25.
26.
7-30
Chemical
APPENDIX A
Summary of Test Data
Six ammonium nitrate plants were tested by the EPA to evaluate
emissions and control techniques at solid ammonium nitrate production
facilities. A description of each plant. its major emission points. and
the operations tested are presented in this Appendix. The facilities
tested at the plants are listed below:
Plant A
Neutralizer scrubber inlet and outlet
Calandria evaporator outlet
Combined calandria - air swept falling film evaporator outlet
High density prill tower scrubber inlet and outlet
Rotary drum cooler scrubber inlet and outlet
Plant B
Rotary drum granulator scrubber inlet and outlet
Rotary drum cooler outlet
Plant C
Rotary drum predryer outlet
Rotary drum dryer outlet
Rotary drum cooler outlet
Plant D
Air swept falling film evaporator outlet
Combined evaporator - pan granulator scrubber inlet and outlet
Rotary drum precooler outlet
Chain mill (crusher) outlet
Combined precooler - chain mill scrubber outlet
Rotary drum cooler outlet
Plant E
Rotary drum cooler scrubber inlet and outlet
Plant Z
Low density prill tower scrubber inlet and outlet and bypass
Rotary drum predryer outlet
A-l
A-2
A.l
Plant A
A.l.l
Process Overview
Plant A produces high density ammonium nitrate prills and various
types of ammonium nitrate solutions. The plant was designed to produce
567 Mg/day (625 TPD) of prilled ammonium nitrate.
Two parallel neutralizers are fed nitric acid and ammonia or ammonia
rich Off-gases from the on-site, once-through urea solution plant, and
produce an 85 percent ammonium nitrate solution. This ammonium nitrate
solution is concentrated
to 99+ percent
,
. in two stages of concentration.
The first stage is a steam heated calandria and the second stage is an
air swept falling film evaporator. A magnesium nitrate additive produced
in a reactor is injected between the two stages of concentration.
The 99+ percent ammonium nitrate melt from the evaporators is
sprayed down through the prill tower, where the droplets are cooled and
solidified into prills by a countercurrent induced air flow. The prills
are then conveyed to a rotary drum cooler, which reduces the temperature
and removes nominal amounts of moisture from the prills by using a
countercurrent flow of heat-tempered, refrigerated air. Prills are then
screened; product sized prills are either bulk loaded or bagged, and
off-size prills are recycled to a weak scrubber liquor evaporator. A
calandria evaporator is used to concentrate recycled scrubber liquor and
redissolved offsize product rejected from the screening operation.
A.l.2 Emission Control Equipment
The emission control equipment used at Plant A is summarized
below. Each neutralizer uses an internal Brinks H-V mist eliminator,
followed by a venturi scrubber and a cyclonic separator. Emissions from
the two evaporators are normally ducted to a Koch valve tray scrubber
along with the prill tower emissions. Emissions from the recycle liquor
calandria evaporator and the magnesium additive reactor are usually
ducted to the Koch valve tray scrubber, too. However, during this
testing program only prill tower emissions were controlled by the Koch
valve tray scrubber; all other facilities normally controlled by
A-3
this scrubber were vented to the atmosphere. Prill tower emissions are
ducted down from the top of the prill tower to the Koch scrubber located
at ground level.
Exhaust from the rotary drum cooler is divided into two streams;
each stream enters a separate spray chamber scrubber. The air exiting
each spray chamber is again divided into two streams, each of which
enters a separate cyclonic separator. The four separator outlets are
then combined into two before being discharged to the atmosphere. The
screening, conveying, and bagging areas are all uncontrolled.
A.l.3 Facilities Tested
The facilities tested at Plant A are listed below:
Neutralizer scrubber inlet and outlet
Calandria evaporator outlet
Combined calandria and air swept falling film evaporator outlet
Prill tower Koch valve tray scrubber inlet and outlet
Prill cooler spray chamber inlet and cyclonic separator outlets
Opacity observations and particle size measurements were performed
at some of the facilities. Particle size was measured with a Sierra
Cascade Impactor, but all of the particulate matter was caught in the
pre-collector. Thus, no reliable size distribution information was
obtained. A discussion of the testing at each facility follows, including
any problems that occurred during testing.
A.l.3.l Neutralizer
The results of the mass emission tests performed at the inlet and
outlet of the neutralizer venturi scrubber are presented in Tables A-la
and A-lb. EPA test methods for high water content gas streams were
followed. The combined opacity of the two neutralizer scrubber plumes
were monitored and are presented in Table A-2. No opacity was observed
from this scrubber.
~4
A-5
A-6
A-7
TABLE A-la.
Test No.
General Data
Date
Isokinetic (%) In/Out
Production Rate (Mg/hr)
Ambient Temp. (K)
Relative Humidity
Exhaust Characteristics
F1owJ:ate
inlet:
(dnm.l/min)
outlet:
Temperature
inlet:
(K)
outlet:
Moisture (% vol) inlet:
outlet:
Control Device Characteristics
Device Type
Pressure Drop (kPa)
Liquor pH (Ave.)
Liquor AN Cone. (%) (Ave.)
Ammonium Nitrate Emissions
Partic~late Cone. inlet:
(g/dnm )
outlet:
Emission Rate
inlet:
(kg/hr)
outlet:
Emi ss i on Factor inlet:
(g/kg)
outlet:
Collection Efficiency (%)
Ammonia Emissions
inlet:
Ammoni~ Cone.
(g/onm )
outlet:
Emission Rate
inlet:
(kg/hr)
outl et:
Emission Factor inlet:
(g/kg)
outlet:
Collection Efficiency (%)
1a
6/19/79
92.74/110.1
10.2
309
34
6/20/79
113.7/114.9
10.5
303
57
6/20/79
126.6/112.8
10.4
305
58
8.938
8.555
408
373
94.43
95.01
7.383
9.241
405
372
95.24
94.85
.7887
10.71
405
374
99.53
94.23
681.0
2.542
32.22
1.696
3.1434
0.16542
94.7
285.3
220.4
134.9
146.9
13.2
14.3
Negative
398.5
412.2
213.6
221.9
20.5
20.9
Negative
A-B
62.83
2.144
27.83
1.226
2.6913
0.11862
95.6
529.7
593.1
234.4
339.1
22.7
32.8
Negative
Ave.
120.2 b/112.6
10.4
306
50
8.162 b
9.502
406
373
94.84
94.70
14.2
8.81
7.0
55.60 b
2.400
27.23
1.416
2.6329
0.13693
94.8
379.0
400.3
185.4
240.0
17 .9
22.8
Negative
TABLE A-lb.
Test No.
General Data
Date
Isokinetic (%) In/Out
Production Rate Tons/hr
Ambient Temp. OF
Relative Humidity
Exhaust Characteristics
Flowrate
inlet:
outlet:
(dscfm)
inlet:
Temperature
(FO)
outlet:
Moisture (: vol) inlet:
outlet:
Contr~l Device Characteristics
Device Type
Pressure Drop (in. W.G.)
Liquor pH (Ave.)
Liquor AN Cone. (~) (Ave.)
la
6/19/79
92.74/110.1
11.3
96
34
6/20/79
113.7/114.9
11.5
86
57
6/20/79
126.6/112.8
11.4
89
58
Ave.
120.2 b/112.6
11.4
90
50
260.7
326.3
270
210
95.24
94.85
288.2 b
335.6
271
212
94.84
94.70
57.1
8.81
7.0
27.85
378.3
269
213
99.53
94.23
297.6
1.111
71.04
3.739
6.2867
0.33088
94.7
124.5
96.25
297.4
323.9
26.32
28.67
Negative
315.6
302.1
275
212
94.43
95.01
23.28
1.089
62.98
2.912
5.4765
0.25326
95.4
174.0
180.0
470.8
489.1
40.94
41.85
Negative
A-9
27.46
.9370
61.36
2.704
5.3825
2.23723
95.6
231.3
259.0
516.8
747.6
45.33
65.59
Negative
24.30 b
1.049
60.03
3.121
5.2658
0.27378
94.8
165.5
174.8
408.7.
529.0
35.85
45.63
Negative
TABLE A-2.
1l,Ile
h-19- 7!'
!~Cl!.!!
:ta
I
-..I
f,-I!'-1!'
II
011
'l'lmo
II!I:JIHI!J 35
0936-0941
11942-0947
0948-0953
0954-0959
1001l-100S
11106-1011
1012-1017
1018-1023
1024-1029
1030-1035
1036-1041
1042-10"7
1048-1053
1054-1059
1100-1105
11116-1111
1112-1117
1I18-1J 23
1124-1129
153U-15J5
1536-1541
1542-1541
1548-15S1
1554-1559
1600-1605
1606-1611
1612-1611
1618-162:\
1624-1629
AveroRe
fJ
Dilte
l.vellt 1011
0
0
62U-79
"
II
II
0
II
0
0
0
0
0
0
0
0
(I
II
0
II
U
II
0
0
0
II
II
II
0
II
6-22-79
Time
0i13C Ity
I:or
~1Il1ute5
133iH13S
1336-1341
1342-1347
1l48-1353
135"-1l59
14011-14115
1406-1411
1412-1411
1418-1423
1424-1429
"
1400-1405
)406-1411
1412-1411
1418-1423
1424-1429
1430-1435
1436-1441
1442-1447
1448-1453
1454-1459
0
0
0
0
0
0
0
0
0
0
0
II
0
0
0
II
0
U
0
2'
General Data
6/22/79
Date
98.3
Isokinetic (%)
Production Rate (Mg/hr)
15.6
Ambient Temp. (K)
301
Ambient Moisture (%) Relative Humidity
67
Exhaust Characteristics
Flowsate
(dnm Imin).
Temperature
6/22/79
105.1
15.9
304
49
0.234
416
417
( K)
Moisture (% Vol.)
Ammonium Nitrate Emissions
Particulate Cone.
(g/dnm 3)
Emission Rate
(kg/hr)
Emiss;on Factor
(g/kg ).
Ammonia Emissions
Ammoni~ Cone.
(g/dnm ).
Emi ss; on Rate
(kg/hr)
Emission Factor
(g/kg)
0.235
99.77
99.78
122.55
119.3
6/22/79
104.1
16.1
306
44
0.291.
416
99.73
132.2
Ave.
102.5
15.9
304
53
0.253
416
99.76
125.2
1.720
1.679
2.307
1.902
0.1102
0.1058
0.1437
0.1198
1484.4
1279.4
20.85
18.01
1.336
A-ll
1.1345
1506.8
26.30
1.638
1428.3
21. 70
1.367
TABLE A-3b.
Test No.
Genera 1 Data
Date
Isokinetic (%)
Production Rate Tons/hr
Ambient Temp. OF
(%) Relative Humidity
Exhaust Characteristics
F10wrate
(dscfm)
Temperature
6/22/79
98.3
17.2
82
67
6/22/79
105.1
17 .5
88
49
6/22/79
104.1
17.7
92
44
8.272
289
291
(F' )
Moisture (% Vol.)
Ammonium Nitrate Emissions
Particulate Cone.
(gr/dscf)
Emission Rate
(1 b/hr)
Emi ss ion Factor
(lb/ton)
Ammonia Emissions
Ammonia Cone.
(gr/dscf)
Emission Rate
(1 b/hr)
Emission Factor
(lb/ton)
8.291
10.280
290
102.5
17.5
87
53
8.948
290
99.n
99.78
99.73
99.76
53.48
52.09
57.72
54.68
3.792
3.702
5.086
4.194
0.22047
0.21154
0.28734
0.23966
648.2
558.7
45.96
2.672
A-12
39.70
2.269
658.0
57.98
3.276
623.7
47.84
2.734
TABLE A-4a.
Test No.
General Data
Date
Isokinetic (%)
Production Rate (Mg/hr)
Ambient Temp. (K)
(%) Relative Humidity
Exhaust Characteristics
Flowrate
(dnm 3/min)
Temperature
(K)
Moisture (% Vol.)
Ammonium Nitrate Emissions
Particulate Cone.
(g/ dnm 3)
Emission Rate
(kg/hr)
Emission Factor
(g/kg)
Ammonia Emissions
All1IlOnia Cone.
(g/dnm3 )
Emission Rate
(kg/hr)
Emission Factor
(g/kg)
6/22/79
113.2
18.4
301
67
6/22/79
127.5
19.1
304
49
6/22/79
111.4
19.1
306
44
117.4
18.7
304
53
90
77
91
86
428
429
430
429
32.45
43.38
35.71
Ave.
37.18
0.2565
0.2739
0.2638
0.2647
1.392
1.269
1.439
1.369
0.0756
0.0666
0.0756
0.0726
14.78
12.42
80.2
57.5
4.357
A-13
3.019
18.37
100.2
5.255
15.22
78.7
4.171
Ave.
6/22/79
113.2
20.3
82
67
6/22179
6/22/79
111.4
21.0
92
44
117.4
20.8
87
53
3196
2728
3213
3046
311
313
315
313
32.45
127.5
21.0
88
49
43.38
35.71
37.18
0.1120
0.1196
0.11.52
0.1156
3.068
2.797
3.173
3.018
0.15113
0.13319
0.15110
0.14510
6.458
5.423
8.02
6.646
176.9
8.714
A-14
126.8
6.038
220.8
10.51
173.5
8.341
TABLE A-5a.
Test No.
Ave.
Genera1 Da ta
Date
Isokinetic (~) In/Out
Production Rate (Mg/hr)
Ambient Temp. (K)
Relative Humidity
: Opacity
5/8/79
99.3/108.4
19.1
299
60
12.8
5/8/79
98.9/110.8
19.1
298
60
15.2
5/9/79
99.3/103.5
19.3
299
65
17 .2
Exhaust Characteristics
inlet:
Flowsate
(dnm lmin)
outlet:
Temperature
inlet:
( K)
outlet:
Moisture (% vol) inlet:
outlet:
7300
7510
307
309
2.049
3.033
7190
7470
306
308
2.466
2.56
7320
7600
306
306
2.542
2.874
7270
7530
306
308
2.352
2.822
2.66
6.50
27
2.66
7.00
32
0.06816
0.03446
29.41
15.43
1.544
0.811
47.5
1. 2641
0.1806
545.2
80.9
28.61
4.24
85.2
0.0002097
0.00006295
0.0905
0.0282
0.00475
0.00148
68.8
*Run 3 results were low and were not included in the average.
A-15
0.07228
0.03794
31. 75
17 .31
1.643
0.896
45.5
0.0460
0.0632
20.2
28.8
1.05
1.49
Negative
0.0002659
0.0001194
0.1168
0.0545
0.00605
0.00282
53.3
99.21107.6
19.2
299
62
15.1
0.07075
0.03585
30.86
16.16
1.612
0.844
47.6
1.2568
0.1920
547.5
86.7
28.6
4.53
84.2
0.0003652
0.0000974
0.1593
0.0440
0.00832
0.00230
72.4
TABLE A-5b.
Tes t No.
Ave.
99.2/107.6
21.1
78
62
15.1
General Data
Date
Isokinetic (%) InlOut
Production Rate Tons/hr
Ambient Temp. OF
Relative Humidity
% Opacity
5/8/79
99.3/108.4
21.0
78
60
12.8
5/8/79
99.8/110.8
60
15.2
5/9/79
99.311 03. 5
21.3
78
65
17.2
Exhaust Characteristics
F10wrate
inlet:
(dscfm)
outlet:
Temperature
inlet:
(FO)
outlet:
Moisture (% vol) inlet:
outlet:
257,800
265,200
93
96
2.049
3.033
253,900
263,700
91
95
2.466
2.56
258,500
268,500
91
91
2.542
2.874
256,700
256,800
92
94
2.352
2.822
10.7
6.50
27
10.7
7.00
32
21.0
77
0.03136
0.01535
69.29
34.88
3.299
1.661
49.7
0.02979
0.01506
64.83
34.02
3.087
1.620
47.5
0.03159
0.01658
69.99
38.16
3.286
1.792
45.5
0.03092
0.01565
68.02
35.64
3.224
1.688
47.6
Ammonia Emissions
Ammoni a Cone.
inlet:
(gr/dscf)
out1 et:
Emission Rate
inlet:
(lb/hr)
outlet:
Emi ss i ,on Factor inlet:
(l b/ton)
outlet:
Collection Efficiency (%)
0.5506
0.08680
1217
197.3
57.95
9.40
83.8
0.5520
0.07886
1202
178.3
57.22
8.48
:65.2
0.0201
0.02760
44.55
63.53
2.092
2.98
Negative
0.5488
0.08386
1207
191.1
57.21
9.05
84.2
Magnesium Emissions
Magnesium Conc.
inlet:
(gr/dscf)
outlet:
Emission Rate
inlet:
(1 b/hr)
outl et:
Emission Factor inlet:
(1 b/ton)
outlet:
Collection Efficiency (%)
0.0002734
0.0004862
0.6041
0.1105
0.02877
0.00526
81.7
0.00009165
0.00002751
0.1995
0.06218
0.00950
0.00296
68.8
*Run 3 results were low and were not included in the average.
A-16
0.0001162
0.00005217
0.25747
0.12007
0.01209
0.00564
53.3
0.0001596
0.00004256
0.35116
0.09696
0.01664
0.00460
72.4
TABLE A-G.
lIalc
5-1 1!'
III"' NlIllll(!r
-----_.... ---_.
NA
):a
........
.....,
SoH -7!'
Tin",
I\ven'l:c C~,lI(I' Y
\=1)" (I ~lillu' C'i
...
---~-_._._-_._.-
ltllIl- "'05
140b-"'11
"'12-1411
1418-142-'
1424-1429
100 ... ]5
14]6-14'"
144214.n
1448-145]
1454-1459
1505-1510
15111516
1511-1511
1521-1528
1529-1534
1535-15411
1541-154(,
1547-1552
155]-IS58
1559-160"
I'\vcn"lc
2.J
1.1
(1.1
8.B
6.5
5.4
_----- _._--
1);llc
III
.. III NlIllhc t
5-B-79
Fur () W III1C e5
"---. "------15.4
15.B
15.0
15.4
17.1
14.8
16.0
14.(,
5.6
4.8
7.5
8.8
6.9
5A
5.4
7.7
0.3
2.]
5.0
6.5
1501l-150S
I 5116-1 !ill
151l-1511
1518-15H
15241529
15301535
1536-1541
1542-1547
1548-1553
1554-1559
1605-1610
IfIIl-IM6
1611-1622
162]-1(1211
1629-1634
1615-IMO
IMI-IM6
1647-1652
1653-1(,511
1659-1104
(,.2
I\ vem ne
15.2
18.3
14.1
17.9
17.1
17.7
18,1
19.U
17 .5
14.8
11.2
6.6
(,.(,
1010-IOJS
1115-1120
Jl21-11 26
1127 -1I1l
lI]l-IBO
I 1J9-IIH
1145-1150
1151-1157
1157-1202
110]-12118
11.6
14.6
14.4
14.2
12.5
11.(1
J2.5
11.7
I J.:\
11150-11156
11157 -1102
1I0J-1I00
1109-1114
1115-1120
II 21-11 26
1127-lIlZ
II.B-1I18
1139-1144
1145-11 SO
I\VCnJ'le
1l.R
I\vcn'l!e
n.o
!i-9-79
....
(,
14.8
II.J
ILl
11.7
1(1.5
15.6
\(,.6
H,.3
16.9
16.7
1(,.7
l1.l
TABLE A-7a.
Test No.
Gene ra 1 Da ta
Date
Isokinetic U~)
Production Rate (Mg/hr)
Ambient Temp. (K)
% Relative Humidity
Exhaust Characteristics
Flowrate
inlet:
(dnm 3/min)
outlet:
Temcerature
inlet:
(K)
outlet:
Moisture (~ Vol.) inlet:
outl et:
Control Oevic~ Characteristics
Device Type
Pressure Drop (kPa)
Liquor pH (Ave.)
Liquor AN Cone. (~)(Ave.)
Ammonium Nitrate Emissions
Particulate Cone. inlet:
(g/dnm3 )
outlet:
Emission Rate
inlet:
(kg/hr)
outlet:
Emission Factor
inlet:
(g/kg)
outlet:
Collection Efficiency (%)
Ammonia Emissions
Ammonia Cone.
inlet:
(g/dnm 3 )
outlet:
Emission Rate
inlet:
(kg/hr)
outlet:
Emission Factor
inlet:
(g/kg)
outlet:
Collection Efficiency (%)
5/10/79
.99.3/97.8
19.1
308
45
5/11/79
99.61100.7
19.1
305
50
5/11/79
98.2/101. 7
18.8
310
37
896
974
62
48
1.879
2.290
881
953
63
46
1.447
3.182
Ave.
99.0/100.1
19.0
308
44
878
939
63
48
0.755
2.428
885
956
63
48
1.360
2.634
0.995
6.43
0.26
0.2803
0.0222
15.07
1.299
0.791
0.0682
91.4
0.2787
0.03613
14.74
2.067
0.774
0.1085
86.0
0.3286
0.0154
17.32
0.867
0.923
0.04618
95.0
0.2956
0.02467
15.70
1.414
0.828
0.0746
91.0
negative
0.00405
negative
0.11721
negative
0.0062
0.00827
0.00902
0.4372
0.2586
0.02295
0.0136
40.7
0.0112
0.0119
0.5905
0.3331
0.0315
0.0178
43.6
0.00965
0.00829
0.5124
0.2371
0.0271
0.0113
58.2
A-18
TABLE A-lb.
Test No.
General Data
Date
Isokinetic (%) In/Out
Production Rate Tons/hr
Ambient Temp. of
(~) Relative Humidity
Exhaust Characteristics
Flowrate
i nl et:
(dscfm)
outlet:
Temperature
inlet:
(FO)
outlet:
Moisture (% Vol.) inlet:
outlet:
Control Oevice Characteristics
Device Type
Pressure Drop (in. W.G.) Avg.
Liquor pH (Ave.)
Liquor AN Conc. (%) (Ave.)
Ammonium Nitrate Emissions
Particulate Conc. inlet:
(gr/dscf)
out1 et:
Emission Rate
inlet:
(lb/hr)
outl et:
Emission Factor inlet:
(1 b/ton)
outlet:
Collection Efficiency (%)
Ammonia Emissions
Ammonia Conc.
inlet:
(gr/dscf)
outlet:
Emission Rate
inlet:
(lb/hr)
outlet:
Emission Factor inlet:
(1 b/ton)
outlet:
Collection Efficiency
Ave.
5/10/79
99.3/97.8
21
95
45
5/11/79
99.6/100.7
21
89
50
5/11/19
99.21101.7
20.7
98
37
31650
34410
143
118
1.879
2.290
31120
33660
144
114
1.447
3.182
31020
33140
145
118
0.755
2.428
99.0/100.1
20.9
94
44
31260
33740
144
117
1.360
2.634
4.0
6.43
0.26
0.1225
0.00971
33.22
2.864
1.582
0.1364
91.4
0.1218
0.01579
32.50
4.556
1. 547
0.2169
86.0
0.1436
0.00673
38.19
1.912
1.845
0.09235
95.0
0.1292
0.01078
34.62
3.118
1.656
0.1492
91.0
negative
0.00177
negative
0.2584
negative
0.0123
0.003613
0.00394
0.9639
0.5701
0.0459
0.0272
40.7
0.00490
0.0052
1.3017
0.7343
0.0629
0.0355
43.6
0.00421
0.00362
1.1297
0.5228
0.0541
0.02264
58.2
A-19
TABLE A-B.
Date
Time
5-10-79
1100-1105
1106-1111
1112-111i
1118-1123
1124-1129
1130-1135
1136-1141
1142-1147
1148-1153
1154-1159
0/0
0/0
0/0
0/0
0/0
0/0
0/0
0/0
0/0
0/0
1200-1205
1206-1211
1212-1217
1218-1223
1224-1229
1230-1235
1236-1241
1242-1247
1248-1253
1254-1259
O/D
0/0
0/9
0/0
0/0
0/0
0/0
0/0
0/0
0/0
0/0
1310-1315
1316-1321
1322-1327
1328-1333
1334-1339
1340-1345
1346-1351
1352-1357
1358-1403
1404-1409
0/0
0/0
0/0
0/0
0/0
0/0
010
0/0
0/0
A-20
A.2
Plant B2
Process Overview
Plant B produces various ammonium nitrate solutions and granulated
solid ammonium nitrate. The solids production was designed for 363
Mg/day (400 TPO) of ammonium nitrate.
An 83 percent ammonium nitrate solution is produced in the neutralizer.
This solution is split into two streams, with some going to the solution
product area; the remainder proceeds to the two-stage concentrator,
where the solution is concentrated to 99+ percent. The ammonium nitrate
melt from the concentrator is sprayed into the rotary drum granulator.
In the granulator a flow of chilled air countercurrent to the granule
flow solidifies and cools the granules. A set of screens separates the
product size granules from offsize granules. Product size granules
proceed to a rotary drum cooler where refrigerated air further cools the
granules. The cooled granules are then coated and either bagged or bulk
loaded.
A.2.l
A-21
A-22
On day five (March 9, 1979), the compressor on the inlet air cooler
of the granulator went out of service, causing granulator temperatures
to become excessively high. Trouble continued with the fan damper
serving the granulator and scrubber. The combined effect of these two
problems eventually led to a rise in the granulator bed temperature to a
point where the granules were agglomerating, forming "rocks". At this
point, the granulator was shut down until the problem was corrected.
Testing did not resume until steady state conditions were again attained.
A-23
TABLE A-9a.
Test No.
General Data
Date
Isokinetic (%) In/Out
Production Rate (Mg/hr)
Ambient Temp. (K)
(%) Relative Humidity
3/7/79
102.6/98.1
13.15
292
40
3/7/79
103.1/97.5
15.82
298
23
Exhaust Characteristics
Flow3ate
inlet:
(dnm Imin)
outlet:
inlet:
Temperature
(K)
outlet:
Moisture (X vol) inlet:
outlet:
1,172
1,091
74
311
2.0
2.9
1,230
1,158
86
316
2.0
3.7
Ave.
3/8/79
101. 7/1 01. 9
18.60
289
41
1,391
1,245
82
319
2.0
7.9
102.5/99.2
15.86
293
34.7
1,264
1,165
81
315
2.0
4.8
3.19
6.51
2.71
6.24
30.43
0.049
2,304.4
3.41
147.2
0.221
99.8
30.46
0.06
2,141.9
3.928
162.9
0.299
99.8
31.73
0.040
2,341. 7
2.779
148.0
0.176
99.9
29.11
0.047
2,429.5
3.511
130.6
0.189
99.8
Ammonia Emissions*
inlet:
Ammo~ia Cone.
(dnm )
outlet:
Emission Rate
inlet:
(kg/hr)
outlet:
Emission Factor inlet:
(g/kg)
outlet:
Collection Efficiency (%)
15.45
0.0183
1085.7
6.046
82.55
0.090
99.89*
0.2817
0.0550
20.78
3.810
1.32
0.240
81.75
1.193
0.270
99.52
20.19
5.35
1.085
79.72
*In1et Run No.1 acid fraction results are inconsistently higher than other test results,
may have had sample carryover in the impinger.
A-24
5.640
0.156
402.0
11.11
29.74
0.675
97.7*
TABLE A-9b.
Test No.
Ave.
General Data
Date
Isokinetic (~) In/Out
Production Rate Tons/hr
Ambient Temp. of
(:) Relative Humidity
3/7/79
102.6/98.1
14.5
66
40
3/7/79
103.1/97.5
17.4
76.6
23
3/8/79
101. 7/101.9
20.5
60.9
41
102.5/99.2
17 .5
67.8
34.7
Exhaust Characteristics
F10wrate
inlet:
(dscfm)
outlet:
Temperature
inlet:
( oF)
outlet:
Moi sture (: vo 1) inlet:
outlet:
41.401
38.521
166
100
2.0
2.9
43,442
40,887
186
109
2.0
3.7
49.120
43.969
180
115
2.0
7.9
44,654
41.126
177
108
2.0
4.8
12.8
6.51
10.9
6.24
13.311
0.026
4.723.6
8.58
325.8
0.59
99.8
13.868
O.Oli
5.163.9
5.96
296.8
0.34
99.9
12.725
0.020
5.357.6
7.54
261.3
0.37
99.8
13.301
0.021
5.081.7
7.36
294.6
0.43
99.8
Ammonia Emissions
Ammonia Cone.
inlet:
(gr/dscf)
outlet:
Emission Rate
inlet:
(lb/hr)
outlet:
Emission Factor inlet:
(1 b/ton)
outlet:
Collection Efficiency (%)
6.745
O.OOB
2.393.6
2.64
165.1
0.18
99.89'"
0.123
0.024
45.8
8.4
2.63
0.48
Bl.75
0.521
0.11 B
219.4
44.5
10.7
2.17
79.72
2.463
0.068
886.3
24.5
59.48
1.35
97.7*
"'Inlet Run No.1 acid fraction results are inconsistently higher than other test results.
may have had sample carryover in the impinger.
A-25
99.99
10
99.9
7 .
99
99
90
50
'0
4J
0.01
i
.
....
2I
. Vj
.~
:E
1!V
~
.2
):w
I
N
en
1-
0.7
(j-
'e
0.5
0."
Run I -IS
Run 2 -IS
o Run 3 -IS
l'&
0.3
0.2 .-
O. I I
0.01
0.1
10
50
90
Figure A-l.
99.9
99.99
TABLE A-10.
Averale :>pacicy
fo~ - 6 ain
tillie
\I1CeC'Ul5,
16:"0: lS-16:'"
16:"6: 15-16:S2
16:52: lS-16:S&
16:S8: 15-11:04
17:04: IS-Ii: 10
17:10:15-17:16
17: :6: 15-11:2:
11:22: 15-17 ::S
5.0
5.0
5.0
5.0
5.2
5.:'
5.0
5.2
12.9
13.5
13.5
iJ.'1
1".')
15.3
1... &
1/0."14.J
;~ .
A"l!!ra~e
.~.d
LO:JJ:':'5-10:;9:.l0
10:39::'5-10: ..):30
LO:45::'5-10:51:30
10:5l:45-!0:H:.l0
17.3
l5.0
15.a
i5.S
Avenge
[b.ll
17 . ~
t5.:>
10.3
15.6
'14.1>
11 :2::.-11:31':'5
11:n-Il:;i:~;
:~.~
:1:38-l,:43::';
1.....
:\vec.J~e
t:. .
11:50: 15-11:5a
11:50:15-12:')2
12,12: 15-[::'18
12:08: Ls-l2: t:'
1:::20:IS-L2:Z/i
15.'"
1:'.:
10.5
l7.5
13.t
~2;26; !5"'1~:~2
!).;:$
1.!:J2:1S-1Z:18
12:38; 1.5-t2:~
12::'':': 15-12:)O
12:50: 15-12:50
12:50: 15-13:'32
n.;
I:. t
D.l
1"-.:'
13.5
14:01-1:':08::'5
14:09-110: 1:'::'5
II.; 15-14:20:45
14:::t-llo:26:105
14:21-1":32:"5
AVlH''le
11o ;)3-'':':J3:.5
OJ-07-a
5.:
'\"l!!~agl!!
IJ~35:T;7:5~:5- -
(~)
- - - -
-tj:~
15. J
lfo.:'
17.t
:6.5
15.:'
16.;
17.::1
12.9
1':'.6
OpAC1Cy
drum
I .....
.5.3
'S.J
I J _5
~
A-27
outLeC
scruDoer
l5.'1
l:':.l9-11o:~::'5
~bS.~3C~Or.S
~ranul~'oc
~t
~~e
<,c~ry
Jcum ,:>oler.
TABLE A-lla.
PLANT B:
Test No.
General Data
Date
Isokinetic (~)
Production Rate (Mg/hr)
Ambient Temp. (K)
(~) Relative Humidity
Ave.
3/8/79
93.7
18.96
297
29
3/9/79
100.7
18.87
296
71
3/9/79
100.4
18.96
298
55
98.3
18.93
297
52
579
565
556
567
310
315
317
314
Exhaust Characteristics
Flo\tl~ate
(dnm Imin)
Temperature
( K)
Moisture
(~
vol)
Emission Rate
(kg/hr )i
Emission Factor
2.1
1.5
1.8
1.8
4.354
3.970
4.178
4.167
151.3
134.6
139.4
141.8
8.0
7.1
7.4
7.5
( g/kg)
Ammonia Emissions a
aAmmonia emissions are all negative, there were more nitrate than ammonia ions present.
A-28
TABLE A-llb.
Test No.
General Data
Date
Isokinetic (~)
Production Rate Tons/hr
Ambient Temp. of
(~) Relative Humidity
Exhaust Characteristics
Flowrate
(dscfm)
Temperature
(FO)
Moisture (~ vol)
Ammonium Nitrate Emissions
Particulate Cone.
(gr/dscf)
Emission Rate
(l b/hr)
Emi ss ion Factor
(lb/ton)
Ammonia Emissions a
Ave.
3/8/79
93.7
20.85
75.3
29
3/9/79
100.7
20.82
73.0
71
3/9/79
100.4
20.85
77 .3
55
98.3
20.84
75.2
52
20.464
19,948
19.620
20.011
99
107
111
106
2.1
1.5
1.8
1.8
1.903
1.735
1.826
1.821
333.8
296.7
307.1
312.5
16.0
14.3
14.7
15.0
aAmmonia emissions are all negative. there were more nitrate than ammonia ions present.
A-29
90
50
10
0.01
5 .-
".J ,-
~
u
,-
Ii
_./
.2
):-
.!! 0.7'u
'f0
n.
0.5'0.4,-
o
h
O.J [
Run I-CO
Run 2-CO
Run J -CO
0.2 -
,
10
50
90
98
99
99.9
Figure A-2.
Plant B:
99.99
A.3
Plant C
Process Overview
Plant C produces ammonium nitrate solutions and low density ammonium
nitrate prills. The plant was designed for a production rate of 161
Mgjday (200 TPD) of prilled ammonium nitrate.
The 83 percent ammonium nitrate solution from the neutralizer is
concentrated to 95 percent in a vacuum evaporator. The 95 percent
ammonium nitrate melt is then pumped to the top of the prill tower,
where it is sprayed down through multiple spray heads. Pril1s formed in
the tower are conveyed to the rotary drum predryer, dryer and cooler,
respectively. The predryer and dryer use heated air flowing countercurrent
to the product flow to remove moisture from the prills. The cooler uses
chilled air to reduce prill temperature.
The pril1s are then screened. Offsize prills are dissolved and
recycled to the vacuum evaporator; product sized pril1s are coated and
either bagged or bulk loaded.
A.3.l
A-3l
A-32
TABLE A-12a.
Tes t No.
General Data
Date
Isokinetic (%)
Production Rate (Mg/hr)
Ambient Temp. (K)
(%) Relative Humidity
3/29/79
93
7.56
292
53
3/30/79
92
8.65
292
53
3/30/79
98
8.06
292
55
Ave.
94
8.09
292
54
Exhaust Characteristics
F1ow~ate
(dnm /min)
Temperature
( K)
~oisture
(% vol)
245
232
162
213
328
334
325
329
2.24
2.24
2.24
2.24
7.94
4.58
6.18
6.22
117
63.5
15.5
Negative
59.9
7.35
7.45
10.1
Negative
1.207
11.7
1.45
A-33
80.3
TABLE A-12b.
Tes t No.
General Data
Date
Isokinetic (%)
Production Rate Tons/hr
Ambient Temp. OF
(%) Relative Humidity
Exhaust Characteristics
Flowrate
(dscfm)
Temperature
(FO )
r,1oisture (% vol)
Ammonium Nitrate Emissions
Particulate Conc.
(gr/dscf)
Emission Rate
(lb/hr)
Emission Factor
(l b/ton)
Ammonia Emissions
Ammonia Cone.
(gr/dscf)
Emission Rate
(1 b/hr)
Emission Factor
(lb/ton)
Ave.
3/29/79
93
8'.33
65.5
53
3/30/79
92
9.54
66
53
3/30/79
98
8.88
66
55
8661
8188
5703
7517
131
142
126
133
94
8.92
65.8
54
2.24
2.24
2.24
2.24
3.47
2.00
2.70
2.72
258
140
14.7
31.0
Negative
Negative
132
14.9
.527
25.8
2.90
A-34
177
20.2
1.0
I
I
.....
:.Q5~~
.u
Figure A-3.
Plant C:
A-35
TABLE A-13a.
Test No.
General Data
Date
Isokinetic (%)
Production Rate (Mg/hr)
Ambient Temp. (K)
(%) Relative Humidity
3/29/79
100
7.56
292
53
3/30/79
101
8.65
292
50
3/30/79
97
8.06
292
51
167
140
257
188
337
345
339
341
Exhaust Characteristics
Flowrate
(dnm 3/min)
Temperature
Ave.
99
8.09
292
54
( K)
Moisture (% Vol.)
2.24
9.61
96.1
2.24
19.2
161
2.24
1.51
23.3
2.24
10.1
93.4
(kg/hr)
Emission Factor
12.7
18.7
2.90
11.4
0.401
(g/k9)
Ammonia Emissions
Ammoni~ Cone.
(g/dnm )
Emission Rate
(kg/hr)
Emission Factor
negative
3.298
27.76
3.205
(gl kg)
A-36
6.17
0.765
TABLE A-13b.
Test No.
General Data
Date
Isokinetic (%)
Production Rate Tons/hr
Ambient Temp. of
(%) Relative Humidity
3/29/79
100
8.33
65.5
53
3/30/79
101
9.54
66
53
3/30/79
97
8.88
66
55
Ave.
99
8.92
65.8
54
5888
4957
9060
6635
148
162
151
154
2.24
2.24
2.24
2.24
4.20
8.37
0.561
4.41
212
25.4
negative
356
37.3
1.44
67.2
64.1
A-37
51.4
206
5.79
22.8
0.175
13.6
1.53
....z:
~1.:..::A".~
..
..:1
.;,)
PERCENT LESS
Figure A-4.
Plant C:
.~
"'
TH~t DrA~~T~R
A-38
.
:-'."
-.
TABLE A-l4a.
General Data
Date
Isokinetic (%)
Production Rate (Mg/hr)
Ambient Temp. ( K)
(%) Relative Humidity
Ave.
3/29/79
104
7.56
292
53
3/30/79
102
8.65
292
50
3/30/79
100
8.06
292
55
217
266
249
244
323
322
319
321
Test No.
Exhaust Characteristics
Flowrate
(dnm 3/min)
Temperature
102
8.09
292
53
( K)
Moisture (% Vol.)
Ammonium Nitrate Emissions
Particulate Cone.
(g/dnm3 )
Emission Rate
( kg/hr)
Emission Factor
(g/kg)
Ammonia Emissions
Arrmonia Cone.
(g/dnm3 )
Emission Rate
(kg/hr)
Emission Factor
(g/kg)
2.24
2.24
2.24
2.24
8.74
9.04
3.36
7.05
109
14.5
negative
A-39
142
16.5
1.088
46.7
99.3
5.80
12.3
2.473
17.15
36.29
1.98
4.51
TABLE A-14b.
Test No'.
General Data
Date
Isokinetic (%)
Production Rate Tons/hr
Ambient Temp. OF
(%) Relative Humidity
Exhaust Characteristics
Flowrate
(dscfm)
Temperature
(FO)
Moisture (% Vol.)
AlTI110nium Nitrate Emissions
Particulate Cone.
(gr/dscf)
Emission Rate
(lb/hr)
Emission Factor
(lb/ton)
Ammonia Enrissions
Ammonia Cone.
(gr/dscf)
Emission Rate
(lb/hr)
Emi ss i on Factor
(lb/ton)
Ave.
3/29/79
10.4
8.33
65.5
53
3/30/79
102
9.54
67
50
3/30/79
100
8.88
66
55
102
8.92
66.2
53
7359
9268
8666
8431
122
121
115
119
2.24
2.24
2.24
2.24
3.82
3.95
1.47
3.08
241
28.9
negative
314
32.9
0.475
37.8
3.96
A-40
109
11.6
1.08
30.0
9.01
219
24.5
I.
::::::
w.J
lw.J
:E:
c::
:E:
l-
z:
;?
r:::I
0
...'1
::::.
l,
;g
Figure A-5.
Plant C:
A-41
A.4 Plant 0
A.4.1
Process Overview
Plant 0 produces granulated ammonium nitrate using a pan granulator.
This plant has a design production rate of 363 Mg/day (400 TPD).
Approximately 90 percent ammonium nitrate solution is produced in a
two-stage neutralizer; consequently, less concentration is required.
The 90 percent ammonium nitrate solution from the neutralizer is combined
with recycled scrubber liquor and fed to an air swept falling film
evaporator, where it is concentrated to an essentially anhydrous ammonium
nitrate melt.
After concentration, an additive is injected into the melt. The
purpose of the additive is to surround the individual crystals formed
during the granulation process, which allows for expansion and contraction
through the various phase changes, while preventing granule disintegration.
The ammonium nitrate melt is sprayed onto a bed of seed material in
the pan granulator. All of the solid product leaving the pan granulator
enters a rotary drum precooler. Chilled air is used to cool the granules.
The cooled granules exiting the precooler are sent through an enclosed
chain mill lump breaker and delivered by bucket to the recycle screen.
Undersize granules are recycled to the pan granulator; oversize granules
are crushed and then recycled.
Correctly sized product leaving the recycle screen is sent through
the rotary drum product cooler. In the cooler, heat-tempered, refrigerated
air flows countercurrent to the product flow. Granules leaving the
cooler are once again screened, coated, and either bagged or bulk loaded.
A.4.2 Emission Control Equipment
The emission control equipment used at Plant 0 consists of an HV
Brinks unit on the first stage neutralizer, a Sly scrubber on the second
stage neutralizer, a variable-throat venturi scrubber on the evaporator
and pan granulator, a Buffalo Forge baffle type scrubber on the precooler/crusher
area, and two wet cyclones on the cooler. Exhausts from coating and
bagging operation are uncontrolled.
A-42
Facilities Tested
The facilities tested at Plant D are listed below:
Evaporator Outlet
Combined Evaporator-Pan Granulator
Venturi Scrubber Inlet and Outlet
Precooler Outlet
Chain Mill (Crusher) Outlet
Combined Precooler - Chain Mill Baffle Scrubber Outlet
Cooler outlet
All facilities were tested for ammonium nitrate (AN) particulate
and ammonia mass emissions. Opacity was observed from the scrubber
discharge stacks. Particle size measurements were performed at some of
the scrubber inlets, using an Anderson Cascade Impactor. A discussion
of the testing at each facility follows. Any problems encountered
during the testing are also discussed in the appropriate sections.
A-43
A-44
A-45
TABLE A-15a.
Test No.
General Data
Date
Isokinetic (%)
Production Rate (Mg/hr)
Ambient Temp. (K)
(%) Relative Humidity
Exhaust Characteristics
Flowrate
idllm3/min)
emperature
(K)
Moisture (% Vol.)
Ammonium Nitrate Emissions
?artic~late Cone.
(g/dnm )
Emission Rate
(k~/hr)
Ammonia Emissions
Ammoni a Conc.
(g/dnm3 )
Emission Rate
(k9/ hr )
E:mssion Factor
11/7/78
104
13.34
299
25
11/8/78
122
13.34
296
34
11/8/78
112
13.79
303
21
113
13.52
299
27
39.71
37.38
29.66
35.57
365
369
55.2
57.9
374
59.8
Ave.
369
57.6
0.2013
C.1898
0.2237
0.2050
0.4808
0.4264
0.3992
0.4355
0.036
0.032
0.029
0.0325
0.4033
0.4216
0.4349
0.4200
0.9616
0.9480
0.7757
0.8936
0.072
0.071
0.056
0.0665
(g/kg}
A-46
TABLE A-15b.
Test No.
Genera1 Da ta
Date
Isokinetic (%)
Production Rate Tons/hr
Ambient Temp. OF
(%) Relative Humidity
Exhaust Characteristics
Flowrate
(dscfm)
Temperature
(FO)
t>'oisture (:' Vol.)
Ammonium Nitrate Emissions
Particulate Cone.
(gr/dscf)
Emission Rate
(1 b/hr)
Emission Factor
(1 b/ton)
Ammonia Emissions
Alrmonia Cone.
(gr/dscf)
Emission Rate
(lb/hr)
Emission Factor
(1 b/ton)
11/7/78
104
14.7
78
25
11/8/78
122
14.7
74
34
11/8/78
112
15.2
86
21
1403
1321
1048
1257
198
205
213
205
55.2
57.9
59.8
113
14.9
79
27
57.6
0.0879
0.0829
0.0977
0.0895
1.06
0.94
0.88
0.96
0.072
0.064
0.058
0.065
0.1761
0.1841
0.1899
0.1834
2.12
2.09
1.71
1.97
0.144
0.142
0.112
0.133
A-47
TABLE A-16a.
Ave.
General Data
Date
Isokinetic (%) In/Out
Production Rate (Mg/hr)
Ambient Temp. ( K)
(~) Relative Humidity
1117178
78/101
13.3
299
25
11/8/78
114/103
13.3
296
34
11/8/78
101/101
13.8
303
21
98/102
13.5
299
27
Exhaust Characteristics
inlet:
F10wrate
(dnm 3/min)
outl et:
Temperature
inlet:
(K)
outlet:
Moisture (% Vol.) inlet:
outlet:
225*
257
358
333
23.2
19.5
208*
248
362
333
27.9
19.5
216*
261
363
332
26.8
19.0
216*
255
361
332
26.0
19.3
Test No.
Venturi Scrubber
6.64
6.74
8.1
7.75
6.74
8.1
6.72
7.98
2.4726
0.0229
33.34*
0.35
2.501
0.027
98.9
0.9548
0.0201
11. 93*
0.30
0.895
0.023
97.5
0.725
0.011
98.5
1.3997
0.0174
18.42*
0.27
1.374
0.020
98.3
Ammonia Emissions
Al111lonia Cone.
i ttl et:
(g/dnm 3 )
outlet:
EmiSSion Rate
inlet:
(kg/hr)
outlet:
Emission Factor
inlet:
outlet:
(9/ k9)
Collection Efficiency (~)
0.1786
0.5125
2.404
7.911
0.181
0.593
negati ve
0.1163
0.3653
1.452
5.443
0.109
0.408
negative
0.1408
0.2631
1.824
4.119
0.132
0.299
negative
0.1452
0.3804
1.892
5.824
0.141
0.433
negative
0.7717
0.0094
9.99*
0.15
A-48
10 to 15
TABLE A-1Gb.
Test No.
General Data
Date
Isokinetic (%) In/Out
Production Rate Tons/hr
Ambient Temp. of
(%) Relative Humidity
Exhaust Characteristics
in1 et:
Flowrate
(dscfm)
outlet:
inlet:
Temperature
(FO)
outlet:
Moisture (% Vol.) inlet:
outlet:
Control Device Characteristics
Device Type
Pressure Drop (in W.G.)
Liquor pH (Ave.)
Ave.
11/1/18
78/101
14 .7
78
25
11/8/18
114/103
14.7
74
34
11/8/18
101/101
15.2
86
21
98/102
14.9
79
27
7936*
9089
186
140
23.2
19.5
7355*
8773
192
140
27.9
19.5
7619*
9214
194
138
26.8
19.0
Venturi Scrubber
26.7
27.1
7.75
8.1
27.1
8.1
7637*
9025
191
139
26.0
19.3
27.0
7.98
1.0807
0.010
73.51*
0.78
5.001
0.053
98.9
0.4173
0.0088
26.31*
0.66
1. 79
0.045
97.5
0.3373
0.0041
22.02*
0.32
1.449
0.021
98.5
0.6118
0.0076
40.61*
0.59
2.747
0.040
98.3
Ammonia Emissions
Ammonia Cone.
inlet:
(gr/dsef)
outlet:
Emission Rate
inlet:
(lb/hr)
outlet:
Emission Factor in1 et:
(lb/ton)
outlet:
Collection Efficiency (:)
0.0780
0.2238
5.30
17.44
0.361
1.186
negative
0.0508
0.159S
3.20
12.00
0.218
0.816
ne9ative
0.0615
0.1149
4.02
9.08
0.264
0.S97
negative
0.0634
0.1661
4.17
12.84
0.281
0.866
negative
A-49
TABLE A-17.
TEST NO.
GENERAL DATA
Date
Time
Steam Dispersion
Distance (Ft)
3'
11/7
lll0-1310
11/7
1600-1700
. Il/8
0915-1115
11/8
1345-1530
80
68
100
47
5
5
7
7.5
5
5
5
6
5
6
5
7
5
5
5
5
10
9.5
II
11
a
II
9
10
10
10
10
10
10
10
10
10
1
2
3
4
5
6
7
9
10
II
12
13
14
15
16
l7
18
19
20
10
ll.5
10.4
ll.5
10
1a
10
10
9
10
10
10
10
10
10
10
10
10
10
.1;2
5
5
10
10
* 3 Minute Interval
A-50
8
10
10
9
10
10
10
10*
TABLE A-18a.
Test No.
General Data
Date
Production Rate (Mg/hr)
Ambient Temp. (K)
(%) Relative Humidity
Exhaust Characteristics
Flowrate
(dnm 3/min)
Ammonium Nitrate Emissions
Particulate Cone.
(g/ dnm 3)
Emission Rate
(kg/hr)
Emission Factor
(g/kg)
Ammonia Emissions
Ammonia Cone.
(g/dnm3 )
Emission Rate
(kg/hr)
Emission Factor
(g/kg)
11/7/78
13.3
299
25
11/8/78
13.3
296
34
11/8/78
13.8
303
21
13.5
299
27
185 b
171 b
186 b
181 b
2.962
1.123
11. 51
32.86
0.859
9.59
Ave.
1.648
17.99
2.465
0.863
0.696
1.341
0.1301
0.0492
0.0939
0.0911
1.442
0.504
1.048
0.998
0.108
0.038
0.076
0.074
aDetermined from the difference of the evaporator and combi~ed evaporator-pan granulator data.
bCyclonic flow suspected at the combined inlet.
A-51
TABLE A-18b.
Test No.
General Data
Date
Production Rate Tons/hr
Ambient Temp. 'F
(%) Relative Humidity
11/7/78
14.7
78
Exhaust Characteristics
flowrate
(dscfm)
Ammonium ~itrate Emissions
Particulate Cone.
(gr/dscf)
Emission Rate
(lb/hr)
Emission Factor
(lb/ton)
Ammonia Emissions
Almtonia Cone.
(gr/dscf)
Emission Rate
(l b/hr)
Emission Factor
(1 bl ton)
25
11/8/78
14.7
74
34
11/8/78
15.2
86
21
6533 b
6034 b
6571 b
1.2934
72.45
0.4904
25.37
0.3752
21.14
Ave.
14.9
79
27
6379 b
0.7197
39.65
4.929
1.726
1.391
2.682
0.0568
0.0215
0.0410
0.0398
3.18
1.11
2.31
2.20
0.216
0.076
0.152
0.148
aOetermined from the difference of the evaporator and combined evaporator pan granulator data.
bCyclonie flow suspected at the combined inlet.
A-52
TABLE A-19a.
Test No.
Genera1 Data
Date
Isok i neti c (%)
Production Rate (Mg/hr)
Ambient Temp. (K)
(%) Relative Humidity
Exhaust Characteristics
Flowrate
(dnm 3/min)
Temperature
11/9/78
100
13.52
295
26
11/10/78
101
13.36
292
57
11/10/78
98
13.25
297
52
6U a
699a
811a
707a
366
356
356
360
Ave.
100
13.36
295
45
( K)
Moisture
(~
Vol.)
2.0
2.0
2.0
2.0
4.890
5.985
5.956
5.611
179.34
13.267
251.14
18.832
289.97
21.893
(g/kg)
Ammonia Emissionsb
a
.
Suspected to be low due to only one traverse belng performed.
bAmmonia emissions are all negative. more nitrate ions than ammonia present.
A-53
240.15
17.997
TABLE A-19b.
Test No.
General Data
Date
Isokinetic (%)
Production Rate Tons/hr
Ambient Temp. OF
(%) Relative Humidity
Exhaust Characteristics
Flowrate
(dscfm)
Temperature
(FO)
Moisture (% Vol.)
Ammonium Nitrate Emissions
Particulate Cone.
(gr/dscf)
Emission Rate
(1 b/hr)
Emission Factor
(lb/ton)
Ammonia Emissions b
11/9/78
100
14.9
72
25
11/10/78
101
14.7
66
57
11/10/78
98
14.6
75
52
21593!
24707
28666
24989
181
182
188
200
100
14.7
71
45
2.0
2.0
2.0
2.0
2.1355
2.6136
2.6009
2.450
395.36
26.534
553.65
37.663
639.26
43.785
aSuspected to be low due to only one traverse being performed during the tests.
bAmmonia emissions are all negative, more nitrate ions than ammonia ~resent.
A-54
529.42
35.994
t,
IQC
I.e
1:C
~~ -~~~_~i~~~~~i~=~~:~_
- ~~-~~~~:;~;~~~~~~~~~;~~~r;=~~I~~-~
- __
-~_~~=_=---~--r _~
-~--~~=-:::== ~=--_
~~
,.e
1-'
~-=:~
----------
I, f
1'1
II
II'
.!
II
"
I.e
Q.I
!:s~
-
_ -_-.:.
- _ -r-
-=-- _:- -
1.
Q,l
-~_
-~~ - ~li~~~~0~~~~~~~~~~?~~~-~~;;~~
----
0..
0.1
Test: 2
o.~
rest: 3
0":
/.
,
a.J
I'll
.va
!U
. I
1,1
I Ill!
ioldl
rl'
"
f'l+
I I
I'll
,
,.
IIII
, I I , I I
I
I'
IA
til
JII
..
if .
,,
I
I I
!II
III
, ,
.,
"" , "
:'Q
',1 11 11
.II'H
.. 1'
II
1111
III
Figure A-6.
Plant 0:
I I I
" i
lIJ
I'
,.
iI II
,j
I,
II t:
I~ I 1
il
PI
.' ,
L.!S~ TlfAlt(O~
,
I
. '"
-I
,, ,
I
0.:
TABLE A-20a.
Test No.
General Data
Date
Isokinetic (~)
Production Rate (Mg/hr)
Ambient Temp. (K)
(%) Relative Humidity
Exhaust Characteristics
Flowrate
(dnm 3/min)
Temperature
(K)
Moisture (% Vol.)
Ammonium Nitrate Emissions
Particulate Cone.
(g/dnm 3)
Emission Rate
(kg/hr)
Emission Factor
(g/kg)
Ammonia Emissions
Ammonia Cone.
(9/dnm3 )
Emission Rate
(kg/hr)
Emission Factor
(g/kg)
11/9178
101
13.5
295
26
47.29
11/10/78
101
13.3
292
57
11/10/78
105
13.2
297
52
39.59
301
300
39.71
307
Ave.
102
13.3
295
45
42.20
302
0.8
1.6
4.4
2.2
2.244
1.754
2.549
2.182
6.369
4.169
6.074
5.539
0.471
0.313
0.459
0.414
0.0421
0.0094
O.Oln
0.0998
0.0227
0.0408
0.0075
0.0015
0.003
negative
A-56
TABLE A-20b.
Test No.
General Data
Date
Isokinetic (~)
Production Rate Tons/hr
Ambient Temp. of
(%) Relative Humidity
Exhaust Characteristics
Flowrate
(dscfm)
Temperature
(FO)
Moisture (~ Vol.)
Ammonium Nitrate Emissions
Particulate Cone.
(gr/ dscf)
Emission Rate
(1 b/hr)
Emission Factor
(lb/ton)
Ammonia Emissions
Ammonia Cone.
(gr/dscf)
Emission Rate
(lb/hr)
Emission Factor
(lb/ton)
11/9/78
101
14.9
11/10/78
101
14.7
66
57
11/10/78
105
14.6
75
52
1671
1399
1403
1491
83
81
93
85
72
26
102
14.7
71
45
0.8
1.6
4.4
2.2
0.9801
0.7658
1.1130
0.9530
14.04
9.19
0.942
negative
A-57
13.39
12.21
0.625
0.917
0.828
0.0184
0.0041
0.0075
0.22
0.05
0.09
0.015
0.003
0.006
TABLE A-21a.
Test No.
General Data
Date
Isokinetic (%) Out
Production Rate {Mg/hr)
Ambient Temp. (K)
(%) Relative Humidity
Exhaust Characteri sti cs
Flowrate
inlet:
outlet:
(dnm 3/min)
Temperature
(K)
outlet:
Moisture (%Vol.) outlet:
Control Device Characteristics
Device Type
Pressure Drop (kPa)
Liquor pH (Ave.)
Ammonium Nitrate Emissions
Partic~late Con.
inlet:
(g/dnm )
outlet:
Emission Rate
inlet:
(kg/hr)
outlet:
Emi ss i on factor inlet:
(g/kg)
outlet:
Collection Efficiency (%)
Ammonia Emissions b
Cone.
(g/dnm )
outlet:
Emission Rate
( kg/hr)
outlet:
Emission Factor
(g/kg)
outlet:
Ammoni~
11/9/78
102
13.5
295
26
11/10/78
102
13.3
292
57
11/10/78
102
13.2
297
52
659
733
739
732
852
766
750
744
317
3.4
317
4.0
318
4.9
318
4.1
0.796
6.3
Ave.
102
13.3
295
45
1.39
6.3
4.6845
0.0247
185.246
1.084
3.705
0.080
99.4
5.7397
0.0460
254.696
2.023
19.099
0.152
99.2
5.7781
0.0332
295.325
1.529
22.297
0.116
99.5
5.4008
0.0345
245.089
1.547
18.367
0.116
99.4
0.0087
0.1001
0.1347
0.0811
0.3810
4.391
6.187
3.652
0.028
0.330
0.468
0.275
alnlet data is based on the cOmbination of the chain mill and precooler data.
bAmmonia emissions from the precooler are all negative.
A-58
TABLE A-21b.
Test No.
General Data
Date
Isokinetic (~) Out
Production Rate Tons/hr
Ambient Temp. of
(%) Relative Humidity
Exhaust Characteristics
flowrate
inlet:
(dscfm)
outlet:
Temperature
(FO)
outlet:
Moisture(% Vol.) outlet
Control Device Characteristics
Device Type
Pressure Drop (in W.G.)
Liquor pH (Ave.)
Ammonium Nitrate Emissions
Particulate Conc. inlet:
(gr/dscf)
outlet:
Emission Rate
inlet:
(lb/hr)
outlet:
Emission Factor inlet:
(lb/ton)
outlet:
Collection Efficiency (%)
Ammonia Emissions b
11/9/78
102
14.9
72
25
23,254
25,866
11/10/78
102
14.7
65
57
11/10/78
102
14.6
75
52
26,106
25,843
112
3.4
30,069
27,062
112
4.0
102
14.7
71
45
26,480
26,257
113
4.9
112
4.1
3.2
6.3
5.6
6.3
2.0474
0.0108
408.39
2.4
27.409
0.161
99.4
2.5086
0.0202
561.50
4.47
38.197
0.304
99.2
2.5254
0.0145
651. 07
3.37
44.594
0.231
99.5
2.3605
0.0152
540.32
3.41
36.733
0.232
99.4
0.0038
0.0437
0.0588
0.0354
0.84
9.68
0.056
0.659
Ammonia Conc.
(gr/dscf)
outlet:
Emission Rate
(lb/hr)
outlet:
Emission Factor
(1b/ton)
outlet:
Ave.
13.54
0.935
aInlet data is based on the combination of the chain mill 3nd precooler data.
bAmmonia emissions from the precooler are all negative.
A-59
8.05
0.550
TABLE A-22.
~'r
GZNE:\AI.
~o.
O~A
U/10
0947-1047
Oat:e
'r~
s=t
11/10
U30-1430
11/10
1430-1630
~n:J':'=: ~~~r.u.
;"~,,:,:..AGZ
OP.;C:-:"!
1
2
3
4
5
5
7
9
2.0
UI)
10
l~
11
2.0
10
U
10
10
10
10
10
10
10
10
10
11
10
10
11
10
11
12
13
14
13
16
17
10
II
10
10
11
10
10
10
10
10
10
10
1Q
10
10
10
10
10
13
13
20
2l
22
23
24
25
26
27
38
29
30
1:)
10
11
11
2.0
2.0
10
2.0
10
10
9
11
10
7.5
a.5
6.3
7
A-GO
.. '.- - -.
TABLE A-23a.
Test No.
Genera1 Data
Date
Isokineti c (%)
Production Rate (Mg/hr)
Ambient Temp. (K)
(%) Relative Humidity
Exhaust Characteristics
Flowrate
(dnm 3/min)
Temperature
11/3/78
96
13.3
302
36
11/4/78
101
12.8
295
49
11/4/78
101
13.3
302
34
351
347
349
350
351
349
352
350
99
13.2
300
40
( K)
Moisture (% Vol.)
Ammonium Nitrate Emissions
Particulate Cone.
(g/dnm3 )
Emission Rate
(kg/hr)
Emission Factor
(g/kg)
Ammonia Emissions a
1.3
1.3
1.2
1.3
0.106
0.205
0.115
0.153
2.227
4.264
2.400
3.216
0.167
0.333
0.180
0.246
aAmmonia emissions are all negative. more nitrate than ammonia ions present.
A-61
TABLE A-23b.
Test No.
General Data
Date
Isokinetic ($)
Production Rate Tons/hr
Ambient Temp. of
(%) Relative Humidity
Exnaust Characteristics
F10wrate
(dscfm)
iemperature
(FO)
~1oisture
(~
Vol.)
11/3/18
11/4/78
11/4/18
101
14.1
96
14.7
85
36
72
49
101
14.7
84
34
99
14.5
80
40
12,396
12,249
12,348
12,382
173
168
174
171
1.3
1.3
1.2
1.3
0.0463
0.0897
0.050
0.0669
4.91
9.40
5.29
7.09
0.334
0.666
0.360
0.492
aAmmonia emissions are all negative, more nitrate than ammonia ions present.
A-62
.....
"
..,
t'o.1
I
I I
HI:
IGllI
II.
t
III
I
i
I
II I
~.o
===---:=-=====---=============--
.0
"'
J I
II
'I
I II ,
"
:1
II
~-=- _--:::::~-
----
'I
.:=:::::::=:===
1=
1.0
1.0
1.0
l.CI
CD
t.Cl
S.CI
SoO
I"
. !.'I'
'f.
.,
i'
I."
I"
II
,'I
I.
.;;1
I t I
"
,II"'l I
,~
1A
U
";
oUr
~.
0.1
~i
--=---=- ---=-
~~1
--~-
---
------=-=--::::--
=~~ ~~~;-=-~--~~=-=-~~~~'==-~-~
:1
'Ill
1;1 I
1111.1
Q.QlI
o..r.
II
:.II
Plant 0:
[r,.
~: "
t q
II
Test: 1
Test: 2
Test 3
!I'
11111111111"
I
II III.
0."
O~
1'1"
'"I
'f'l/:11
I"
lill;,:::.
1".,,:I'III"I'I!
II' I'
I .
1~11,
;D:II40ilIllI:01II
ctJaUJL~T1VE
Figure A-7.
'11
------ - - - - - -
,,
~.
KEY
.-=-----:="--=-
,,"'
a,.
I'
I 1111111; I
11 ~ \ Ill; I 1 ,. ,
I
HI':
, ,- l l t : I ' - :
iU....
:lII
"
0.1
A.5
Plant E
A.5.l
Process Description
Plant E produces aTTlllonium nitrate granules in rotary drum granulators.
This plant has a design production rate of 435 Mg/day (480 TPD) of
ammonium nitrate.
The 85 percent ammonium nitrate solution produced in the neutralizer
is combined with recycled scrubber liquor and the product from cleanup
operations. This combined stream is concentrated to a 99+ percent
ammonium nitrate melt in two steps. First, the AN solution is concentrated
in a flash evaporator, then this product is split and sent through two
parallel air swept falling film evaporators. The melt is then sprayed
into the granulators.
There are two rotary drum granulators; each has its own set of
screens and product cooler. Oversize particles from the screens are
crushed and returned to the granulator. Undersize particles are returned
directly to the granulator. The product size granules are cooled in the
rotary drum coolers with refrigerated air flowing countercurrent to the
granule flow. The cooled granules are then coated and bulk loaded.
Emission Control Equipment
The emission control equipment used at Plant E consists of a condenser
for neutralizer overheads, wet scrubbers for granulators and coolers,
and baghouses to control emissions from coating, handling and shipping
operations. Emissions from the air swept falling film evaporator and
the hammennill are directed to the granul ator scrubber. Emiss ions from
the flash evaporator are exhausted to the atmosphere uncontrolled.
Each granulator has two wet scrubbers controlling exhausts, and
each cooler has one scrubber. The exhausts from all the wet scubbers
are ducted to a common stack. The condensate from the neutralizer
overhead is used as scrubber liquor in these wet scrubbers.
The wet scrubbers used are Joy Turbulaire medium pressure drop wet
impingement scrubbers, referred to as "Doyle" units. Air entering the
A.5.2
A-64
A-65
TABLE A-24a.
Test No.
General Data
Date
Isokinetic (%) In/Out
Production Rate (Mg/hr)
D,mbient Temp. {K)
(~) Relative Humidity
Exhaust Characteristics
Flowrate
inlet:
outlet:
(dnm3/min)
Temperature
inl et:
( K)
outlet:
Moisture(% Vol.) inlet:
outlet:
Ave.
11/15178
11/15/78
105/105
11.26
281
54
*11/16/78
11.86
278
69
*
105/106
11.38
279
62
397
455
329
308
1.5
3.5
424
483
319
308
0.7
3.1
413
459
327
307
1.3
3.5
109/106
11.52
279
62
428
438
325
307
1.1
3.4
1021104
3.86
0.014
99.17
0.38
8.65
0.033
99.6
4.09
0.135
97.55
0.37
8.65
0.33
99.6
0.945
5.25
Negative
3.98
0.014
98.36
0.38
8.65
0.033
99.6
Ammonia Emissions
Ammonia Cone.
inlet:
(g/dnm 3)
outl et:
Emission Rate
inlet:
(kg/hr)
:lutl et;
Emission Factor inlet
(g/kg)
outlet:
Collection Efficiency (%)
0.5526
0.0080
14.20
0.209
1.235
0.018
98.5
0.5279
0.0066
12.57
0.181
1.115
0.016
98.6
1. 3481
0.0373
34.25
1.08
2.88
0.091
96.8
0.5402
0.0073
13.38
0.195
1.175
0.017
98.6
A-66
0.441
2.14
11.23
62.10
3.27
4.2
25
TABLE A-24b.
Ave.
11/15/78
104/106
12.69
43
62
11/15/78
105/105
12.41
46
54
*11/16/78
102/104
13.07
41
69
*
104/105
12.54
43
62
Test No.
Genera1 Da ta
Date
Isokinetic (%) In/Out
Production Rate Tons/hr
Ambient Temp. of
(%) Relative Humidity
Exhaust Characteristics
Flowrate
inlet:
(dscfm)
outlet:
Temperature
inlet:
(FO)
outlet:
Moisture (% Vol.) inlet:
outlet:
Control Device Characteristics
Device Type
Pressure Drop (in. W.G.)
Liquor pH (Ave.)
Liquor AN Conc. (%) (Ave.)
14,018
16,065
133
95
1.5
3.5
15,111
15,471
125
94
1.1
3.4
13.2
3.7
23
14,968
17,044
115
95
0.7
3.1
14,600
15,768
129
94
1.3
3.5
13.1
4.2
25
1.688
0.0063
218.6
0.835
17.3
0.066
99.6
1.790
0.0059
215.0
0.816
17.3
0.066
99.6
0.1929
0.9371
24.74
136.9
1.89
10.5
1. 739
0.0061
216.8
0.826
17.3
0.066
99.6
Ammonia Emissions
Ammonia Conc.
inlet:
(gr/dscf)
outlet:
Emission Rate
inlet
(lb/hr)
outlet
Emission Factor
inlet
(lb/ton)
outlet
Collection Efficiency
0.2413
0.0035
31.3
0.461
2.47
0.636
98.5
0.2305
0.0029
27.7
0.399
2.23
0.032
98.6
0.5887
0.0163
75.5
2.38
5.76
0.182
96.8
0.2359
0.0032
29.5
0.430
2.35
0.034
98.6
A-67
,Q,Q
10.0
'S:
'.0
f.O
1.0
,..0
1.0
1.0
1.0
'.0 0
\II
2:
c:
5.~
. 0
5.0
:i
Z
I"U
N
~..o
~"l
...
loll \oJ
I-
0::
.,
,.0
I.~
1,
'1
<
.!
;1
11"
Q"
./.
I"
I.
1.0
..
::l.J
:'J
0.'
0..7
,'.1
_~=~~~
_-: =-_
:=-
-~
0.'
_=__ ~:-L
0.5
0.4
o.~
o..zlll
0.1
1l.Z
,.
l.C1
CUMUl.ATl'lE
Figure A-8.
.'
Plant E:
iI
:0
19
19.'
0.:
19.
A.6 Plant Z
A.G.l
Process Description
Plant Z produces both low density and high density ammonium nitrate
prills. The plant was designed to produce 726 Mg/day (800 TPD) of
prilled ammonium nitrate. Only the emissions from the solids formation
and finishing equipment were monitored; therefore, only these solids
production facilities are discussed.
The prill tower at Plant Z is designed to produce both high and low
density prills. The type of product produced depends upon the concentration
of the AN melt used. A 99.8 percent AN melt is used to produce high
density prills, and a 96 percent AN melt is used to produce low density
prills.
During the testing program low density prills were being produced.
For low density prill production, a 96 percent AN melt is delivered from
the evaporators to the top of the prill tower. A spinning bucket at the
top of the tower receives the melt, where it rotates to force a stream
of melt through orifices in the bucket. The melt stream breaks up into
discrete droplets as it falls through the tower. Four fans located at
the top of the prill tower create an airflow which cools the falling
droplets. The prills are conveyed from the bottom of the tower to the
finishing train, the predryer, dryer and cooler. First, the low density
prills are conveyed to a rotary drum predryer, where moisture is removed
from the prills. Finally, a fluidized bed cooler is used to remove
nominal amounts of moisture and to cool the prills. Cooled prills are
then screened to yield a properly sized product.
Offsize prills are redissolved and recycled to the melt concentration
process. Product sized prills are coated in a rotary drum coater with
kaolin (clay). A coating is used to prevent the solids from becoming
moist and caking. The coated product is then either bulk shipped or
bagged.
A-69
A-70
A.6.3
Facilities Tested
The facilities tested at Plant Z are listed below:
Low density prill tower scrubber inlet, outlet and bypass
Rotary drum predryer outlet
Rotary drum dryer outlet
Combined predryer-dryer scrubber outlet
Fluidized bed cooler scrubber inlet
Bagging and coating operations
Visible emission observations were performed at all of the scrubber
outlets and at the outlets from the coater and bagger. Particle size
measurements were performed at all of the scrubber inlets and bypasses.
An Anderson High Capacity Stack Sampler was used to determine particle
size distributions. A discussion of the testing at each facility including
any testing problems that occurred, follows.
A.6.3.l Low Density Prill Tower Scrubber
The results of the mass emission tests performed on the bypass and
the Brinks Mist Eliminator inlet and outlet are presented in Tables
A-25a and A-25b. Prill tower emissions are ducted to the Brinks Mist
Eliminator through three inlet ducts. Three ducts are also used to
bypass the mist eliminator. During each test run, emissions were measured
at one inlet, one bypass and the outlet. Velocity traverses were performed
at the other two inlets and two bypasses during each test run in order
to determine flow rates through these ducts. Estimates of emissions
from all the inlets and bypasses during each test run were made by
assuming the grain loadings measured in a given inlet or bypass existed
in the other two inlets or bypasses.
The opacity readings at the Brinks Mist Eliminator outlet are
presented in Table A-26; opacity readings for the scrubber bypass are
presented in Table A-27. Particle size results at the scrubber inlet
are presented in Figure A-9, particle sizes results for the bypass are
presented in Figure A-10. No problems were encountered during testing
at this scrubber.
A-71
A-72
Particle size results for the scrubber inlet and bypass are presented in
Figures A-13 and A-14, respectively. Visible emissions observations,
performed at the scrubber outlet and bypass, are presented in Tables A-33
and A-34, respectively.
No problems were encountered during testing at the fluidized bed
cooler scrubber, although ammonia emissions during some of the tests
were negative. This was probably due to inaccuracies inherent in the
ammonia analyses and in the excess ammonia calculation.
A.6.3.5 Coater and Bagger
Visible emission observations were performed at the outlets from
the coating and bagging fabric filters. These opacity readings are
presented in Table A-35.
A.6.4 Process Operation During Testing
The process was operating at 56 to 80 percent of design capacity
during testing. Production rates reflect market demands.
A review of the operating logs during testing revealed that there
were no anomalies in process operation during the test period that
affected emissions. Slight variations in operations which occurred were
all within normal operative conditions.
A few minor problems occurred and are detailed below. At 9:00 a.m.
on August 13, 1980, there was a ten minute decrease in production due to
steam loss in the evaporator. On August 14, 1980 the system was down at
8:00 a.m., but returned to normal operation at 9:30 a.m. Also, on
August 14, 1980 at 1:30 p.m. ammonium nitrate production was cut back
five percent.
A-73
TABLE A-25a.
Ave.
B/12/BO
99.5/105.7/98.4
21.1
305
55
B/12/BO
100.7/103.7/98.1
22.2
308
45
B/13/80
100.5/99.2/103.3
23.1
302
68
100.4/102.9/99.9
22. 1
305
56
1277
1447
6579
1269
1497
6958
1308
1468
5983
1285
1471
6507
325
307
315
326
307
319
322
307
313
325
307
316
2.82
6.66
1.99
2.94
3.38
2.35
3.28
4.35
3.02
3.01
4.80
2.44
3.4
3.87
71.8
3.4
4.43
Test No.
Genera 1 Oa ta
Date
Isokinetic (:) In/Out/Bypass
Production Rate (Mg/hr)
Ambient Temp. (K)
Relative Humidtiy (:)
Exhaust Characteristics
F10wrate (dnm 3/nin)
scrubber fnlet:
scrubber outlet:
scrubber bypass:
Temperature (K)
scrubber inlet:
sCnJbber outlet:
scrubber bypass:
Moisture (% Vol.)
scrubber fnlet:
scrubber outlet:
scrubber bypass:
Control Device Characteristics
Device Type
Pressure Orop (kPa)
Liquor pH (Ave.)
Liquor AN Conc. (pplll) (Ave.)
Ammonium Nitrate Emissions
Particulate Conc. (gr/dnm 3)
scrubber inlet:
scrubber outlet:
scrubber bypass:
Emission Rate (kg/hr)
scrubber inlet:
scrubber outlet:
scrubber bypass:
total bypass and outlet:
Emi ss ion Factor (g/kg)
scrubber fnlet:
scrubber outlet:
scrubber bypass:
total bypass and outlet:
Collection Efficiency (%)
scrubber:
total:
73.9
0.D364
0.00371
0.0104
0.0524
0.00336
0.0130
0.0547
0.00796
0.0152
0.0478
0.00501
0.0129
2.79
0.321
4.11
4.43
3.99
0.303
5.41
5.71
4.29
O. 703
5.47
6.17
3.69
0.442
5.00
5.44
0.132
0.015
0.195
0.210
0.180
0.014
0.244
0.257
0.186
0.031
0.237
0.267
0.167
0.020
0.226
0.246
88.5
35.8
92.4
39.2
83.6
36.8
88.0
37.4
0.0344
0.0120
0.0016
0.0302
0.0105
0.0015
0.0236
0.0116
0.0015
0.0293
0.0114
0.0015
2.632
1.043
0.631
1.674
2.302
0.943
0.631
1.574
1.851
1.025
0.526
1.551
2.259
1.007
0.599
1.606
0.125
0.050
0.030
0.080
0.101
0.043
0.029
o.on
0.080
0.045
0.023
0.067
0.102
0.046
0.027
0.073
60.2
51.5
57.7
55.0
44.4
65.4
55.4
56.2
AlI'mOnia Emissions
Ammonia Conc. (gr/dnn 3 )
scrubber inlet:
scrubber outlet:
scrubber bypass:
Emission Rate (kg/hr)
scrubber inlet:
scrubber outlet:
sCnJbber bypass:
to:al bypass and outlet:
Emission :actor (g/kg)
;crubber inlet:
;crubber outlet:
scrubber bypass:
Total bypass and outlet:
Collection Efficiency (%)
scrubber:
total:
aThe inlet and bypass results -ere obtained by weighing the individual results at each of the three sampling points.
Pounds per hour values were calculated by assuming that the grain loadings measured at one point existed at the
other two points. and then ".ltiplying by the total f1owrate.
A-74
TABLE A-25b.
Test No.
Ave.
Genera1 oa ta
Date
Isokinetic (~l In/Out/Bypass
Production Rate tons/hr
AIIil ient Temp. OF
Relative Humidity (l:l
8/12/80
99.9/105.7/98.4
23.3
90
55
8/12/80
100.7/103.7/98.1
24.5
95
45
8/13/80
100.5/99.2/103.3
25.5
85
68
100.4/102.9/99.9
24.4
90
56
Exhaust Characteristics
Flowrate (dscfml
scrubber inlet:
scrubber outlet:
scrubber ~ypass:
Temperature (OF)
scrubber inlet:
scrubber outlet:
scrubber bypass:
Moisture (': Vol.)
scrubber inlet:
scrubber outlet:
scrubber bypass:
45,130
51,120
232,460
44,850
52,910
245,870
46,220
51,870
211,417
45,400
51,970
229,920
126
94
107
128
93
115
120
94
104
125
94
109
2.82
6.66
1.99
2.94
3.38
2.35
3.28
4.35
3.02
3.01
4.80
2.44
14.2
5.36
76.6
13.6
3.87
71.8
13.8
4.43
73.9
0.0159
0.00162
0.00455
0.0229
0.00147
0.00566
0.0239
0.00348
0.00665
0.0209
0.00219
0.00562
6.150
0.708
9.066
9.774
8.803
0.667
11.928
12.595
9.468
1.549
12.051
13.600
3.133
0.975
11.015
11. 990
0.264
0.030
0.389
0.419
0.359
0.027
0.487
0.514
0.3n
0.061
0.473
0.534
0.333
0.040
0.451
0.491
88.5
35.8
92.4
39.2
83.6
36.8
88.0
37.4
0.0150
0.00526
0.00070
0.0132
0.00459
0.00066
0.0103
0.00508
0.00064
0.0128
0.00498
0.00067
5.802
1.39
3.69
5.074
2.08
1.39
3.47
4.081
2.26
1.16
3.42
4.981
2.22
1.32
3.54
0.249
0.099
0.060
0.159
0.085
0.057
0.142
~.201
0.160
0.089
0.045
0.134
0.204
0.091
0.054
0.145
57.7
55.0
44.4
65.4
55.4
56.2
2.30
60.2
51.5
aThe inlet and ~ypass results were obtained ~y ~i9hi"g the individual results at each of the three sampling points.
?ounds per hour values ~re calculated by assuming that the grain loadings measured at one point existed at the other
two points. and then multiplying by the total flowrate.
A-75
TABLE A-26.
~k-
Run
NUlJlber
Six-Minute
Tillie Per lad
8-12-80
1046 - 1051
1052 - 1057
1058 - 110]
1104 - 1109
1110 - 1115
1116 - 1121
1122 - 1127
1128 - 1133
1134 - 1139
1140 - 1145
1141 - 1152
1153 - 1158
1159 - 1204
1205 - 1210
1211 - 1216
1211 - 1222
1223 - 1228
1229 - 1234
1235 - 1240
1241 - 1246
Averaqe
Averaqe Opacity
(Percent,
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
)::0
.......
0'\
8-12-80
1520 - 1525
1526 - 1531
15H - 1537
1538 - 1543
1544 - 1549
1550 - 1555
1556 - 1601
1602 - 1607
1608 - 1613
1614 - 1619
1620 - 1625
1626 - 163J
16]2 - 16J7
1638 - 164]
1644 - 1649
1650 - 1655
1656 - 1701
1702 - 1707
1708 - 1711
1714 - 1719
Averaqe
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
TO~ER
Run
lJa te
8-13-80
~~
SCRUBBER OUTLET
six-Minute
T illle Pe dod
Averaqe opacity
(Percent)
0850
0856
0902
0908
0914
0920
0926
0932
0938
0944
0950
0956
1002
1008
1014
1020
1026
1032
1038
1044
1050
1056
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1255 - 1300
1301 - 1306
1307 - 1312
lll3 - 1318
1319 - 1324
1325 - 1330
13ll - 1336
1337 - 1342
1343 - 1348
1349 - 1354
1355 - 1400
1401 - 1406
1407 - 1412
1411 - 1418
1419 - 1424
1425 - 14]0
1431 - 1436
1437 - 1442
1443 - 1448
1449 - 1454
Average
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0845
0851
0857
0903
0909
0915
0921
0927
0933
0939
0945
0951
0957
1003
1009
1015
1021
1021
IOn
1039
1045
1051
TABLE A-27.
!~~~~if!~!
Bvpass B
~t,,_
8-12-80
Run
lIu llllJ t l
)=t
I
""
BVl'a,." A
1049 - 1054
1055 - HOO
HOI - H06
ll07 - II 1 2
1111 - 1118
lI19 - 1124
ll25 - ll10
llH - 11 16
lln - lI41
llO - ll48
ll4!l - 1154
ll55 - 1201
1202 - 1206
1207 - 1212
121l - 121B
1219 - 1224
1225 - 12)0
12H - 1216
12]1 - 1241
1241 - 124B
Averaq"
1520 - 1525
1526 - ISH
1512 - 1517
1518 - ISH
1544 - 1549
1550 - 1555
1556 - 1501
1602 - 1601
160B - 1611
1614 - 1619
1620 - 1625
1626 - 1611
16.l2 - 16J1
1618 - 1641
1644 - 1649
1650 - 1655
1656 - 1101
1102. - 1101
110B - nil
1114 - 1119
IIv"raq"
B.l
1.1
6.J
6.0
6.5
6.J
5.2
5.4
6.1
6.9
5.6
6.4
B.)
1.)
7.5
6.7
6.5
6.1
6.5
5.2
5.6
5.4
6.1
1.5
6.0
5.6
5
5
5
5
5
5
6.0
Run
~'=.!~~'!
~t"-
Bvpass C
B-lJ-BO
!!!!",""r
9lx-H lnule
!!!!!!L!! r lod
0952 - 0957
095B - 100)
1004 - 1009
1010 - 1015
1016 - 1021
1022 - 1027
1028 - 101)
1014 - 10]9
1040 - 1045
1046 - 1051
1052 - 1057
105B - 110]
1104 - 1109
1110 - 1115
IJl6 - Jl21
1122 - 1119
1120 - Ull
1114 - 1119
1140 - 1145
1146 - lI51
IIv"raq"
~~.!'1!!l.
o
o
o
o
o
o
II
o
II
o
o
o
o
o
o
o
o
o
o
TABLE A-28a.
Test No.
Ave.
8/14/80
83.9
20.0
306
56
8/14/80
93.4
19.9
308
8/14/80
93.1
18.5
306
54
90.1
19.5
307
52
1088
1095
1096
1093
339
339
339
339
4.8
3.6
3.5
4.0
10.63
11.31
11.57
11.18
637
744
761
714
31.91
39.21
21 .11
37.28
0.0321
0.1443
0.0616
0.0772
2.53
9.48
4.15
5.40
0.127
0.50
0.224
0.292
Genera1 Data
Date
Isokinetic (%)
Production Rate (Mg/hr)
Ambient Temp. (K)
Relative Humidity (%)
46
Exhaust Characteristics
F10wrate
(dnm 3/min)
Temperature
(K)
Moisture (% Vol.)
Ammonium Nitrate Emissions
Particulate Cone.
(g/dnm 3)
, Emission Rate*
(kg/hr)
Emission Factor
(g/kg)
Ammonia Emissions
Ammon; a Cone.
(g/dnm 3)
Emission Rate*
(kg/hr)
Emission Factor
(g/kg)
*For runs with percent isokinetic less than 90%. mass f10wrates (kg/hr) presented here are
averages of mass flowrates calculated by concentration method and area ratio method.
A-78
TABLE A-2ab.
Test No.
8/14/80
83.9
22.0
92
56
8/14/80
8/14/80
93.1
20.4
92
54
38440
38680
38720
38610
151
151
151
151
4.8
3.6
3.5
4.0
4.64
4.94
5.05
4.88
1404
1639
1677
1573
63.82
78.42
42.21
74.55
0.0140
0.06303
0.0269
0.0337
5.58
20.9
9.14
11.9
0.254
1.00
0.448
0.583
Ave.
General Data
Date
Isolcinetic (%)
Production Rate tons/hr
Ambient Temp. OF
Relative Humidity (%)
93.4
20.9
95
46
90.1
21.1
93
52
Exhaust Characteristics
F10wrate
(dscfm)
Temperature
(OF)
Moisture (% Vol.)
Ammonium Nitrate Emissions
Particulate Cone.
(gr/dscf)
Emission Rate*
(1 b/hr)
Emission Factor
(lb/ton)
Ammonia Emissions
Ammonia Cone.
(gr/dscf)
Emi ss i on Ra te*
(lb/hr)
Emission Factor
(lb/ton)
*For runs with percent isolcinetic less than 90% mass f10wrates (lb/hr) presented here are
averages of mass flowrates calculated by concentration method and area ratio method.
A-79
Ave.
8/14/80
84.9
19.9
308
46
8/14/80
83.0
18.5
306
54
83.7
19.5
307
52
General Data
Date
Isokinetic (~)
Production Rate (Mg/hr)
Ambient Temp. (K)
Relative Humidity (~)
8/14/80
83.3
20.0
306
56
Exhaust Characteristics
Flowrate
(dnm 3/min)
Temperature
955
988
962
967
336
334
335
335
5.2
4.5
4.4
4.7
29.54
36.87
34.58
33.66
1552
2016
1814
1794
77.75
106.32
97.99
93.70
Negative
0.2725
1.079
0.449 b
14.06
57.61
24.36
0.742
3.113
1.300b
( K)
Moisture
(~
Vol.)
aFor runs with isokinetic percent less than 90~ mass f10wrates (kg/hr) presented here
are averages of mass f10wrates calculated by concentration method and area ratio method.
bThe average was calculated by assuming Run 1 values are zero.
A-aD
TABLE A-2gb.
Ave.
8/14/80
83.3
22.0
92
56
8/14/80
84.9
20.9
95
46
8/14/80
83.0
20.4
92
54
83.7
21.10
93
52
33.750
34,900
33,890
34,180
146
142
144
144
5.2
4.5
4.4
4.7
12.9
16.1
15.1
14.7
3421
4444
3998
3954
155.5
212.63
195.98
187.39
Negative
0.119
0.471
31.0
127.0
O.196 b
53.70b
1.483
6.225
2.600 b
Test No.
General Data
Date
Iso kinetic (%)
Production Rate tons/hr
Ambient Temp. of
Relative Humidity (%)
Exhaust Characteristics
F10wrate
(dscfm)
Temperature
(OF)
Moisture (% Vol.)
Ammonium Nitrate Emissions
Particulate Cone.
(gr/dscf)
Emission Rate a
(lb/hr)
Emission Factor
(l b/ten)
Ammonia Emissions
Ammoni a Cone.
(gr/dscf)
Emission Rata a
(lb/hr)
Emission Factor
(1 b/ton)
aFor runs with isokinetic percent less than 90% mass f10wrates (lb/ton) presented here are
averages of mass f10wrates calculated by concentration method and area ratio method.
bThe average was calculated by assuming Run 1 values are zero.
A-81
TABLE A-30a.
Tes t No.
Ave.
General Data
Date
Isokinetic (%)
Production Rate (Mg/hr)
Ambient Temp. (K)
Relative Humidity (%)
8/14/80
8/14/80
8/14/80
83.61102.3
89.21101.3
88.1/100.8
87.0/101.5
19.9
20.0
18.5
19.5
306
308
306
307
46
56
54
52
Exhaust Characteristics
F10wrate
(dnm 3/min)
Temperature
( K)
Moisture (% Vol.)
inlet:
outlet:
inlet:
outlet:
inlet:
outlet:
2084
2070
337
315
4.0
4.8
2056
2071
337
316
3.9
4.1
2061
2077
337
315
4.3
4.5
6.33
677
6-.36
631
2044
2089
338
315
5.0
4.6
19.4
0.0991
2189
12.4
109.66
0.623
99.4
23.3
0.0936
2759
11.5
145.53
0.613
99.5
22.3
0.107
2574
13.3
139.10
0.718
99.5
21.7
0.0999
2507
12.4
131.00
0.6145
99.5
0.0321 b
0.0698 b
2.531
8.755
0.127 b
0.439
Negative
0.2052
0.1074
11.653
13.381
0.6145
0.7055
Negative
0.5439
0.0669
29.502
8.301
1.594
0.4485
97.2
0.2604
0.0813
14.561
10.161
0.7785
0.531
31.8
Ammonia Emissions
Ammonia Cone.
inlet:
(g/dnm 3)
outlet:
Emission Rate
inlet:
(kg/hr)
outlet:
Emission Factor
inlet:
(g/kg)
outlet:
Collection Efficiency {%}
aThe inlet values are weighted by the predryer and dryer f1owrates.
bIncludes only the inlet predryer concentration. the dryer ammonia emissions
were negative.
A-82
TABLE A-30b.
Test No.
Ave.
8/14/80
89.2/101.3
20.9
95
8/14/80
88.1/100.8
20.4
92
54
87.0/101.5
21.1
93
52
General Data
Date
Isokinetic (%) In/Out
Production Rate tons/hr
Ambient Temp. of
Relative Humidity (%)
8/14/80
83.6/102.3
22.0
92
56
46
Exhaust Characteristics
F10wrate
(dscfm)
Temperature
(OF)
Moisture (% Vol.)
inlet:
outlet:
inlet:
outlet:
inlet:
outlet:
73,580
73,100
147
108
4.0
4.8
72,610
73,120
148
110
3.9
4.1
72,790
73,330
148
109
4.3
4.5
6.33
677
6.36
631
10.2
0.0409
6083
25.6
291.05
1.225
99.6
9.74
0.0467
5675
29.3
278.19
1.436
99.5
9.48
0.0436
5528
27.4
261.99
1.299
99.5
0.0896
0.0469
25.69
29.5
1.229
1.411
Negative
0.2375
0.0292
65.04
18.3
3.188
0.897
97.2
0.1137
0.0355
32.10
22.4
1.557
1.062
31.8
72,190
73,770
149
108
5.0
4.6
8.50
0.0433
4825
27.4
219.32
1.245
99.4
Ammonia Emissions
Ammonia Conc.
inlet:
(gr/dscf)
outlet:
Emission Rate
inlet:
(lb/hr)
outlet:
Emission Factor
inlet:
(1b/ton)
outlet:
Collection Efficiency
0.0140 b
0.0305 b
5.58
19.3
0.254b
0.877
Negative
aThe inlet values are weighted by the predryer and dryer flowrates.
bIncludes only the inlet predryer concentration, the dryer ammonia emissions were negative.
A-83
TABLE A-31.
Run
.J!!.~
8-14-80
NlJlnb~
)00
CO
.J::o
11-14-80
Average Opacity
TAllie Pe r lod
_l.f!:. r ce Il tI
1105 - 1110
1111 - 1116
1111 - 1122
1121 - 1128
1129 - 1114
11]5 - 1140
1141 - 1146
1141 - 1152
1151 - 1158
lU9 - 1204
1205 - 1210
1211 - 1216
1217 - 1222
1223 - 1228
1229 - 1234
1235 - 1240
1241 - 1246
1241 - 1252
125] - 1258
1259 - 1304
Average
1510 - 1515
1516 - 1521
1522 - 1521
1528 - ISH
15]4 - 1519
1540 - 1545
1546 - 1551
1552 - 1557
1558 - 1601
1604 - 1609
1610 - 1615
1616 - 1621
1622 - 1627
1628 - 16ll
16]4 - 1619
1640 - 1645
1646 - 1651
1652 - 1651
1658 - 1101
1104 - 1109
Average
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
hun
.J!!.tL
8-14-80
~t
Six-Minute
!!~ Period
1110 - 1715
1116 - 1121
1122 - 1121
1128 - 11)]
11)4 - 11)9
1140 - 1745
1146 - 1151
1152 - 1151
1158 - 180]
1804 - 1809
1810 - 1815
1816 - 1821
1822 - 1821
1828 - 18ll
18]4 - 1839
1840 - 1845
1846 - 1851
1852 - 1851
1858 - 1901
1904 - 1909
Average
Average 0l'a::lty
_-_ ..H!!.~_H_
0.6
2.1
1.1
1.5
0.8
1.5
0
0.2
0.6
0.2
0
0
0
0
0
0
0
0
0
0
0.5
TABLE A-32a.
Ave.
8/15/80
99.7/101.5
19.1
304
67
8/15/80
100.4/102.2
18.5
305
62
8/16/80
100.6/103.2
20.3
301
100.2/102.3
1160
569
325
318
3.18
2.63
1145
540
327
319
3.20
2.58
1142
543
326
319
3.67
2.75
1149
551
326
319
3.35
2.65
inlet:
bypass:
inlet:
bypass:
inlet:
bypass:
total:
12.89
0.175
896
5.99
47.02
0.315
47.33
8.885
0.232
610
7.48
32.94
0.405
33.35
9.755
0.186
668
6.08
32.86
0.299
33.16
10.51
0.1857
724
6.12
37.54
0.318
37.85
inlet:
bypass:
inlet:
bypass:
inlet:
bypass:
total:
0.2405
0.0027
16.78
0.0939
0.881
0.005
0.886
Negative
0.0013
Negative
0.0422
Negative
0.0025
Negative
Negative
0.0802
0.0014
5.58
0.045
0.294
0.0025
0.296
Tes t No.
General Data
Date
Isokinetie (%) In/Bypass
Production Rate (Mg/hr)
Ambient Temp. (K)
Relative Humidity (S)
77
304
69
Exhaust Characteristics
Flowrate
(dnm3/min)
Temperature
(K)
Moisture (% Vol.)
inlet:
bypass:
inlet:
bypass:
inlet:
bypass:
A-8S
TABLE A-32b.
8/15/80
100.4/102.2
20.4
90
62
8/16/80
100.6/103.2
22.4
83
40,970
20,120
126
113
3.18
2.63
40,450
19,070
129
114
3.20
2.58
40,350
19,190
127
115
3.67
2.75
40,590
19,460
127
114
3.35
2.65
inlet:
bypass:
inlet:
bypass:
inlet:
bypass:
total:
5.63
0.0754
1975
13.2
94.048
0.629
94.667
3.88
0.1011
1344
16.5
65.882
0.809
66.691
4.26
0.0813
1472
13.4
65.714
0.598
66.312
4.59
0.0811
1596
13.5
75.07
0.635
75.705
inlet:
bypass:
inlet:
bypass:
inlet:
bypass:
total:
0.105
0.0012
37.0
0.207
1.762
0.010
l.772
Negative
0.00057
Negative
0.093
Negative
0.005
Test No.
General Data
Date
Isokinetic (5) In/Bypass
Production Rate tons/hI'
Ambient Temp. OF
Relative Humidity (~)
8/15/80
99.7/101.5
21.0
88
67
77
100.2/102.3
21.3
87
69
Exhaust Characteristics
Flowrate
(dscfm)
Temperature
(OF)
Moisture
(~
Vol.
inlet:
bypass:
inlet:
bypass
inlet
bypass
A-86
Negative
Negative
0.035*
0.00059
12.3
0.100
0.587
0.005
0.592
TABLE A-33.
Date
Run
Numbe r
8-14-80
Six-Minute
Time Per iod
1450
1456
150'
1508
1514
1520
1526
1532
15]8
1544
1550
1556
1602
1608
1614
1620
1626
1632
16]8
1644
j;:o
I
00
......
1455
1501
1507
1513
1519
1525
1531
1537
1543
1549
1555
1501
1607
1613
1619
1625
1631
1637
164]
1649
Average
8-15-80
1100
1106
1112
1118
1124
11]0
11]6
1142
1148
1154
1105
1111
1117
112]
1129
1135
1141
1147
115]
1159
Average Opacity
( Percent)
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
0
0
0
0
0
0
0
0
0
0
Date
8-15-80
Run
Number
1
Six-Minute
Time Pe r iod
1200
1206
1212
1218
1224
12]0
12]6
1242
1248
1254
1205
1211
1217
1223
1229
12]5
1241
1247
1253
1259
Average'
0
0
0
0
0
1.9
5
5
5
5
2.2
TABLE A-34.
Date
Run
Number
8-15-80
8-15-80
8-15-80
Six-Minute
Time Period
1100 - 1105
1106 - 1111
1112 - 1117
1118 - 1123
1124 - 1129
1130 - 1135
1136 - 1141
1142 - 1147
1148 - 1153
1154 - 1159
Average
Average Opacity
(Percent)
a
a
0
0
a
a
0
0
0
a
a
1210 - 1215
1216 - 1221
1222 - 1227
1228 - 1233
1234 - 1239
1240 - 1245
1246 - 1251
1252 - 1257
1258 - 1303
1304 - 1309
Average
a
a
a
a
a
a
1545 - 1550
1551 - 1556
1557 - 1602
1603 - 1608
1609 - 1614
1615 - 1620
1621 - 1626
1627 - 1632
1633 - 1638
1639 - 1644
Average
0
0
A-88
a
a
a
0
a
a
a
0
a
0
a
0
0
TABLE A-35.
Date
8-13-80
Coater Baghouse
Average Opacity
Six-Minute
Time Period
(Percent)
0845
0851
0857
0903
0909
0915
0921
0927
0933
0939
0850
0856
0902
0908
0914
0920
0926
0932
0938
0944
Average
Date
8-14-80
0
0
0
0
0
0
0
0
0
0
0
1255
1301
1307
1313
1319
1325
1331
1337
1343
1349
1355
1300
1306
1312
1318
1324
1330
1336
1342
1348
1354
1359
Average
8-13-80
1355
1401
1407
1413
1419
1425
1431
1437
1443
1449
1400
1406
1412
1418
1424
1430
1436
1442
1448
1454
Average
1014
1020
1026
1032
1038
1044
1050
1056
1102
1019
1025
1031
1037
1043
1049
1055
1101
1107
Average
8-14-80
8-13-80
Bagging Baghouse
Average Opacity
SiX-Minute
(Percent)
Time Period
0
0
0
0
0
0
0
0
0
0
0
0
1123
1129
1135
1141
114 7
1128
1134
1140
1146
1152
Average
8-14-80
0
0
0
0
0
a
0
0
0
0
0
1235
1241
1247
1253
1259
1305
1311
1317
1323
1329
1335
1341
1347
1353
1240
1246
1252
1258
1304
1310
1316
1322
1328
1334
1340
1346
1352
1358
Average
A-89
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
wr::!t;!-lT
ft' ,..
100
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eo
10 SO 50 .., 30
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Figure A-9.
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Figure A-IO.
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A-91
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Figure A-ll.
% t.ESS
A-92
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A-95
APPENDIX A REFERENCES
1.
2.
3.
4.
5.
6.
A-96
APPENDIX B
Ammonium Nitrate Emission Measurement
B.1
B.1.1 Background
The standard method for determining particulate emissions for
stationary sources is EPA Method 5, whereby a particulate sample is
extracted isokinetically from a source and is collected on a heated
filter. The particulate mass is then determined gravimetrically.
Initial evaluations by EPA and others of the applicability of Method 5
for ammonium nitrate (AN) sampling indicated that in fact the standard
procedures of Method 5 would not be pract;cal. 1,2 Factors that affected
the sampling and analysis procedures of Method 5 included the following:
High water-solubility of AN (greater than 1 gram per ml water);
Relatively high vapor pressure and volatility of AN (AN
decomposes at 483 K (410F)); and,
High moisture levels present at certain AN emission sources
(percent moisture exceeding 50 percent).
As a result of these factors, major modifications to Method 5 were
adopted. A summary of these modifications and the reasons for each are
presented in the remainder of Section B.1.
B.1.2 Brief Summary of AN Method Development
Preliminary emission testing programs by industry and EPA in 1975
and 1976 demonstrated the applicability of the following modifications
to Method 5 for AN sampling and analysis:
Use of water-filled impingers as the primary AN collection
devices;
Placement of the filter after the water impingers as a back-up
collector;
Use of a specific ion electrode (SIE) for measurement of AN in
the impinger water;
Use of a water rinse instead of an acetone rinse because of
the explosion hazard when organic solvents mix with AN;
B-1
B-3
13-4
B-5
8-6
The fourth plant8 was tested in March 1979, for uncontrolled emissions
from the predryer, dryer and cooler operations. The train filter was
not analyzed separately. The percent insoluble particulate catch averaged
about 0.6% of the total particulate catch for all the process operations
tested. Approximately 3% of the total AN catch was detected in the acid
impingers, and these results are suspect because of acid interference. 13 ,14
The fifth plant 9 was tested in May and June 1979 for controlled and
uncontrolled emissions from a prill tower, prill cooler, evaporators and
neutralizers. The train filter was not analyzed separately. The percent.
insoluble particulate catch for uncontrolled emissions averaged 4.4%,
0.9%, and 1.2% at the prill tower, cooler and neutralizer, respectively;
and 5.8%, 10%, and 18% for the controlled emissions at the same process
units. Acid impinger samples were not analyzed for nitrate. The
neutralizer and evaporator samples contained very high concentrations of
ammonia compared to AN. As a result, some positive interference in the
AN analyses of these samples was evident due to their high background
ionic strength.
The results of these five emission testing programs demonstrated
that:
Little or no particulate is collected by the in-train filter;
Nearly all AN is collected in the water impingers; and,
The SIE nitrate analysis is subject to interference in high
ionic strength solutions. This interference will normally be
confined to neutralizer/evaporator emission samples.
8.1.3.4 Method Modifications
EPA further modified the AN sampling and analytical method to
reflect the findings of the first five testing programs and to discontinue
the requirement for ammonia sampling and analysis. No immediate need
for an ammonia emissions evaluation was foreseen. The modifications
consisted of the following:
Sampling
Use of five impingers with the following sequence: impingers
1 and 2 each contain 100 ml water (for AN collection), impinger
B-7
8-8
B-ll
APPENDIX B REFERENCES
1.
2.
3.
4.
5.
6.
7.
B.
9.
10.
EPA Report 79-NHF-3, "Emission Test Report W.R. Grace and Co.,
Memphis, Tennessee.
Prepared by TRC-Environmenta1 Consultants,
Inc., under EPA Contract 68-02-2820, Work Assignment 9.
1I
11.
12.
B-12
13.
14.
B-13
1. REi'ORT NO.
EPA-450/3-81-002
5. REPORT OATE
Janua ry 1981
6. PERFORMING ORGANIZATION eOOE
7. AuTHORtSI
Radian Corporation
3024 Pickett Road
Durham, North Carolina 27705
n. CONTRACT/GRANT NO.
68-02-3058
Final
.'
f:rlrolini'l
27711
16. ABSTRACT
'0
This report presents information on the emission levels, control techniques, and
costs associated with the control of particulate emission sources and facil Hies in
the ammonium nitrate solids producing industry. Sources of emissions include prill
towers, granulators, predryers, dryers, and coolers. Alternative control techniques
and supporting data are described and discussed, and an analysis of environmental and
economic impacts of control techniques are presented .
.
17.
a.
OESCFUPTORS
Air Pollution
Control Technology
Ammonium Nitrate
Particulate Emissions
:lISi"16\.iT,Cr-. STATEMeNT
Unl imited
Unclassified
=Q:~ .. 'Ol""iS
c.
eOSATI
Field/Gcoup
t
:~a.
~CfT'ON
15 OBSOL..ETE
Unclassified
I
i22. PRiCe