Ammonia Safety Training

AMMONIA SAFETY TRAINING
FOR SNCR RELATED PROJECTS
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
1
NOx Emission Reduction Process
What are Nitrogen Oxides?
• NOx emissions are the product of every air-fed combustion

process.
– Cars
– Industrial Processes
– Solid Waste Disposal
• Nitric Oxide and Nitrogen Dioxide are a product of high

temperature combustion.
• Nitrogen Dioxide is the compound largely responsible for the
orange to reddish-brown color NOx imparts to the air.
2
- In reality, more than 95% of NOx from cement plants is NO, but it will
oxidize in the atmosphere to form NO2
- While NOx consists of both NO and NO2, it is reported to regulatory

agencies as NO2
3
NOx Sources
• Feed NOx – Very minor to no contribution
• Thermal NOx – Created by reaction of N2 and O2 molecules in air at

Temperatures > 1300°C (i.e. - Kiln)
• Fuel NOx - Formed in calciner by combustion of N atoms in fuel
4
How do they effect us?
• NOx emissions are suspected of contributing directly and

indirectly to several atmospheric processes that are known to be
degrading the environment
– Acid Rain
– Forest and Vegetable Decline
– Changes to Ozone Layer
– Greenhouse Effect and Global Warning
5
Regulatory Issues Dictating NOx Reduction
• The Clean Air Act

– Enacted November 15, 1990
– Final rulemaking by EPA was November, 1992
6
US NOX Limits
•Emission levels for NOx have been set in the past on a state-by-state
basis, using BACT guidelines
–1998 – 2.8 lb NOX/ST clinker ~ 1.4 kg/t of Clinker
–2006 – 1.95 lb NOX/ST clinker ~ 0.98 kg/t of Clinker
7
NOX Limits for India
For new plants : 600 mg/Nm3 @ 10 % O2 dry basis.
For existing plants : 800 mg/Nm3 @ 10 % O2 dry basis
8
Destroying NOX
•Selective Non Catalytic Reduction (SNCR)
9
How does ammonia reduce Nitrogen Dioxide?
– Injection of ammonia in the flue gas in the presence of a

catalyst which causes chemical reactions that convert the
NOx into free nitrogen and water vapor.
• NH3 + OH  NH2 + H2O (1) Activation of the
ammonia water.
• NO + NH2  N2 + H2O (2) Reduction reaction
• O2 + NH2  NO + H2O (3) Burning of ammonia
if the temperature > 1000C
10
How does ammonia reduce Nitrogen Dioxide?
– Temperatures for ideal NOx reduction must take place

between 800 and 1100°C.
– Temperatures above 1000°C can cause a reverse reaction

where ammonia is converted back into NOx.
– Temperatures below 800°C can lead to unreacted ammonia

leaving the tower (slip).
• Ammonia salts can form at temperatures below
200°C.
11
SNCR Testing
- For non-FLS systems, testing of various ammonia locations is generally

performed
- Results of testing are normalized using the molar flows of ammonia and
starting NOx
- Mole weights
- Ammonia – 17 kg/k-mole
- NOx – 46.07 kg/k-mole
- NOx reduction rates are based off of a baseline figure
12
FLSmidth SNCR Short-Term Test
Results
100%
90%
80%
70%
% Reduction
60%
50%
40%
30%
20%
10%
0%
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90
NH3/NOx Molar Ratio
13
TRAINING
To reduce NOx through SNCR requires the safe

handling of ammonia.
The purpose of this training is to provide you with the

information you need in order to work safely around
ammonia.
14
Sources of Ammonia
• Ammonia is found in a number of industrial uses:
– Chemical Processes
– Diazo Machines
– Pharmaceuticals
– Water Treatment
– NOx Emission Reduction
15
MSDS
Information on the hazards associated with the
ammonia used in the SNCR process may be found on
the manufacturer’s Material Safety Data Sheet (MSDS).
Much of the physical and chemical data on ammonia

shown in this presentation can be found on the MSDS.
16
MSDS
•The MSDS will be

provided by the specific
supplier of the Aqua
Ammonia for each Job.
•Typical MSDS sheet for 19

% Acquoes solution
17
AMMONIA
• AMMONIUM HYDROXIDE
– Classified by OSHA, DOT and EPA as a hazardous substance.
– Because of the hazardous material classification, several regulations

have been put in place to protect employee’s who handle, work
around or respond to ammonia releases, from injury or death.
18
Physical Properties of
Ammonium Hydroxide
• Ammonium Hydroxide is a chemical compound of Nitrogen,
Hydrogen and Oxygen.
• It’s commercial symbol is NH4OH.
• Other trade names are Aqua Ammonia, Ammonia Solutions and

Ammonia Liquer.
• It is commercially available in various strengths but most

commonly as 26° Baume or 29.4% solution.
• The cement industry typically uses 19% - 25 % solution.
• The Baume reading refers to a specific gravity scale.
19
Ammonium Hydroxide
• The density of 25 % ammonium hydroxide in comparison to water is 0.908.
• Aqua Ammonia is not compatible with copper, brass, bronze, zinc or

mercury.
• Aqua Ammonia is corrosive to copper, copper alloys, aluminum alloys and

galvanized surfaces (zinc).
• When ammonia corrodes copper or brass, it turns it into a bluish-green

salt.
20
Ammonium Hydroxide
• 25% Aqua Ammonia is a strong alkaline.
• It’s PH varies with concentration.
• Typical values are:
– 11.7% at 1%
– 12.2 at 5%
– 12.4 at 10%
– 13.5 at 30%
• Aqua Ammonia is an excellent acid neutralizer
21
Ammonium Hydroxide
• Aqua Ammonia’s vapor pressure will vary with temperature
– A 25 % w/w solution has a vapor pressure of:
• 310 mmHg @ 20°C
• 500 mmHg @ 30°C
• 720 mmHg @ 40°C
• 1100 mmHg @ 50°C
• Ammonia Hydroxide is stable at atmospheric conditions.

– This permits the material to be shipped and stored in “non-
pressurized” containers.
• Aqua Ammonia should be stored in a closed container and kept
cool. Otherwise, the ammonia gas will dissipate out of solution.
22
Physical Properties of Ammonium Hydroxide
• One gallon of 25 % solution aqua ammonia weighs 7.58 lbs (3.43 kg) and
contains 1.9 lbs (0.857kg) of NH3.
• Aqua Ammonia is classified by the Department of Transportation (DOT) as

Corrosive.
23
Ammonium Hydroxide
•Aqua Ammonia is produced by dissolving anhydrous ammonia
in water. The mixing will produce an exothermic reaction. The
solution is circulated through a cooling tower or chiller.
•Aqua Ammonia is tested for trace elements introduced by
water. Iron, heavy metals such as lead, chloride, carbonate,
sulfate, arsenic, zinc, and chromate are typical elements used.
24
Ammonium Hydroxide
• Typical Analysis
– Appearance: Colorless and free from suspended matter or sediment
– Assay: 25 %
– Residue after Ignition: 0.0010%
– Carbon Dioxide (CO2): Less than 0.002%
– Chloride (Cl): Less than 0.002%
– Phosphate (PO4): Less than 0.002%
– Total Sulfur (as SO4): Less than 0.002%
– Heavy Metals (as Pb): Less than 0.002%
– Iron (Fe): Less than 0.002%
– Substances Reducing Permanganate: Pass
– Specific Gravity at 16°C: 0.908
25
Ammonia Health Hazards
• Ammonia is irritating and corrosive to the skin, eyes, respiratory tract
and mucous membranes.
• It can cause severe burns to the eyes, lungs and skin.
• Skin and respiratory related diseases can be aggravated by exposure.
• Not listed as a carcinogen by OSHA, the National Toxicology Program

annual report or the International Agency for Research on Cancer.
26
Exposure Limits
• Exposure limits are set in ppm measurements.
– Parts
– Per
– Million
• PPM is parts of a substance per million of air or water.
27
Exposure Limits
• USA Federal OSHA PEL – 50 ppm – 8 hour (TWA)

– OSHA set a Permissible Exposure Limit allowing a Time Weighted
Average air concentration of 50 ppm ammonia in the workplace over
an 8 hour day.
• USA NIOSH REL – 25 ppm – 10 hour (TWA)
– NIOSH (National Institute of Occupational Safety and Health)
recommends PEL limits to OSHA.
– NIOSH set the Recommended Exposure Limit at a Time Weighted
Average of 25 ppm ammonia air concentration over a period of 10
hours a day.
28
Exposure Limits
• ACGIH TLV – 35 ppm – 15 min. (STEL)

– Threshold Limit Values are recommended air concentrations in which
most people can work without suffering ill effects.
– ACGIH (American Conference of Governmental Industrial Hygienists)
recommends the Short Term Exposure Limit for ammonia at 35 ppm in
a 15 minute time period.
29
Exposure Limits
• IDLH – 300 ppm

– The Immediately Dangerous to Life & Health limit for ammonia is 300
ppm.
– 300 ppm is the maximum concentration of ammonia from which a
person could escape within 30 minutes without any impairing
symptoms or irreversible health effects.
30
Routes of Entry
• Absorption – through the eyes and skin
• Inhalation – Ammonia Health Hazard
• Ingestion
• Injection/Puncture
31
Routes of Entry
• Absorption
– The skin acts as a barrier against entry of foreign materials

into the body.
– If the protective barrier is weakened or compromised, toxic

chemicals enter.
– The barrier is greatly diminished by lacerations or abrasions.
32
Routes of Entry
• Inhalation
– The most rapid route into the body, immediately introducing toxic
chemicals to respiratory tissues and the bloodstream.
– Once admitted to the blood through the lungs, these chemicals are
quickly transported throughout the body.
– Ammonia is an Inhalation Hazard.
33
Routes of Entry
• Ingestion
– Materials get into the mouth through hand to mouth contact and
through coughing when inhaled particulate material is removed from
the lungs to the throat and then swallowed.
34
Routes of Entry
• Injection
– The injection of hazardous materials into the body can occur by

stepping on or bumping against a sharp object.
– The best precaution is wear protective clothing and observe safe work
habits.
35
Effects of Overexposure
• Chronic
– Several small exposures over a period of time cause no immediate
effect.
• Acute
– A large, single dose received over a short period of time may or may
not produce an immediate effect.
– Exposure may exceed the threshold sensitivity of the individual

causing a serious delayed effect, such as pulmonary edema or lung
injury.
36
Effects of Overexposure and Emergency Aid
• Eye: May cause lacrimation, edema or blindness.

– Lacrimation – the secretion of tears, especially in abnormal
abundance.
– Edema – an abnormal accumulation of fluid in the tissue spaces,
cavities or joint capsules of the body, causing swelling of the
area.
– Blindness – unable to see; lacking the sense of sight.
• Emergency Aid:
– Flush the eye with copious amounts of water for a minimum of
15 minutes.
– Eyelids should be held apart and away from the eyeball for
thorough rinsing.
• Contact lenses should NOT be worn around ammonia.

37
• Skin: May result in irritation, corrosive burns and blister formation.

Contact with liquid will freeze and produce caustic burn.
– Corrosive and Caustic Burns – (First Degree): a burn caused by
chemicals or abnormal cold that is characterized by painful reddening
and swelling of the epidermis.
– (Second Degree): damage extending into the dermis, usually with
blistering.
– (Third Degree): destruction of the epidermis and dermis extending
into the deeper tissue.
38
• Emergency Aid: (Skin)

– Flush with copious amounts of water for a minimum of 15 minutes
while carefully removing contaminated clothing and shoes.
– Note: Do NOT apply ointment on affected area!!
39
• Inhalation: Acute exposure may result in severe irritation of the

respiratory tract, bronchospasm, edema or respiratory arrest.
– Bronchospasm – spasmodic contraction of the muscular lining of the
bronchi, as in asthma, causing difficulty in breathing.
– Edema – an abnormal accumulation of fluid in tissue spaces, cavities
or joint capsules of the body, causing swelling of the area.
– Pulmonary Edema – Edema affecting the lungs.
– Respiratory Arrest – Extreme shortness of breath caused by an acute
illness or injury.
40
• Emergency Aid: (Inhalation)

– Remove to fresh air
– Administer oxygen or artificial respiration, if necessary.
41
• Ingestion: Lung irritation or pulmonary edema may occur.

– Pulmonary Edema – an abnormal accumulation of
fluid in the lungs causing swelling.
• Emergency Aid:
– If conscious, give large amounts of water or citrus
juice to drink. Citrus will counteract the ammonia.
– Do NOT induce vomiting!!!
• Seek Medical Attention for all Ammonia Related
Exposures!!!
42
Fire and Explosion Hazard Data
• Flashpoint: None.
• Flammable Limits in Air: 16 – 25%.
43
Ammonia Fire-Fighting Procedures
•Use water spray or fog to extinguish flames and cool down fire exposed
containers.
•Use water spray or fog to control ammonia vapors; dike or contain run-
off.
•Dike or contain run-off for recycling or controlled evaporation.
44
Chemical Reactivity of Ammonia
• Reacts violently and/or explosively with acids.
• Explosive mixture/products are formed when mixed with chlorine,

bromine, fluorine, iodine (Partial Listing).
• Corrosive reaction to copper, brass, bronze, gold, silver and mercury

(Partial Listing).
45
• Selection and Use of Personal Protective
Equipment
46
Personal Protective Equipment (PPE)
• Chemical Goggles – for eye protection

– #1 most important piece of PPE.
– Eyes are most susceptible to vapor exposure because ammonia has a
strong affinity for water and eyes are made mostly of water.
– Should be worn when working with or around ammonia systems.
– Contact lenses are not permitted!!!
• Rubber gloves – for hand protection
– Neoprene.
– Should be worn when a danger exists of contact with liquid or vapor
ammonia.
– A cuff should be made to prevent ammonia from running down the
arm.
47
Personal Protective Equipment (PPE)
• Face Shield – protects against splash exposures.
– Highest risk is when making and breaking connections.
– Should be worn when a danger exists of contact with liquid
or vapor ammonia.
– Should be worn with goggles, not as a substitute.
• Rain Gear – protects against splash exposures
– Rubber rain coat or suit.
– Should be worn when a danger exists of contact with liquid
or vapor ammonia.
• Hard Hat – for head protection.
– Should be worn where head exposures exist.
48
Levels of PPE
• Level D:
– Minimal protection used for nuisance contamination only.
– Chemical Goggles, Face Shield, Rubber Gloves, Chemical Suit or Rain

Gear and Chemical Boots.
49
Determining Levels of Protection
• Level D protection should be worn when:
– The atmosphere contains no known hazard.
– Work functions do not involve the direct contact of hazardous levels of

any chemicals.
50
Levels of PPE
• Level C:
– Protection that is worn when the concentrations and types of airborne

substances are known and the criterion for air-purifying respirators is
met.
– Rubber Gloves, Hard Hat, Chemical Suit with Hood, Full Face Cartridge
Respirator and Chemical Boots.
51
• Level C protection should be worn when:
– The direct contact with the contaminant will not be harmful to the
skin.
– The type of contaminant has been identified and measured and meet
the air-purifying respirator criteria.
Note: Should not be worn if contaminant exceeds or could exceed IDLH

levels and/or atmosphere contains less than 19.2% oxygen.
52
Levels of PPE
• Level B:
– The highest level of respiratory protection is required but lesser skin

protection is needed.
– Level B Protective Suit with Hood, SCBA, Hard Hat, Rubber Gloves and
Chemical Boots.
53
• Level B protection should be worn when:
– The type and atmospheric concentration of substances have been

identified and require a high level of respiratory protection but lesser
skin protection.
– IDLH concentrations of substances do not pose a severe skin hazard or
do not meet respirator criteria.
– The atmosphere contains less than 19.2% oxygen.
Note: Level B suits cannot protect against high concentrations of vapors

or gases that are harmful to the skin.
54
Levels of PPE
• Level A:
– Greatest level of respiratory, eye and skin protection is required.
– Fully encapsulated Level A Suit and Chemical Boots; Rubber Gloves, if

not incorporated with Level A Suit.
55
• Level A protection should be worn when:

– The hazardous material has been identified and requires the highest
level of protection.
– High concentrations of atmospheric gases, vapors or particulates.
– High potential of exposure to splashes or immersion.
– High degree of skin hazard is known or suspected to be present.
– Operations must be conducted in confined or poorly ventilated areas.
– Conditions requiring Level A have not yet been determined.
56
Levels of PPE
• Level C:
– Work around ammonia in cement plants generally requires level C

protection including full face respirator as a minimum
57
Respirator Types
• Full Face Cartridge Respirator:
– Allows employees to breathe easily in atmospheres below IDLH levels.
– IDLH for Ammonia is 300 ppm.
– Negative pressure mask that allows the contaminated air to be filtered

through a cartridge, specific to the contaminant type.
– Ammonia cartridges have expiration dates.
58
Respirator Types
• PAPR – Positive Air-Purifying Respirator:

– Provides positive flowing filtered air through a respirator.
– Recommended when long hours of wearing a respirator is required.
– Mandatory option if an employee does not pass the Medical
Evaluation per the Respirator Standard.
– Ammonia cartridges have expiration dates.
– Filters may be added to cartridges.
– Battery powered unit that supplies air through cartridge.
59
Respirator Types
• SCBA – Self Contained Breathing Apparatus:
– The greatest form of respiratory protection used in Level A and B

emergencies.
– A positive air-supplying respirator that allows a designated time of air

to flow through a full face gas mask.
60
Respirator
• Respirator Good Habits

– Read and comprehend respirator manual.
– Get a good fit.
– Clean and inspect respirator.
• Fit Checks
– Positive Fit Check
– Negative Fit Check
• Fit Testing
– Quantitative Fit Testing
– Qualitative Fit Testing
61
Respirator
• Cartridges: Protect against vapors.

– Use only cartridges specific to ammonia.
– Filters may be added to cartridges to protect against additional air
contaminants.
– Replacement:
• When you begin to smell or taste contaminants (Leave
contaminated area before changing).
• Reach expiration date.
• After they have been used and sealed for 6 months.
62
Respirator
• Using Your Respirator
– Straps should not be too tight or too loose.

– All straps should be fastened.
– Both inhalation and exhalation valves should be working properly.
– Assure hair, including facial hair, and glasses do not interfere with the
seal around your face.
– Glass adaptor option.
63
Respirator
• Cleaning
– Remove cartridge
– Wash with warm water and soap or alcohol
– Rinse with clean warm water
– Allow respirator to dry to prevent decay in storage.
64
Respirator
• Inspection
– Once a month.
– Inspect rubber for cracks, wrinkles, distortions and holes.
– Check both inhalation and exhalation valves and they are clean.
– Check lens for scratches, looseness and cracks.
– Inspect straps they should not be losing elasticity or breaking.
– Check that buckles and attachments work properly.
– Assure there is no damage to the respirator.
– Check cartridge expiration, type and condition.
65
Ammonia Detection
• Portable Electrochemical Ammonia Detector

– LED Screen Display
• Range (0 – 500 ppm)
• Warning Set Point (100 ppm)
• Alarm Set Point (300 ppm)
• Current ammonia gas value
– Set Points are Adjustable
– Alarms – Visible and Audible
• “Warning” w/intermittent audible alarm
• “Alarm” w/continuous audible alarm
• “Pump Out” w/intermittent audible alarm
• “Low Batt” w/intermittent audible alarm
66
Ammonia Detection
• Maintenance
– Response test before each use
– Calibration every six months
– Keep plugged into charger when not in use
– Flow meter check before each use
– Filter check every six months
– Typical sensor life is 3 years, return to manufacturer
– Detector should be stored in air conditioned office to preserve sensor
life
67
Ammonia Detection
• Sensor
– When cell becomes depleted, sensor will not respond and must be
returned to manufacturer
– Sensor life will shorten due to:
• A long period of time
• Exposure to high temperatures
• Exposure to varying concentrations of NH3 gas
• Exposure to high moisture
68
• Ammonia Incidents
69
Hazardous Material Incident
• Definition:
– The unintentional or uncontrolled release of a hazardous material.
70
Emergency Response Plan Elements
• Standard Operating Procedures for hazardous materials incidents.

– Pre-Incident Planning
– Site Control
– Evacuation Plans
– Decon Procedures
– Medical Response Plans
– Training
71
OSHA’s Emergency and Fire Prevention Plan
(29 CFR 1910.111)
• Emergency Program
– Must have clear escape procedures and escape route
assignments. Retreat to designated areas or Shelter – In –
Place.
– Must have well defined procedures for employees who
remain to operate critical procedures. Plant procedures and
shut down of equipment.
– Procedures to account for all employees Count Heads
– A list of workplace hazards use proper methods of storage
and handling.
– A list of possible ignition sources Responsible personnel
knowing control procedures.
72
Training Levels
• OSHA 29 CFR 1910.120 (q) and ANSI K- 61.1-3.1 state that all employees
must be trained to their specific job level.
• There are five levels of Ammonia training
• 1. Awareness Level
• 2. Operations Level – your training level
• 3. Technician Level
• 4. Specialists
• 5. Incident Commander
73
Awareness Level
• 2 hour training session that provides a General Ammonia

Overview.
• For personnel who work around, not directly with, hazardous
materials.
• Awareness level responders are expected to:

• - Recognize the presence of a hazardous material.
• - Protect themselves while safely evacuating the scene.
• - Call for trained personnel.
• - Secure the area.
74
Operations Level
• 8 hour training session that provides an Operating System

Overview.
• For those employees who work directly with hazardous materials.
• Operations level responders are expected to:
• Recognize the presence of a hazardous material.
• Protect themselves while shutting-down critical operations, if
possible, and evacuating the scene (Defensive Actions ONLY!).
• Call Emergency Responders.
• Secure the area.
75
Technical Level
• 24 Hour Mandatory Training

• Hazardous Materials Technicians are individuals who respond to releases
for the purpose of stopping or mitigating them, by using trained methods
such as, plugging or patching.
• You must pass a basic physical, Pulmonary Function Test (PFT) and Medical
Evaluation.
76
Specialist Level
• Personnel who respond with and support Hazardous Materials

Technicians.
• Duties require more of a specific knowledge of the hazardous material

released or spilled.
• Act as liaison with Federal, State and other governing agencies in regard to
site activities.
77
Incident Commander Level
• Assumes control of incident scene

• Directs all actions and operations on scene
• Must be trained and competent in:
– Incident Management System
– Emergency Operations Plans
– Hazards and Risks of Operating at the Scene
– State and Federal Resources and Plans
– Decontamination Procedures
– Formulate Response Objectives, Action
Options and Plan of Action.
78
Standard for Professional
Competence of Responders to
Hazardous Material Incidents
NFPA 472
• First Responders at Operational Level
– First responders at the operational level are those persons
who respond to releases or potential releases of hazardous
materials as part of the initial response to the incident for
the purpose of protecting nearby persons, the environment,
or property from the effects of the release. They shall be
trained to respond in a defensive fashion to control the
release from a safe distance and keep it from spreading.
79
First Responders at Operational Level
• Goals
1. Analyze a HAZMAT incident
• Survey the incident
• Identify Hazardous Material
• Container labels
• Container shapes
• Visual, odor
• Consequences
• MSDS
• CHEMTREC, Shipper, Manufacturer
• Predict likely behavior of the material
• Estimate potential harm at the HAZMAT Incident
80
• Goals continued
2. Plan an initial response
• Objective is to control events as they occur or
keeping even more severe events from occurring.
• Establish communications
• Take defensive action; diking, placing a pail under a
leaking valve, closing a valve.
• Understand the limitation of PPE at this level.
• Identify decontamination procedures if personnel
were exposed.
81
• Goals continued
3. Implement the response
• Establish and enforce scene control.
• Initiate the IMS (Incident Management System)
• Don PPE correctly
• Perform defensive controlled functions
82
• Goals continued
4. Evaluate the progress of the actions taken
• Are the defensive actions taken having the desired
results.
• Communicate the status of the response to IC
(Incident Commander).
83
OSHA’s Storage & Handling of
Anhydrous Ammonia
•
(29 CFR
A list of fire protection equipment
1910.111)
Responsible personnel maintaining
the equipment Facilities which manufacture or use NH3 as a refrigerant
only are exempt.
– Water for First Aid must be accessible.

– Two full face respirators remote from each other are mandatory.
– Proper container marking – hazard warning labels
– Container must be located away from fire hazards and ten seconds
away from water.
– Proper equipment and system use.
– Valve and appurtenances must be compatible with NH3.
– Piping and hose specifications – pressure ratings.
84
PPE Requirements
OSHA 29 CFR 1910.132-.134
• Employers are responsible for supplying safety equipment to employees to
protect the eyes, face, head and extremities from hazardous contact.
• OSHA requires the use of PPE when working with or around ammonia.
• The safety equipment must be kept available, accessible and properly

maintained at all times.
85
Process Safety Management (PSM)
29 CFR 1910-38
• The purpose is to minimize the consequences of catastrophic release

of toxic, reactive, flammable or explosive chemicals.
• Applies to processes that involve chemicals at or above the

threshold quantities specified.
• Anhydrous Ammonia threshold is 10,000 lbs (4525 kg)
• Ammonium Hydroxide threshold is 20% or greater = 20,000 lbs

((9050 kg).
86
Process Safety Management
Elements
• 14 Elements
1. Employee Participation
2. Process Safety Information
3. Process Hazard Analysis
4. Emergency Planning and Response
5. Operating Procedures
6. Employee Training
7. Contractor Qualification
87
Process Safety Management
Elements Continued
8. Pre-Startup Safety Review
9. Mechanical Integrity
10. Hot Work Permits
11. Management of Change
12. Incident Investigation
13. Compliance Audits
14. Trade Secrets
88
EPA’s Risk Management Plan
• Purpose is to prevent accidental chemical releases or to
minimize their impact to the community and environment.
– A process is regulated if a listed substance is present above
the threshold quantity. NH3 = 10,000 lbs (4525 kgs) ;
NH4OH = 20% or greater = 20,000 lbs (9050 kgs).
– Perform hazard assessments.
– Worst-case scenarios and alternative release scenarios.
– Set up an Accident Prevention Plan.
– EPA’s version of Process Safety Management.
– Emergency Response Program
– Intended for those facilities that will have employees
responding to emergencies; if not, coordinate with local
responders.
89
EPA’s Form “R”
• Toxic Release Inventory reporting
– Chemical must be on the 313 chemical list

– Over 10 employees
– Must have noted Standard Industry Code
– Manufacturer’s who use 25,000 lbs (11312 kgs) . or more. Otherwise
use 10,000 lbs (4525kgs). or more.
– Purpose is to define how much product was release and how to lessen
amount in the future.
90
Ammonia Spill Planning
• Written Emergency Response Planning

• Evacuation Plan/Sitting Factors
• Ammonia System Equipment Inspection
– Mechanical Integrity Program
• Training of Operators and Maintenance Personnel
• Training of Plant Personnel
• Training of Emergency Response Team
91
Ammonia Spill Planning
• Release Prevention
• Incident Command System
• Communications
• Planning for Natural Disasters
• Power Outages
92
Emergency Planning
• Meet with outside agencies
– Local Emergency Planning Commission

– Fire Department
– Police Department
– Emergency Medical Services EMS
– Neighborhood Industry
93
Aqua Ammonia Storage Tanks and Fittings
• Tanks
– Stationary storage tanks are regulated by department of labor (29 CFR
1910.111)
• Safety Relief Valves
– Are designed to relieve pressure, liquid or vapor, that exceeds 30 psig
(2 bar) on storage tanks.
• Vacuum Breakers
– Are designed to prevent the tank from being exposed to substantial
vacuum.
94
• LIQUID CONNECTION:
– Used for charging the tank with liquid.
• VAPOR CONNECTION:
– Used to recover vapor from the tank and equalize pressures between
the delivering tanker and a storage tank.
95
• BALL VALVE
– Designed to isolate flow.
• Electronic Level Probe (Capacitance Type)

– Designed to measure the liquid level in the tank.
• Thermocouple
– Designed to measure the liquid’s temperature.
96
Task Specific Training
For
Operation of the FLS SNCR Rig
97
FLS Test Rig
• FLS can provide a temporary test rig to customers for use with 19%
ammonia solution for SNCR trials
98
FLS Test Rig
99
FLS SNCR Test Rig
100
Filters
- Note that inlet filters are located on the rig between the connection to the
truck and the pump
- Tanks may have particulate due to reactions with minerals in the water –
filters are to prevent damage to pump and clogging of injectors
- If flow rates are very low even with the line to the injectors fully open, the
strainer may be clogged
- The strainer may be removed and cleaned with water and/or air
101
Connections to Truck
• Tankers supplying ammonia must be equipped with a quick-acting shut-off

as mandated by DOT rules
• - Check that a shut-off is provided before accepting the truck
102
103
Connections to Tote
- Connection to pump comes from bottom valve
- Return line is connected to top of the tote
- The tote must have a vacuum breaker installed so that the tote walls do
not “suck in”
104
105
Safety When Making Connections
- Wear appropriate PPE (covered earlier in lecture
- Try to capture any spilled ammonia when making or breaking connections

(bucket, tarp, etc.)
106
Containment
• - Both the ammonia vessel (tanker or tote) and the rig should be placed on
a flat area and contained
- Typically, containment is achieve using an earthen wall and/or a concrete

pad
- Ammonia must NOT be routed to storm drains or waterways
107
Containment
108
Containment
109
Containment
110
Housekeeping
- Run ammonia and air supply lines carefully
- Always hoist and lower supply lines to tower using a strong rope
- Attempt to avoid dangerous “piles” of equipment
- Secure lines for safety
- Keep supply lines away from hot surfaces
- Avoid “kinking” hoses
111
Housekeeping
112
Housekeeping
113
Housekeeping
Poor Sealing – Not
recommended
114
Recommended sealing
3/22/2019 CSD/AT 115

Additional Safety
- Ensure that eyewash stations and shower locations are known and
accessible in case of emergency
- Know the locations of the nearest First Aid kits
- Understand plant procedures in case of emergency
116
Additional Safety
- Place safety tape around areas where ammonia exposure can occur
- Levels of injection
- Locations of connections (tanks, supply lines, etc.)
117
Entry Warnings
118
Starting Test Rig
• Plant electrician should provide power to breaker
• Check the rotation of pump prior to start of unit with ammonia – reverse
direction if necessary
• Do not start pump with “dead-heads” – ensure path for ammonia is open
for start
• Always test with water before using ammonia
• Ensure adequate heating of lines in cold weather once water has been run
through the lines
119
Running Test Rig
• Provide adequate atomization air (typically 40 psi min.) – Adjust as

necessary when water testing
Adjust flow of ammonia to injectors using recycle valve
• Monitor flow and tank level to ensure that pump does not run dry
• Clean filters as necessary
• Ensure adequate heating of lines in cold weather
120
Clean-up
• Run water through lines prior to disconnecting ammonia for the last time
Clean equipment prior to storage (wipe down hoses, coil and secure for
transport, etc)
• Never leave uncoupled unions exposed in transit
121
Questions?
122

Ammonia Safety Training

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AMMONIA SAFETY TRAINING

FOR SNCR RELATED PROJECTS

• NOx emissions are the product of every air-fed combustion

• Nitric Oxide and Nitrogen Dioxide are a product of high

- While NOx consists of both NO and NO2, it is reported to regulatory

• Feed NOx – Very minor to no contribution

• Thermal NOx – Created by reaction of N2 and O2 molecules in air at

• Fuel NOx - Formed in calciner by combustion of N atoms in fuel

• NOx emissions are suspected of contributing directly and

• The Clean Air Act

–1998 – 2.8 lb NOX/ST clinker ~ 1.4 kg/t of Clinker

–2006 – 1.95 lb NOX/ST clinker ~ 0.98 kg/t of Clinker

For new plants : 600 mg/Nm3 @ 10 % O2 dry basis.

For existing plants : 800 mg/Nm3 @ 10 % O2 dry basis

•Selective Non Catalytic Reduction (SNCR)

– Injection of ammonia in the flue gas in the presence of a

– Temperatures for ideal NOx reduction must take place

– Temperatures above 1000°C can cause a reverse reaction

– Temperatures below 800°C can lead to unreacted ammonia

- For non-FLS systems, testing of various ammonia locations is generally

- NOx reduction rates are based off of a baseline figure

To reduce NOx through SNCR requires the safe

The purpose of this training is to provide you with the

• Ammonia is found in a number of industrial uses:

– NOx Emission Reduction

Much of the physical and chemical data on ammonia

•The MSDS will be

•Typical MSDS sheet for 19

– Because of the hazardous material classification, several regulations

• It’s commercial symbol is NH4OH.

• Other trade names are Aqua Ammonia, Ammonia Solutions and

• It is commercially available in various strengths but most

• The cement industry typically uses 19% - 25 % solution.

• The Baume reading refers to a specific gravity scale.

• The density of 25 % ammonium hydroxide in comparison to water is 0.908.

• Aqua Ammonia is not compatible with copper, brass, bronze, zinc or

• Aqua Ammonia is corrosive to copper, copper alloys, aluminum alloys and

• When ammonia corrodes copper or brass, it turns it into a bluish-green

• Ammonia Hydroxide is stable at atmospheric conditions.

• Aqua Ammonia is classified by the Department of Transportation (DOT) as

• It can cause severe burns to the eyes, lungs and skin.

• Skin and respiratory related diseases can be aggravated by exposure.

• Not listed as a carcinogen by OSHA, the National Toxicology Program

• Exposure limits are set in ppm measurements.

• PPM is parts of a substance per million of air or water.

• USA Federal OSHA PEL – 50 ppm – 8 hour (TWA)

• ACGIH TLV – 35 ppm – 15 min. (STEL)

• IDLH – 300 ppm

• Absorption – through the eyes and skin

• Inhalation – Ammonia Health Hazard

– The skin acts as a barrier against entry of foreign materials

– If the protective barrier is weakened or compromised, toxic

– The barrier is greatly diminished by lacerations or abrasions.

– Ammonia is an Inhalation Hazard.

– The injection of hazardous materials into the body can occur by

– Exposure may exceed the threshold sensitivity of the individual

• Eye: May cause lacrimation, edema or blindness.

• Contact lenses should NOT be worn around ammonia.

• Skin: May result in irritation, corrosive burns and blister formation.

• Emergency Aid: (Skin)

– Note: Do NOT apply ointment on affected area!!

• Inhalation: Acute exposure may result in severe irritation of the

• Emergency Aid: (Inhalation)