EPA-
October 1974
BACKGROUND INFORMATION
FOR STANDARDS OF PERFORMANCE:
PHOSPHATE FERTILIZER INDUSTRY
VOLUME 2: TEST DATA SUMMARY
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Qu.li,, Planning and Standard,
Re.earch Triangle Park, North Carolina 27711
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EPA 450/2-74-019B
BACKGROUND INFORMATION
FOR STANDARDS OF PERFORMANCE;
PHOSPHATE FERTILIZER INDUSTRY
VOLUME 2: TEST DATA SUMMARY
Emission Standards and Engineering Division
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
October 1974
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This report is issued by the Environmental Protection Agency to report
technical data of interest to a limited number of readers. Copies are
available free of charge to Federal employees, current contractors and
grantees, and nonprofit organizations as supplies permit from the Air
Pollution Technical Information Center, Environmental Protection Agency,
Research Triangle Park, North Carolina 27711; or for a fee, from the
National Technical Information Service, 5285 Port Royal Road,
Springfield, Virginia 22161.
Publication No. EPA-450/2-74-019b
II
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CONTENTS
Section page
INTRODUCTION 1
WET-PROCESS PHOSPHORIC ACID PLANTS 2
Fluoride Test Results 2
Facilities ' 2
References 16
SUPERPHOSPHORIC ACID PLANTS 17
Fluoride Test Results .••'•' 17
Facilities 17
References 21
DIAMMONIUM PHOSPHATE PLANTS 22
Fluoride Test Results 22
Facilities 22
References 30
RUN-OF-PILE TRIPLE SUPERPHOSPHATE MANUFACTURING PLANTS
AND STORAGE PILES 31
Fluoride Test Results 31
Facilities . 31
References 40
GRANULAR TRIPLE SUPERPHOSPHATE PRODUCTION PLANTS . . . 41
Fluoride Test Results 41
Facilities 41
References 49
GRANULAR TRIPLE SUPERPHOSPHATE STORAGE FACILITIES 50
Fluoride Test Results 50
Facilities 50
References 58
TECHNICAL REPORT DATA SHEET 59
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INTRODUCTION
This document presents summaries of source tests and visible emission
measurements cited in Volume 1 of this background information document. It
is concerned principrlly with tests for fluorides, but also describes the
facilities tested, their operating conditions, and characteristics of
exhaust gas streams.
Facilities are identified by the same coding used in Volume 1. For
example, for wet process phosphoric acid plants, Table 1 summarizes the
results of EPA tests conducted in December of 1971 at Facility A. These
same results are also plotted on Figure 7 of Volume 1 identified as EPA
test results at Plant A.
Many of the tests summarized herein were conducted using EPA Method 13
which will be proposed in the Federal Register at or before the time of
proposal of standards of performance for five processes in the phosphate fertilizer
industry.
The types of facilities covered by the proposed regulation and covered
in this document are as follows:
1. Wet-process phosphoric acid plants.
2. Superphosphoric acid plants.
3. Diammonium phosphate plants.
4. Run-of-pile triple superphosphate plants.
5. Granular triple superphosphate plants.
6. Storage of granular triple superphosphate.
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WET-PROCESS PHOSPHORIC ACID (WPPA) PLANTS
Fluoride Test Results
A test program was undertaken by EPA to evaluate the best fluoride control
equipment available for installation on new or substantially modified WPPA
plants. Three plants, identified as A, B, and C were tested by EPA. Additional
data reported include two plants, identified as D and E, tested during a joint
study by the Manufacturing Chemists' Association and the U. S. Public Health
Service. Data submitted by operators of plants A, B, and C are also included.
All of the plants were operating at or near design capacity during the tests.
All plants used scrubbers to control fluorides. These scrubbers were operating
normally during all EPA tests.
Figure 1 presents emission rates (pounds of fluorides per ton of P205
input to the process) for the six plants.
The test results of 0.0638 Ib F/ton P205 reported for Run Number 1 at
Plant A are not believed to be accurate. Plant A routinely measures emissions
from the plant. The highest valid fluoride emissions recorded by this plant
in 1972 (78 test runs) was 0.053 Ib F/ton P205-
Facilities
A. Conventional multi-compartment tank reactor (Prayon continuous process)
designed for a production rate of 660 TPD P205- The plant was operat-
ing at 25 percent above design capacity during the EPA tests. EPA
data are based on samples obtained using EPA Method 13 for fluorides.
The operator collected samples using the State of Florida method for
fluorides. In this method, sampling is conducted at the point of
-------
average gas velocity. Two Greenberg-Smith impingers containing 20
milliliters of distilled water are used. The probe washing and im-
pinger solutions are included in the analysis. Fluoride emissions
from the reactor, the filter, and miscellaneous sources are controlled
by a spray-concurrent packed scrubber. Gypsum pond water is used as
the scrubbing medium. Opacity of exhaust gases was less than 10
percent during the EPA tests.
B. Conventional multi-compartment tank reactor (Prayon continuous
process) designed for a production rate of 550 TPD P205. The plant
was operating at 30 percent above design capacity during the EPA
tests. EPA data are based on samples obtained using Method 13. The
operator collected samples using the State of Florida method. Fluoride
emissions from the reactor, filter, and miscellaneous sources are
controlled by a spray-crossflow packed scrubber. Gypsum pond water
is used as the scrubbing medium. Opacity of exhaust gases was less
than 10 percent during the EPA tests. Additional visible emission
observations were made by EPA contractor personnel at another time.
EPA Method 9 was used for these observations.
C. Conventional multi-compartment tank reactor (Prayon continuous process)
designed for a production rate of 525 TPD P2°5- Tne plant was operat-
ing at 95 percent of design capacity during the first EPA test
(designated C^) and at 27 percent above design capacity during a
second EPA test (designated C2). EPA data are based on samples
obtained using Method 13. The operator collected samples using the State of
Florida method. Fluoride emissions from the reactor, filter, and
-------
miscellaneous sources are controlled by a spray-crossflow packed
scrubber. Gypsum pond water is used as the scrubbing medium.
Opacity of exhaust gases was less than 10 percent during EPA tests.
D. Conventional multi-compartment tank reactor (Prayon continuous process)
designed for a production rate of 660 TPD P205- The plant was operat-
ing at six percent above design capacity during the test and was
tested by the U. S. Public Health Service using their test method. The
test train is similar to that for EPA Method 5 except there are three
wet impingers. Fluoride emissions from the reactor, filter, and
miscellaneous sources are controlled by a spray-crossflow packed
scrubber. Gypsum pond water is used as the scrubbing medium. Opacity
of exhaust gases was not reported.
E. Two WPPA production lines controlled by a common scrubber. Each line
is of the Dorr-Oliver single-tank reactor design and is designed for
a production rate of 600 TPD P205. The plant was operating at 10
percent below design production rate during the test. The fluoride
scrubbing system consists of two impingement scrubbers in series.
This scrubbing system also serves part of a nearby triple superphosphate
plant. This connection was closed off during sampling. The plant was
tested by the U. S. Public Health Service using their test method.
Opacity of exhaust .gases was not reported.
-4-
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FIGURE 1.
FLUORIDE EMISSIONS FROM WET-PROCESS
PHOSPHORIC ACID PLANTS
I
in
u.u/
o 0.06
CL
o
^ 0.05
_Q
i
g 0.04
o
CX>
g 0.03
LLJ
III
LLJ
o
5 0.02
o
ra
^ 0.01
0 00
J> ' 1 1 1 1
—
—
—
__
'D ' K>EY
(Ui AVERAGE —
| 1
0
€ EPA TEST METHOD "~
0 OTHER TEST METHOD _
a - NORMAL KANGE OF
EMISSIONS MEASURED
BY PLANT.
~~ ^ ft ^ ~~
h-H C] Q W ' ""
— TTft '•|1~H^IK^ "~
1 Y f 1 ifi f 4)'a 1 T
PLANT A A B B Ci C2 Cl D E D - PACKED SCRUBBER
CONTROL D-D DDDDDII D N - IMPINGEMENT SCRUBBER*
EQUIPMENT
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opaci
Tab! e i
FACILITY A
Summary of Results
of Test by EPA
Ha)
12/14/71
120
31.6
6
MM
2.68
34,327
'5 65,212
35
3.8
<0.2
20.0
<0.2
ty <10
0.3069
0.0065
2.02
0.0638
2
12/15/71
120
31.6
6
:n
4.44
33,384
63,421
85
4.1
<0.2
20.2
<0.2
<10
0.0012
0.0012
0.35
0.0112
3
12/15/71
120
31.6
6
:«i
3.29
34,635
65,797
84
3.8
0.5
20'. 5
<0.2
<10
0.0020
0.0019
0.59
0.0186
Average (a)
-
120
31.6
6
0.043(h)
3.87
34,010
64,609
85
3.9
<0.3
20.3
<0.2
<10
0.0016
0.0016
0.47
0.0149
Run Number
Date
Test Time-minutes
Production rate - TPH P205
Scrubber Operation
Pressure Drop - In.
L/G ratio - gal/SCF
N°- transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol .%
C02 - Vol.% dry
02 - Vol.% dry
CO - Vol.% dry
Visible Emissions -
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P205
MM - Mot Measured
(a) - Run Ilumber 1 is not an accurate measure of this plant's emissions The average
is computed as the average emissions measured during run number; ^ and 3.
(b) - Calculated using the design scrubbing liquor flow rate and the average measured
stack gas flow rate.
Reference 1.
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Table 2
FACILITY A
Summary of Results
of Test by Operator
Run Number
Date
Test Tims-minutes
Production rate - TPH P205
Scrubber Operation
Pressure Drop - In. 1^0
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - JSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol.%
C02 - Vol.% dry
02 - Vol.1 dry
CO - Vol.% dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P205
MR - Mot Reported
(a) - calculated from the plants normal production rate and the emission rate (1n Ib/hr)
submitted by the plant operator.
Reference 2.
1
12/71
IIR
NR
NR
NR
'IR
MR
MR
NR
NR
NR
"NR"
MR
•MR
NR
0.22
0.007
2 Avera
.12/71
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
0.55 0.39
0.018 0.013
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Table 3
FACILITY B
Summary of Results
of Test by EPA
1
1/4/72
120
30.0
NM
NM
2.82
15,981
31 ,962
93.8
4.9
NM
NM
NM
0;0010
0.0009
0.135
0.0045
2
1/5/72
120
30.3
NM
NM
3.28
16,832
33,331
94.2
5.2
NM
NM
NM
0.0018
0.0016
0.252
0.0083
3
1/5/72
120
30.5
NM
NM
3.96
16,825
33,098
96.4
5.2
NM
.NM
NM
0.0009
0.0008
0.125
0.0041
Average
-
120
30.3
5(a)
0.078(b)
3.69
16,546
32,797
94.8
5.1
-
-
<10
0.0012
o.oon
0.171
0.0056
Run Number
Date
Test Time-minutes
Production rate - TPH P205
Scrubber Operation
Pressure Drop - In. f^O
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Plow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol.%
COz - Vol.% dry
02 - Vol.% dry
CO - Vol.% dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P205
{a) - Design
(b) - Calculated using the design scrubbing liquor flow rate and the average measured
stack gas flow rate.
NM - Not Measured.
Reference 3.
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Table 4
FACILITY B
Summary of Results
of Test by Operator
Run Number
Date
Test Time-minutes
Production rate - TPH P_0C
2 p
Scrubber Operation
Pressure Drop - In. F^O
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol.%
C02 - Vol.% dry
02 - Vol.% dry
CO - Vol.% dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P2o|a^
MR - Not Reported
1
1/72
rm
NR
rin
NR
NR
NR
riR
NR
NR
NR
MR
NR
MR
NR
NR
0.013
2
1/72
NR
NR
MR
MR
NR
NR
MR
MR
MR
NR
NR
MR
NR
NR
NR
0..012
3
1/72
MR
NR
MR
NR
MR
NR
MR
MR
NR
MR
.NR
NR
MR
NR
NR
0.015
Average
-
:IP
NR
'ip
:JR
'in
NR
"IP
'IP
MR
MR
:in
-IP
MR
MR
NR
0.013
(a) - Calculated using the emission rate (in Ib/ton) submitted by operator and the
plant's normal production rate.
Reference 4.
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Table 5
FACILITY B
SUMMARY OF VISIBLE EMISSIONS'
0)
Date: 2/26/74
Type of Plant: Wet-Process Phosphoric Add
Type of Discharge: Stack from scrubber
Location of Discharge: Top of stack
Height of Point of Discharge: 100 ft
Description of Background: Sky
Distance from Observer to Discharge Point: * 400 ft
Height of Observation Point: •»• 5 f t
Direction of Observer from Discharge Point: East
Description of Sky: Clear
Wind Direction: From south
Color of Plume: White
Interference of Steam Plume: Yes
Duration of Observation: 4 hrs.
Wind Velocity:
Detached Plume:
15 - 20
No
mi/hr
Summary of Data:
Opacity,
Percent
5
10
15
20
25
30
35
40
45
50
Total Time Equal to or Greater
Than Given Opacity
Mln.
Sec.
Opacity,
Percent
55
60
65
70
75
80
85
90
95
100
Total Time Equal to or Greater
Than Given Opacity
Mln.Sec.
Sketch Showing How Opacity Varied With Time:
r
I
T
I
I
I
TIME, hours
(1) Two observers made simultaneous readings. The greater of their readings 1s reported.
Reference 5.
10
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Table 6
FACILITY c,
Summary of Results
of Test by EPA
Run Number
Date
Test Time -minutes
Production rate - TPH
Scrubber Operation
Pressure Drop - In. h^O
L/G ratio - gal/SCF
No- transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton P2n5
Temperature - °F
Water vapor - Vol .%
C02 - Vol.% dry
02 - Vol.* dry
CO - Vol.% dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of
1
11/17/71
120
20.8
MM
MM
MM
17,855
50,904
75
1.1
MM
MM
MM
0.0003
0.0003
0.046
0.0022
2
11/17/71
120
20.8
MM
MM
MM
19,232
56,113
73
1.0
rn
MM
MM
0.0002
0.000?
0.033
0.0016
3
11/18/71
120
20.8
MM
MM
MM
16,746
47,697
72
1.9
MM
JIM
MM
0.0005
0.0005
0.072
0.0034
Average
-
120
20.8
. 6(a>
0.06^
-
17,944
51,573
73
1.3
-
-
<10
0.0003
0.0003
0.050
0.0024
MM - riot Measured
(a) - Design
(b) - Calculated from design scrubbing liquor flow rate and average measured stack
gas flow rate.
Reference 6.
11
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Run Number
Date
Test Time-minutes
Production rate - FPH
Scrubber Operation
Pressure Drop - In.
L/G ratio - gal/SCF
NO. transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton P205
Temperature - °F
Water vapor - Vol.%
C02 - Vol.% dry
02 - Vol.% dry
CO - Vol.% dry
Visible Emissions - % opacity
fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P00C
i D
!1M - Mot Measured
(a) - Design
Reference 7.
Table 7
FACILITY C2
Summary of Results
of Test by EPA
1
8/31/72
120
26.9
NM
0.07
MM
14,363
32,036
93
4.7
MM
NM
NM
0.004
0.004
0.5
0.0184
2 3
8/31/72 9/1/72
120 80.5
27.1 29.1
NM NM
0.03 0.05
MM HM
12,462 19,149
27,591 39,482
92 79
4.4 4.4
MM MM
MM MM
NM NM
0.004 0.001
0.003 0.001
0.4 0.1
0.0143 0.0031
Average
-
107
27.7
6
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Run Number
Date
Test Time-minutes
Production rate - TPH
Scrubber Operation
Pressure Drop - In.
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Table 8
FACILITY C]
Summary of Results
of Tests by Operator
RANGE
1971
NR
MR
rin
rip.
NR
NR
NR
NR
MR
MR
MR
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol.%
C02 - Vol.% dry
02 - Vol.% dry
CO - Vol.% dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of ?205
MR - Not Reported
(a) - Normal production rate (not recorded during test).
(b) - Calculated from assumed production rate and emission rates (in Ib/ton)
submitted by operator.
Reference 8.
NR
NR
NR
0.05-0.5
0.002-0.02
13
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Table 9
FACILITY D
Summary of Results of
Test by U. S. Public-Health Service
Run Number
Date
(a)
Test Time-minutes
Production rate - TPH PgOs
Scrubber Operation
Pressure Drop - In. h^O
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - DSCFM ^
Flow rate - DSCF/ton P2Q5 ^
.
Temperaturp - °F
Water v. -' - Vol.%
C02 - Vol.% dry
0?. - Vol.%' dry
CO - Vol.% dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of ?205
1
NR
NR
' =28.5
NR
0.043
MR
18,685
39,189
90
7w
MR
NR
NR
MR
MR .
0.0032
NR
0.513
0.0180
2
NR
NR
". 28.9
NR
0.042
NR
19,118
39,691
90
NR
NR
NR
NR
NR
0.0015
NR
0.246
0.0085
3
NR
NR .
28.8
NR
0.044
MR
18,338
38,204
90
NR
NR
NR
MR
MR
0.0011
MR
0.173
0.0060
Average
-
-
28.7
-
0.043
18,714
39,028
90
NR
NR
MR
MR
MR
0.0019
NR
0.311
0.0108
MR - Mot Reported
(a) - Probably 15 minutes per sample
(b) - Calculated, not reported
Reference 9.
14
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Table 10
FACILITY E
Summary of Results of
Test by U. S. Public Health Service
Run Number
Date
Test Time-minutes(a)
Production rate - TPH
Scrubber Operation
Pressure Drop - In.
L/G ratio - gal/SCF
Mo. transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton PgO,.
Temperature - °F
Water vapor - Vol.%
C02 - Vol.% dry
02 - vol.1 dry
CO - Vol.% dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P205
MR - Mot.Reported.
(a) - Probably 15 minutes per sample.
(b) - Calculated, not measured.
Reference 9.
15
1
NR
:IR
45.4
NR
NR
MR
16,670
22,031
NR
MR
NR
MR
MR
NR
0.0037
NR
0.508
0.0112
2
NR
MR
45.2
MR
NR
MR
16,670
22,128
MR
NR
MR
NR
NR
MR
0.0020
NR
0.271
' 0.0060
3
NR
MR
45.1
MR
MR
MR
16,670
22,177
NR
MR
NR
HR
NR
MR
0.0024
NR
0.325
0.0072
Average
NR
MR
45.3
NR
NR
NR
16,670
22,112
NR
NR
NR
NR
MR
MR
0.0027'
MR
0.368
0.0081
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REFERENCES
Wet Process Phosphoric Acid Plant Data
1. Emission Test Report for WPPA Facility A, prepared for EPA by Environmental
Engineering, Inc., Contract No. CPA-70-82, EPA Test No. 71-CI-36.
2. Data provided to EPA by the owner of WPPA Facility A.
3. Emission Test Report for WPPA Facility B, prepared for EPA by Environmental
Engineering, Inc., Contract No. CPA-70-82, EPA Test No. 72-CI-l.
4. Data provided to EPA by the owner of WPPA Facility B.
5. "A Review of Field Conditions and Observational Variables Encountered
During the Determination of Visible Emissions in the Phosphate Industry
for the Environmental Protection Agency," March, 1974, prepared for EPA
by Environmental Science and Engineering, Inc.
6. Emission Test Report for WPPA Facility C, prepared by EPA and Environmental
Engineering, Inc., EPA Test No. 71-CI-31.
7. Emission Test Report for WPPA Facility C (Retest), prepared for EPA by
Environmental Engineering, Inc., Contract No. 68-02-0232, EPA Test No.
73-PSA-2.
8. Data provided to EPA by the owner of WPPA Facility C.
9. Atmospheric Emissions from Wet-Process Phosphoric Acid Manufacturers, U.S.
Department of Health, Education and Welfare. NAPCA No. AP-57, April, 1970.
16
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SUPERPHOSPHORIC ACID (SPA) PLANTS
Fluoride Test Results
A test progrdm was undertaken by EPA to evaluate the best fluoride control
equipment available for installation on new or substantially modified super-
phosphoric acid fertilizer plants. Only one plant, identified as A, was
tested since this plant has demonstrated far better fluoride control than any
other SPA fertilizer plant. The plant uses a scrubber to control fluorides.
The scrubber was operating normally during the EPA tests.
Figure 2 presents the emission rate (pounds of fluoride per ton of P20g
input to the process) for the plant.
Facilities
A. This facility uses a vacuum evaporator to produce 70-72 percent P^Oc
phosphoric acid (SPA) from 54 percent PpOc phosphoric acid. The design pro-
duction rate is 280 TPD PoOc- The plant was operating at 25 percent above
design capacity during the EPA tests. Data are based on samples obtained using
EPA Method 13. This facility was tested twice, and the two tests are designated
A.J and A2, respectively. Fluoride emissions from the barometric condenser
hotwell and the product acid cooling tank are controlled by a water-induced
venturi scrubber. Gypsum pond water is used as the scrubbing medium.
Opacity of stack gases was less than 10 percent.
17
-------
FIGURE 2
PLUORIDE EMISSIONS FROM SUPERPHOSPHORIC ACID PLANTS
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CONTROL EQUIPMENT V V V - VENTURI SCRUBBER
-------
Table 11
FACILITY A-!
Summary of Results of Test by EPA
Run Number
Date
Test time - minutes
Production rate - TPH P205
Scrubber Operation
Pressure drop - In. H20
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - Dv
Flow rate - OSCF/ton P205
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol.,% .dry
CO - Vol. % dry
'• Visible Emissions - % opacity
Fluoride Emissions
yr/DSCF
•gr/ACF
Ib/hr
Ib/ton of P20r
NH - Not Measured
(a) - Typical value
Reference 1.
1
n/19/71
120
14.6
NM
NM
NM
420
1726
72
1.9
<0.2
19.2
<0.2
0.0022
0.0022
0.008
0.0006
2
11/19/71
120
14.6
NM
NM
NM
420
1726
72
1.9
NM
NM
NM
0.0062
0.0061
0.022
0/0015
3 Average
11/19/71
120 120
14.6 14.6
NM 0.1 (a)
NM 0.2^
NM
420 420
1726 1726
71 72
1.8 1.9
NM
NM .
NM
0.0020 0.0035
0.0020 0.0035
0.007 0.012
0.0005 0.0009
19
-------
Table 12
FACILITY A2
Summary of Results of Test by EPA
Run Number
Date
Test time - minutes
Production rate - TPH Po05
Scrubber Operation
Pressure drop - In. H20
L/G ratio - gal/SCF
No, transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - OSCF/ton P205
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol..% dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P205
NM - Not Measured
(a) - Typical value
Reference 2.
1
8/29/72
120
11.86
NM
NM
NM
305
1538
77.5
2.8
NM
NM
NM
0.0021
0.0020
0.0054
0.00046
2
8/29/72
120
11.73
NM
NM
NM
302
1549
82
3.6
NM
NM
NM
0.0019
0.0018
0.0048
0.00041
3
8/30/72
120
13.19
NM
NM
NM
308
1400
82
1.5
NM
NM
NM
0.0026
0.0025
0.0069
0.00052
Averagi
120
12.26
0.1
0.2
-
305
1496
80.5
2.6
-
-
;o
0.0022
0.0021
0.0057
0.00046
(a)
20
-------
REFERENCES
Superphosphoric Acid Plant Data
1. Emission Test Report for SPA Facility A, prepared for EPA by Environmental
Engineering, Inc., Contract No. CPA 70-82, EPA Test No. 71-CI-32.
2. Emission Test Report for SPA Facility A (Second Test), prepared for EPA
by Environmental Engineering, Inc., Contract No. 68-02-0232, EPA Test
No. 73-PSA-l.
21
-------
PIAMMONIUM PHOSPHATE (DAP) PLANTS
Fluoride Test Results
A test program was undertaken by EPA to,evaluate the best fluoride control
equipment available for installation on new or substantially modified DAP
plants. Two plants, identified as A and B were tested by EPA.
Emission data submitted by operators of Plants A and B are also reported.
Both plants use scrubbers to control fluorides. The scrubbers were operating
normally during all EPA tests.
Figure 3 presents the emission rates (pounds of fluorides per ton of P -
input to the process) for the two plants.
Facilities
A. Conventional continuous DAP manufacturing train consisting of a
reactor, a granulator, a dryer, and a cooler. Reactor-granulator
emissions, dryer emissions, and cooler emissions are vented to indi-
vidual venturi scrubbers followed by spray-crossflow packed scrubbers.
EPA data are based on samples collected using Method 13. Operator
data are based on samples collected using the state of Florida method for
fluorides. The design production rate is 331 TPD P^Og. The plant
was operating at 53 percent above the design production rate during
the EPA test. Production rate during the operator's test is unknown.
Opacity of exhaust gases was less than 10 percent.
B. Conventional DAP manufacturing train consisting of a reactor, a
granulator, a dryer, and a cooler. The design production rate is
345 TPD P0* Reactor-granulator emissions, dryer emissions, and
22
-------
cooler emissions are vented to individual venturi scrubbers followed
by spray-crossflow packed scrubbers. The scrubbing medium used in the
venturi scrubbers is 25 percent P205 phosphoric acid. Gypsum pond
water is used in the packed scrubbers. The plant operator collected
data while fluoride free water was being used in the packed scrubbers
controlling the reactor-granulator and dryer emissions. The plant
tests were performed using the company's own test method. This
method is similar to EPA Method 13 except that sampling is conducted
non-isokinetically, a particulate and condensate collector is used
before the impingers, and the first impinger contains 100 milliliters
of weak sodium hydroxide solution. EPA samples were collected using
EPA Method 13. Opacity of exhaust gases and production rate during
operator conducted tests are unknown.
23
-------
FIGURE 3
FLUORIDE EMISSIONS FROM DIAMMONIUM PHOSPHATE PLANTS
0.30
ro
ft 0-25
Q_
u: 0.20
_Q
0.15
u 0.10
o
ce
o
0.05
0.00
1
—
—
•MM
«H ^
1
1
|
T A
L V
1 i
KEY
H-HAVERAGE
D'
O EPA TEST METHOD
© OTHER TEST METHOD
a. RANGE OF 23 TESTS
OVER 12 MONTH
PERIOD
^ 4^ •-&
* *^ &
\ I
1 A2 Ai
D VD VD
1 1
—
—
^
« i
^ 'U1
i ^«
B B D - PACKED !
VD VD w . VENTIIRI
EQUIPMENT
-------
Table 13
FACILITY A
Summary of Results of Test by EPA
Run Number
Date
Test time - minutes
Production rate - TPH P205
Scrubber Operation
Pressure drop - In. HgO
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton P00C
C 0
Temperature - °F
Water vapor - Vo|, %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P^p5
NM - Not Measured
(a) - Normal range
(b) - Estimate
Reference 1.
1
1/19/72
120
21
NM
NM
1.7
106,917
305,477
94.6
4.6
NM
NM
NM
0.0012
0.0011
1.10
0.0523
2
1/20/72
120
22
NM
NM
2.0
99,051
270,139
100.0
5.4
NM
NM
NM
0.0007
0.0007
0.59
0.0270
3
1/20/72
120
21
NM
NM
1.6
98,964
282,754
99.7
5.6
NM
NM
NM
0.0006
0.0006
0.51
0.0243
Average
-
120
21
l-5
0.012(b)
1.8
101,644
286,123
98.1
5.2
.-
-
<10
0.0008
0.0008
0.73
0.0345
25
-------
Summary
Run Number
Date
Test time - minutes
Production rate - TPH j?2P_5
Scrubber Operation
Pressure drop - In. HLO
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton P205
Temperature - °F
Water vapor - Vol. %
CO, - Vol. % dry
C- <«
02 - Vol . % dry
CO - Vol . % dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P205
Table
U
FACILITY A2
of Results of Test by
1
9/26/72
120
20.7
NM
NM
NM
94,225
273,114
109
6.1
NM
NM
NM
<10
0.0008
0.0007
0.67
0.0324
2
9/27/72
120
20.7
NM
NM
NM
85,5$6
^48,075
109
6.3
NM
NM
NM
<10
0.0008
0.0007
0.56
0.0272
EPA
3
9/27/72
120
20.7
NM
NM
NM
80,346
232,887
111
6.6
NM
NM
NM
<10
0.0008
0.0007
0.53
0.0261
Average
.
120
20.7
NM
NM
NM
86,719
251,359
109.7
6.3
.
-
-
<10
0.0008
0.0007
0.59
0.0286.
NM - Not Measured
Reference 2.
26
-------
Table 15
FACILITY A,
Summary of Results of Test by Operator
Run Number
Date
Test time - minutes
Producti on rate - TPH J
Scrubber Operation
Pressure drop - In.
L/6 ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - %
Fluoride Emissions
gr/DSCF^
gr/ACF
Ib/hr
Ib/ton of PoOc
1
1/19/72
NR
'^ NR
H20 NR
NR
NR
NR
P2°5 NR
NR
NR
NR
NR.
opacity NR
0.0006
NR
0.55
0.026
2
1/19/72
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
0.0007
NR
0.73
0.035
3
1/19/72
NR
NR
NR
:NR
NR
NR
NR
NR
NR
NR
NR
NR
0.0009
NR
0.87
0.041
Average
-
NR
NR
NR
NR
NR
NR
324,427
NR
NR
NR
NR
'NR
0.0007
NR
0.72
0.034
(a)
(a). Calculated using an assumed stack gas flow rate.
(b)- Calculated by using emission data submitted by plant officials and an assumed stack
gas flow rate.
(c)- Calculated by using emission data submitted by plant officials and normal production
rate of plant.
NR - Not reported Reference 3
27
-------
Table 16
FACILITY B
Summary of Results of Test by EPA
Run Number
Date
Test time - minutes
Production rate - TPH P,0C
i. o
Scrubber Operation
Pressure drop - In. H20
L/6 ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - ^SCF/ton P20§
Temperature - °F
Water vapor - Vol, %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P205
NM - Not Measured
(a) - Normal range per scrubber (reported by plant operator).
(b) - Calculated by using design scrubbing water flow rates and the measured
1
3/21/73
120
14.0
NM
NM
NM
135,060
578,629
112
6.5
0.3
20.5
<0.6
0.0004
0.0003
0.485
0.036
2
3/21/73
120
15.3
NM
NM
NM
142,550
559,020
112
6.6
0.6
21.0
<0.6
0.0007
0.0006
0.849
0.055
3
3/22/73
120
18.2
NM
NM
NM .
129,498
426,916
114
6.5
0.2
20.2
<0.6
0.0004
0.0003
0.465
0.026
Average
-
120
15.8
2-4(a)
0.013(b)
-
135,703
521 ,588
113
6.5
0.4
<0.6
0.0005
0.0004
0.600
0.039
average gas flow rate.
Reference 4.
28
-------
• Table17
FACILITY B
Summary of Results of Test by Operator
Run Number Average(a)
Date 6/31/71 to 5/31/72
Test time - minutes NR
Production rate - TPH P205 14.37
Scrubber Operation
Pressure drop - In. H20 NR
L/G ratio - gal/SCF °-009
No. transfer units NR
Stack Effluent
Flow rate - DSCFM^ 130,000 - 150,000
Flow rate - USCF/ton 542,608 - 626,087
Temperature - °F 100-150
Water vapor - Vol. % NR
C02 - Vol. % dry NR
02 - Vol. % dry HR
CO - Vol. % dry m
Visible Emissions - % opacity MR
Fluoride Emissions
gr/DSCF (c) °-0005
gr/ACF NR
Ib/hrU) °-592
/ ,N n run References 5 and 6.
Ib/ton of P205 (J) U'MI
NR - Not Reported
(a) - Jata expressed as an average of 23 emission tests taken during the period shown
by the above dates.
(D) - Approximate range.
(c) - Calculated using 0.592 Ib/hr and 140,000 USCFM.
(cl) - Calculated using production rate of 345 tons Pz^S Per day (production rate
given by plant officials). 2g
-------
REFERENCES
Diammonium Phosphate Plant Data
1. Emission Test Report for DAP Facility A, prepared for EPA by Environmental
Engineering, Inc., Contract No. CPA-70-82, EPA Test No. 72-CI-3.
2. Emission Test Report for DAP Facility A (Retest), prepared for EPA by
Environmental Engineering, Inc., Contract No. 68-02-0232, EPA Test No.
73-FRT-13.
3. Data supplied to EPA by the owner of DAP Facility A.
4. "Source Testing Report," for DAP Facility B, prepared by Midwest Research
Institute, Contract No. 68-02-0228, Task 22, EMB Project No. 73-FRT-l.
5. Letter and attachment from the plant manager of Plant B to Lee Beck, EPA,
October 18, 1972.
6. Letter and attachments from the plant manager of Plant B to Andrew R.
Trenholm, EPA, October 4, 1972.
30
-------
RUN-OF-PILE TRIPLE SUPERPHOSPHATE (ROP-TSP)
MANUFACTURING PLANTS AND STORAGE PILES
Fluoride Test Results
A test program was undertaken by EPA to evaluate the best fluoride control
equipment available for installation on new or substantially modified ROP-TSP
manufacturing plants and storage facilities. Two plants, identified as A and
B, were tested by EPA. Emission data submitted by operators of Plants A and
B are also reported. Both plants were operating at or near design capacity
during the tests and scrubbers were operating normally during all EPA tests.
Figure 4 presents the emission rate (pounds of fluorides per ton of PgOg
input to the process) for the two plants.
Facilities
A. Conventional continuous den ROP-TSP manufacturing train consisting
of a mixing cone, a continuous den (setting belt), and a cutter. The design
production rate is 372 TPD P205- The plant was tested twice (designated
as tests A] and A2) by EPA. The design production rate was maintained during
all EPA tests. EPA data are based on samples obtained using Method 13. The
operator collected samples using the State of Florida method. Emissions from the
cone, the continuous den, the transfer conveyors, and the storage pile are
controlled by a venturi scrubber followed by a cyclonic scrubber with a packed
section. Gypsum pond water is the scrubbing medium used in each of the scrubbers.
Opacity of exhaust gases was less than 10 percent during the EPA tests. Addi-
tional visible emission data were obtained using EPA Method 9 by EPA and
contractor personnel at another time.
31
-------
B. Conventional continuous den ROP-TSP manufacturing train consisting
of a mixing cone, a continuous den (setting belt), and a cutter. The design
production rate is 773 TPD P205> The plant was operating at about 19 percent
above the design rate during both EPA and operator performed tests. EPA
data are based on samples obtained using Method 13. The operator collected
samples using the State of Florida method. Emissions from the mixer cone and the
continuous den are controlled by two cyclonic scrubbers in series with
pressure drops of 4.4 and 2.6 in. H20, respectively. Emissions from the
storage pile are controlled by two different cyclonic scrubbers in series with
pressure drops of 3.5 and 4.5 in. H20, respectively. Both sets of scrubbers
are ducted to a coirmon stack. Gypsum pond water is used as the scrubbing
medium in each of the scrubbers. Opacity of the exhaust gases was less than
10 percent.
-------
Co
GO
in
O
og
Q_
LU
LU
O
OC
O
FIGURE 4
FLUORIDE EMISSIONS FROM RUN-OF-PILE TRIPLE SUPERPHOSPHATE PLANTS
0.5
0.4
0.3
0.2
0.1
0.0
PLANT
EQUIPMENT
1 1 1 1
1
— W ^
1 '
I '
—1 '
1 1 1
Wl
1 . . i
1 1 1 1
Ti i t ^J
!• •" • i
w
1C H-H
— i
nt ^
I i I I
Al A2 A B
VF VF VF F-Ff
1
KEY
P
h-H AVERAGE
O
C EPA TEST METHOD
0 OTHER TEST METHOD
a RANHF OF ^R TF^T^
"• rxnlMuu Ur Jj 1 CO 1 o
OVER 11 MONTH
PERIOD
^
1
V - VENTURI SC
: F-FF F - CYCLONIC !
—
—
)RU
5CR
-------
Table 18
FACILITY A]
Summary of Results of Test by EPA
Run Number
Date
Test time - minutes
Production rate - TPH P^Q^
Scrubber Operation
Pressure drop - In. HpO
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - USCF/ton P205
Temperature - °F
Water vapor - Vol.%
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P205
M - Hot Measured
(a) - Normal Range
Reference 1.
1
2/29/72
120
15.6
NM
0.019
NM
107,058
411,762
91.5
3.0
HM
NM
NM
0.0053
0.0051
5.01
0.321
2
2/29/72
120
16.0
NM
0.019
NM
106,012
397,545
90
3.0
NM
NM
NM
0.0040
0.0038
3.65
0.228
3
3/1/72
120
16.6
NM
0.019
NM
106,681
385,593
80.6
0.3
NM
NM
NM
0.0006
0.0005
0.58
0.035
Average
-
120
16.1
12-14(a)
0.019
-
106,584
398,300
87.4
2.1
-
-
-
0.0033
0.0031
3.08
0.194
34
-------
Table 19
FACILITY A2
Summary of Results of Test by EPA
Run Number
Date
Test time - minutes
Production rate - TPH ?205
Scrubber Operation
Pressure drop - In. H20
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - JSCF/ton P205
Temperature - °F
Water vapor - Vol,%
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P205
NM - Not Measured
(a) - Normal Range
Reference 2.
1
9/19/72
120
17.8
NM
0.020
NM
97,835
329,781
101.2
3.2
NM
NM
NM
0.0038
0.0035
3.22
0.181
2
9/19/72
120
17.7
NM
0.020
NM
99,215
336,322
102.4
3.5
NM
NM
NM
0.0063
0.0057
5.37
0.304
3
9/20/72
120
18.0
NN
0.020
NM
98,079
326,930
101.0
3.9
NM
NM
NM
0.0032
0.0029
2.64
0.147
Average
-
120
17.8
12-14
-------
Run Number
Date
Test time - minutes
Production rate - TPH P?0r
Scrubber Operation
Pressure drop - In. FLO
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - ^SCF/ton P205
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
Table 20
FACILITY A
Summary of Results of Test by Operator
Range of 35 Stack Tests
1/12/72 - 12/7/72
NR
NR
Average
CO - Vol. % dry
Visible Emissions -
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P
opaci ty
(a)
NR
NR
NR
HR
NR
NR
NR
NR
NR
NR
NR
NR
NR
1.15 - 5.34
0.074 - 0.345
2.34
0.151
NR - Not Reported
(a) - Calculated by using the plant's normal production rate (15.5 TPH P20,-) and the
plant's hourly fluoride emissions.
Reference 3.
36
-------
Table 21
FACILITY A
SUMMARY OF VISIBLE EMISSIONS
(1)
Date: 2/28/74
Type of Plant: Run-of-pile triple superphosphate
Type of Discharge: Stack from scrubber
Location of Discharge: Top of stack
Height of Point of Discharge: 75 ft
Description of Background: Sky
Distance from Observer to Discharge Point: * 400 ft
Height of Observation Point: Ground level
Direction of Observer from Discharge Point: East
Description of Sky: Hazy during the first 2 hours of observation and clear thereafter
Wind Direction: From North
Color of Plume: White
Interference of Steam Plume: None
Duration of Observation: 4 hrs.
Wind Velocity: 0-5
Detached Plume: No
mi/hr
Summary of Data:
Opacity,
Percent
5
10
15
20
25
30
35
40
45
50
Total Time Equal to or Greater
Than Given Opacity
RT7TSec.
237
56
12
3
0
0
30
0
30
15
15
0
Opacity,
Percent
55
60
65
70
75
80
85
90
95
100
Total Time Equal to or Greater
Than Given Opacity
Min.Sec.
Sketch Showing How Opacity Varied With Time:
I
Jl
I
12 3 4
TIME, hours
(1) Two observers made simultaneous readings. The greater of their readings is reported.
Reference 4.
37
-------
Table 22
FACILITY B
Summary of Results of Test by EPA
Run Number
Date
Test time - minutes
Production rate 9 TPH P20g
Scrubber Operation
Pressure drop - In. H-O
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - USCF/ton P205
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P.,0,-
i D
NM - Not Measured
(a) - See facility description
Reference 5.
1
9/14/72
120
37.0
NM
0.019
NM
60,485
98,0b3
100.8
4.8
NM
NM
NM
0.0089
0.0030
4.62
0.125
2
9/15/72
120
38.4
NM
0.019
HM
59,578
93,091
100.5
5.1
NM
NM
NM
0.0094
0.0085
4.82
0.126
3
9/15/72
120
39.5
NM
0.020
NM
58,156
88,338
103.3
5.2
NM
NM
NM
0.0098
0.0088
4.94
0.125
Avera
-
120
38.3
(a?)
0.019
-
59,406
93,171
101.5
5.0
-
-
<10
0.0094
0.0084
4.79
0.125
38
-------
Table 23
FACILITY B
Summary of Results of Test by Operator
Run Number Ran9e of 51 Tests Average
Date 1/18/72 - 1/24/73
Test time - minutes '""*
Production rate - TPH P205 NR
Scrubber Operation
Pressure drop - In. H,,0 NR
L/G ratio - gal/SCF NR
No. transfer units . NR"
Stack Effluent
Flow rate - DSCFM NR
Flow rate - *CF/ton P205 NR
Temperature - °F NR
Water vapor - Vol. % NR
C02 - Vol. % dry NR
02. - Vol. % dry NR
CO - Vol. % dry NR
Visible Emissions - % opacity NR
Fluoride Emissions
gr/DSCF NR
gr/ACF NR
lb/hr 0.704 - 7.40 3.23
Ib/ton of P205 U) 0.022 - 0.230 0.10
NR - Not Reported
(a) - Calculated from the plant's normal production rate
(32.2 TPH P205) and the plant's hourly fluoride emissions.
Reference 6. 39
-------
REFERENCES
Run-of-Pile Triple Superphosphate Manufacturing
Plant and Storage Pile Data
1. Emission Test Report for ROP-TSP Facility A, prepared for EPA by Environ-
mental Engineering, Inc., Contract No. 68-02-0232, EPA Test No. 72-CZ-18.
2. Emission Test Report for ROP-TSP Facility A (Retest), prepared for EPA by
Environmental Engineering, Inc., Contract No. 68-02-0232, EPA Test No.
73-FRT-ll.
3. Letter from plant manager of Facility A to Lee Beck, EPA, December 12, 1972,
4. "A Review of Field Conditions and Observational Variables Encountered
During the Determination of Visible Emissions in the Phosphate Industry
for the Environmental Protection Agency," March, 1974, prepared for EPA
by Environmental Science and Engineering, Inc.
5. Emission Test Report for ROP-TSP Facility B, prepared for EPA by Environ-
mental Engineering, Inc., Contract No. 68-02-0232, EPA Test No. 73-FRT-10.
6. Letter and attachment from the general manager of Facility B to Don R.
Goodwin, EPA, February 16, 1973.
40
-------
GRANULAR TRIPLE SUPERPHOSPHATE (GTSP) PRODUCTION PLANTS
Fluoride Test Results
A test program was undertaken by EPA to evaluate the best fluoride control
equipment available for installation on new or substantially modified GTSP pro-
duction plants. Two plants, identified as A and B, were tested by EPA. Both
plants were operating at or near design capacity during the EPA tests.
Results of a test performed by the operator of Plant A are also included. All
of the plants tested use scrubbers to control fluorides. The scrubbers were
operating normally during all EPA tests.
Figure 5 presents the emission rate (pounds of fluoride per ton of P205 input
to the process) for the two plants.
Facilities
A. Conventional production train for continuous GTSP manufacture consisting
of a reactor-granulator, dryer, and cooler. Design production rate is
221 TPD P205. The plant was tested by EPA twice (tests designated
A, and A2). The plant operated at 20 percent above design capacity
during the first EPA test (A]) and at 30 percent above design capacity
during the second EPA test (A2). The production rate during the plant's
test is unknown. EPA tests were by Method 13. The operator collected
samples using the State of Florida method. Reactor-granulator emissions, dryer
emissions, and cooler emissions are vented to individual venturi
scrubbers followed by spray-crossflow packed scrubbers. Gypsum pond
water is used as the scrubbing medium. Opacity of exhaust gases was
less than 10 percent during all EPA tests. Additional visible emission
data were obtained using EPA Method 9 by EPA and contractor personnel
at another time.
41
-------
B. Conventional production train for continuous GTSP manufacture consisting
of a reactor, granulator, dryer, and cooler. Design production capacity
is 384 TPD P205. The plant operated at 22 percent above design capacity
during the test. EPA Method 13 was used. The control system conducted
all process gases to two venturi scrubbers followed by a cyclonic
scrubber, then a spray-cross flow packed scrubber. Gypsum pond water
was used as the scrubbing medium in all scrubbers. Opacity of exhaust
gases was less thjan 10 percent.
42
-------
FIGURE 5
FLUORIDE EMISSIONS FROM GRANULAR TRIPLE SUPERPHOSPHATE
PRODUCTION PLANTS
CO
to
O
CM
a.
0
u_
_O
z
o
to
LU
UJ
O
DC
O
—I
u.
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
ft nn
r- i
1
__
—
- ft
'KEY
P
H-^AVERAGE
d
O EPA TEST
,
1
METHOD
O OTHER TEST METHOD
i i
- 4J.
—
- ici -ft
t1
i i
PLANT AI A2
CONTROL EQUIPMENT VD VD
i
—
<—
C)
1 1 —
1 1
II
hr1 —
w
(3
1 i —
1 1 l|
fcsl
^^^f ^BBMHI
••^^H
1 1
Al R V-VENTURI SCRUBBER
..,!; urn F- CYCLONIC SCRUBBER
vu vru D - PACKED SCRUBBER
-------
Table ^4
FACILITY A]
Summary of Results of Test by EPA
Run Number
Date
Test time - minutes
Production rate - TPH P Og
Scrubber Operation
Pressure drop - In. H20
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton PgOg
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P205
NM - Not Measured
(a) - Normal Range
(b) - Estimated
Reference 1.
1
1/25/72
120
10.9
NM
NM
3.28
103,106
567,556
88
2.4
NM
NM
NM
0.0032
0.0030
2.83
0.26
2
1/25/72
120
10.9
NM
NM
3.16
103,267
568,442
90
2
NM
NM
NM
0.0012
0.0012
1.06
0.097
3
1/26/72
120
11.2
NM
NM
2.55
105,651
565,988
84
2.1
NM
NM
NM
0.0022
0.0021
2.01
0.18
Average
—
120
11.0
l-s'9'
0.012^t>'
3.00
104,008
567,329
87
2.2
-
-
<10
0.0022
0.0021
1.97
0.18
44
-------
Table 25
FACILITY A2
Summary of Results of Test by EPA
Run Number
Date
Test time - minutes
Production rate - TPH PgOg
Scrubber Operation
Pressure drop - In. HgO
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton P20g
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P205
NM - Not Measured
(a) - Normal Range
(b) - Estimated
Reference 2.
1
9/11/72
120
12
NM
NM
NM
109,554
547,770
82.2
4.5
NM
NM
NM
0.0013
0.0012
1.201
0.100
2
9/11/72
120
12
NM
NM
NM
108,552
542,760
iiiSO.I
4.4
NM
NM
NM
0.00059
0.0005
0.544
0.045
3
9/12/72
120
12
NM
NM
NM
90,146
450,730
87.7
4.6
NM
NM
NM
0.00068
0.0006
0.525
0.044
Average
-
120
12
l-5<*>
0.012(b)
-
102^751
513,753
83.3
4.5
-
-
<10
0.00086
0.0008
0.757
0.0632
45
-------
Table 26
FACILITY A]
Summary of Results of Test by Operator
Run Number
Date
Test time - minutes
Production rate - TPH P00r
-------
Table ?7
FACILITY A
SUMMARY OF VISIBLE EMISSIONS
0)
Date: 3/1/74
Type of Plant: Granular Triple Superphosphate
Type of Discharge: Stack from scrubber
Location of Discharge: Top of stack
Height of Point of Discharge: •*• 200 ft
Description of Background: Sky
Description of Sky: Clear
Wind Direction: Calm
Color of Plume: White
Interference of Steam Plume: Yes
Duration of Observation: 4 hrs.
Distance from Observer to Discharge Point: * 700 ft
Height of Observation Point: Ground level
Direction of Observer from Discharge Point: West
Wind Velocity: Calm
Detached Plume: No
m1/hr
Summary of Data:
Opacity,
Percent
5
10
15
20
25
30
35
40
45
50
Total Time Equal to or Greater
Than Given Opacity
Min.
240
0
Sec.
0
0
Opacity,
Percent
55
60
65
70
75
80
85
90
95
100
Total Time Equal to or Greater
Than Given Opacity
M1n.
Sec.
Sketch Showing How Opacity Varied With Time:
10
I
I
12 3 4
TIME, hours
(1) Two observers made simultaneous readings. The greater of their readings is reported.
Reference 4.
47
-------
Table 28
FACILITY B
Summary of Results of Test by EPA
Run Number
Date
Test time - minutes
Production rate - TPH P205
Scrubber Operation
Pressure drop - In. hLO
L/6 ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton P00C
£ b
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol . % dry
CO - Vol . % dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of P90,
c. 0
1
6/14/72
120
13.4
NM
0.0018
NM
109,548
490,513
121
2.9
NM
NM
NM
<10
0.0040
0.0035
3.73
0.278
2
6/15/72
120
15.2
NM
0.0019
NM
103,555
408,770
126
5.6
NM
NM
NM
<10
0.0030
0.0025
2.64
0.174
3
6/15/72
120
15.1
NM
0.0020
NM
102,729
408,195
127
6.3
NM
NM
NM
<10
0.0031
0.0027
2.76
0.182
Average
-
120
14.6
2-6^a
0.0019
-
105,277
435,826
125
4.9
-
-
-
<10
0.0034
0.0029
3.04
0.211
NM - Not Measured
(a) -Design Range
Reference 5.
48
-------
REFERENCES
Granular Triple Superphosphate Production Plant Data
1. Emission Test Report for GTSP Facility A, prepared for EPA by Environmental
Engineering, Inc., Contract No. CPA 70-82, EPA Test No. 72-CI-5A.
2. Emission Test Report for GTSP Facility A (Retest), prepared for EPA by
Environmental Engineering, Inc., Contract No. 68-02-0232, EPA Test No.
73-FRT-9.
3. Data supplied to EPA by the owner of GTSP Facility A.
4. "A Review of Field Conditions and Observational Variables Encountered
During the Determination of Visible Emissions in the Phosphate Industry
for the Environmental Protection Agency," March, 1974, prepared for EPA by
Environmental Science and Engineering, Inc.
5. Emission Test Report for GTSP Facility B, prepared for EPA by Environmental
Engineering, Inc., Contract No. 68-02-0232, EPA Test No. 72-CI-30.
49
-------
GRANULAR TRIPLE SUPERPHOSPHATE (GTSP) STORAGE FACILITIES
Fluoride'Test Results
A test program was undertaken by EPA to evaluate the best fluoride control
equipment available for installation on new or substantially modified GTSP
storage facilities. Two facilities, idenfitied as A and B, were tested by
EPA. Data submitted by the operator of plant B are also included. Both plants
use scrubbers to control fluorides. These scrubbers were operating normally
during the EPA tests.
Figure 6 presents the emission rates (pounds per hour of fluorides per
ton of P205 in storage) for the two facilities.
Facilities
A. Typical open bay type storage building designed for a maximum capacity
of 6,900 tons of P205< The building was about 21 percent full during
the EPA test. GTSP is loaded into the building by an overhead conveyor.
Fresh air enters through ducts on the opposite side of the building.
Fumes and dust are exhausted from the building by ducts along one
side and are removed from the exhaust gases by a spray-crossflow packed
scrubber. Gypsum pond water is used as the absorbing medium. EPA
data are based on samples obtained using Method 13. Opacity of
exhaust gases was less than 10 percent.
B. Typical open bay type storage building designed for a maximum capacity
of 16,000 tons P205. EPA tested this facility twice (tests are desig-
nated B] and B2). The building was about 30 percent full during the
first EPA test (B^ and the test conducted by the operator. It was
50
-------
about 15 percent full during the second EPA test (B2). A drag scraper
or a front-end loader is used to move 6TSP in the building. 6TSP is
loaded into the building by an overhead conveyor. Air enters the
building through a vent running almost the length of the building on
the roof. Fumes and dust are exhausted from the building by ducts
along one side and are removed from exhaust gases by a spray-crossflow
filter scrubber. Gypsum pond water is used as the absorption medium.
EPA data is based on samples obtained using Method 13. The operator
collected samples using the State of Florida method. Opacity of exhaust gases
was less than 10 percent during the EPA tests. Additional visible
emission data were obtained using EPA Method 9 by EPA and contractor
personnel at another time.
51
-------
FIGURE e
FLUORIDE EMISSIONS FROM GRANULAR TRIPLE SUPERPHOSPHATE
STORAGE FACILITIES
tn
ro
Q
LU
QC
0
1—
GO
GO "">
GO „_
GO o
S C
LU .8
LU Jrr
Q S.
CD'S
_J><
Lu "^
U-
_Q
CONTROL
0
7
6
5
4
3
2
1
o
1
a
_
••«•
—
ID
1
KEY
Pj
I
^ AVERAGE
0
1 1
€ EPA TEST METHOD Q
0 OTHER TEST
i i
ID
_
—
H§H
1 1
PLANT A BI
EQUIPMENT D D
METHOD ^-
i n^ i
1 1 ' __
___
ID
••^
K^H
—
1 1
Bl B2 D - PACKED SCRUBBER
D D
-------
Table 29
FACILITY A
Summary of Results of Test by EPA
Run Number
Date
Test time - minutes
TQn« P.,0b in Storage During Test
Scrubber Operation
Pressure drop - In. ^0
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - DSCFM
"°» rate - ™" %
Temperature - °F
Water vapor - Voj.%
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/hr per ton of P205 stored
NM - Not Measured
Reference 1.
1
1/24/72
120
1,430
NM
»H ji
NM
1.1
64,844
45,35
75
2.3
NM
NM
NM
0.0011
0.0010
0.612
0.000«2
2
1/24/72
120
1,430
NM
MM
MM
0.56
64,401
45.04
75
2.3
NM
NM
NM
0.0008
0.0008
0.442
0.00031
3
1/24/72
120
1,430
NM
MM
lin
1.1
65,744
45.97
25
2.2
NM
NM
NM
0.0009
0.0008
0.507
0.00035
Averag<
-
120
1,430
-
0.92
64,996
45.45
75
2.3
-
-
<10
0.0009
0.0009
0.520
0.00036
53
-------
Table 30
FACILITY B,
Summary of Results of Test by EPA
Run Number
Date
Test time - minutes
Tons of PyQ in Storage Juring
£» O -r •
Test
Scrubber Operation
Pressure drop - In. FLO
L/G ratio - gal/SCF
No. transfer unite
Stack Effluent
Flow rate - DSCFM
Flow rate - USCFM/ton P2°B
stored
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/hr per ton of PgO,. stored
NMM - Not Measured
(a) - design range
(b) - Calculated using measured
Reference 2.
1
6/14/72
120
4,318
NM
0.028
NM
64,587
14.96
81
3.9
NM
NM
NM
0.0005
0.0005
0.279
0.00006
2
6/14/72
120
4,625
HM
0.029
NM
62,633
13.54
80
3.5
NM
NM
NM
0.0005
0.0004
0.245
0.00005
3
6/15/72
120
4,685
NM
0.028
NM
63,658
13.59
81
3.6
NM
NM
NM
0.0005
0.0005
0.276
0.00006
Average
-
120
4,543
4-7(
0.028(
NM
63,640
14.03
81
3.7
-
-
<10
0.0005
0.0005
0.267
0.00006
DSCFM and design liquid flow rate,
54
-------
Table 3V
FACILITY B1
Summary of Results of Test by Operator
Run Number
Date
Test time - minutes
Tons of P205 stored during test
Scrubber Operation
Pressure drop - In. H20
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - DSGFM
Flow rate - DSCF/ton P205
stored
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
Ib/hr per ton of P205 stored
NM - Hot Measured
Reference 3.
I
5/19/72
30
2782
2.8
NM
NM
81,970
29.46
82°F
3.2
NM
NM
i>IM
NM
0.0400
0.0377
0.43
0.00015
55
-------
Table 32
FACILITY B2
Summary of Results of Test by EPA
Run Number
Date
Test time - minutes
Tons of P.,05 in Storage During
Test
Scrubber Operation
Pressure drop - In. H-O
L/G ratio - gal/SCF
No. transfer units
Stack Effluent
Flow rate - DSCFM
Flow rate - ^SCFM/ton PyO,
stored
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluoride Emissions
gr/DSCF
gr/ACF
Ib/hr
16/hr per ton of P0 stored
NM - Not Measured
a) - Jesign range
i) - Calculated using measured OSCFM and design liquid flow
Reference 4.
56
1
9/21/72
120
2,031
NM
0.023
NM
78,044
38,42
81.6
2.9
NM
NM
NM
0.0020
0.0019
1.334
0.0007
2
9/21/72
120
2,094
NM
0.022
NM
81 ,289
38.82
88.0
1.4
NM
NM
NM
0.0007
0.0007
0.503
0.0002
3
9/22/72
120
2,179
NM
0.023
NM
77,078
35.37
76.8
2.9
NM
NM
NM
0.0016
0.0015
1.040
0.0005
Average
-
120
2,101
4_7(a)
0.022(b)
-
78,804
37.54
84.5
2.4 '
-
-
-
0.0014
0.0014
0.959
0.0005
rate
-------
Table 33
FACILITY B
SUMMARY OF VISIBLE EMISSIONS
0)
Date: 2/25/74
Type of Plant: Granular Triple Superphosphate Storage
Type of Discharge: Stack from scrubber Distance from Observer to Discharge Point: 300 ft
Location of Discharge: Top of stack Height of Observation Point: Ground lev*
Height of Point of Discharge: 100 ft Direction of Observer from Discharge Point: East
Description of Background: sky
Description of Sky: Light haze
Wind Direction: From Sotth
Color of Plume: White
Interference of Steam Plume: yes
Duration of Observation: 4 hrs.
Wind Velocity:
Detached Plume:
m1/hr
No
Summary of Data:
Opacity,
Percent
Total Time Equal to or Greater
Than Given Opacity
RTrTSec.
90
11
0
30
0
0
5
10
15
20
25
30
35
40
45
50
Sketch Showing How Opacity Varied With Time:
Opacity,
Percent
55
60
65
70
75
80
85
90
95
100
Total Time Equal to or Greater
Than Given Opacity
MTrTSec.
15
i ii i i nnr
I i
01234
TIME, hours
(1) Two observers made simultaneous readings. The greater of their readings 1s reported.
Reference 5.
57
-------
REFERENCES
Granular Triple Superphosphate Storage Facility.Data
1. Emission Test Report for GTSP Storage Facility A, prepared for EPA by
Environmental Engineering, Inc., Contract No. CPA-70-82, EPA Test No.
72-CI-5B.
2. Emission Test Report for GTSP Storage Facility B, prepared for EPA by
Environmental Engineering, Inc., Contract No. 68-02-0232, EPA Jest No.
72-CI-30B.
3. Data supplied to EPA by the owner of GTSP Storage Facility B.
4. Emission Test Report for GTSP Storage Facility B (Retest), prepared for
EPA by Environmental Engineering, Inc., Contract No. 68-02-0232.
5. "A Review of Field Conditions and Observational Variables Encountered
During the Determination of Visible Emissions in the Phosphate Industry
for the Environmental Protection Agency," March, 1974, prepared for EPA
by Environmental Science and Engineering, Inc.
58
-------
TECHNICAL REPORT DATA .
(Please read Instructions on the reverse before completing)
1. REPORT NO.
-019b
4. TITLE AND SUBTITLE
BACKGROUND INFORMATION FOR STANDARDS OF PERFORMANCE:
PHOSPHATE FERTILIZER INDUSTRY
VOLUME 2. SUMMARY OF TEST DATA . .
1974
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
9 PERFORMING ORGANIZATION NAME AND ADDRESS
'U.S. Environmental Protection Agency
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Research Triangle Park, N.C. 27711 ,
11. CONTRACT/GRANT NO.
12. SPONSORING AGENCY NAME AND ADDRESS
13. TYPE OF
Final
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT
This document provides background infpjnmation on the derivation of the Standards of
performance for the phosphate fertilizer industry. Volume 1 provides a general
description of the facilities for which standards are proposed and provides the
rationale for the proposed standards of performance. Volume 2 presents summaries
of the emission testiKg data cited in Volume 1. The summaries are concerned prin-
cipally with tests for fluorides and visible emissions, but also describe the
facilities, characteristics of the exhaust gas streams, and conditions of operation,
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
Air Pollution
Pollution control
*Performance standards
*Phosphate fertilizer industry
*Wet-process phosphoric acid plants
*Superphosphoric acid plants
*Diammoniurn phosphate plants
Air Pollution Control
*Run-of-pile triple supe
*Granular triple superph
*Granular triple superph
phosphate plants
sphate plants
sphate storage
18. DISTRIBUTION STATEMENT
19. SECURITY CLASS (ThisReport)
Unclassified
68
Unlimited
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
59
U.S. GOVERNMENT PRINTING OFFICE: 1974 - 640-877/623 - Region 4
-------
-------
-------
ENVIRONMENTAL PROTECTION AGENCY
Technical Publications Branch
Off ice of Administration
Research Triangle Park. N.C. 27711
POSTAGE AND FEES PAID
ENVIRONMENTAL PROTECTION AGENCY
EPA - 335
OFFICIAL BUSINESS
AN EQUAL OPPORTUNITY EMPLOYER
Return this sheet if you do NOT wish to receive this material CD,
or if change of address is needed I I (Indicate change, including
ZIP code.)
PUBLICATION NO. EPA-450/2-74-019b
------- |