Emission Testing Report
EMB Test No.: 73-FRT-15
INTERNATIONAL MINERALS AND CHEMICALS
Americus, Georgia
Stanley Spruiell
Project Officer
Environmental Protection Agency
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
-------
Emission Testing Report
EMB Test No.: 73-FRT-15
INTERNATIONAL M.INERALS AND CHEMICA L .!S
Aitiericus, Georgia
Stanley Spruiell
Project Officer
Environmental Protection Agency
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
-------
TABLE OF CONTENTS
Page Number(s)
I. INTRODUCTION 1
II. SUMMARY OF RESULTS 2-22
A. English Units
Participate (Tables 1-4) 3-6
Fluoride (Tables 5-8) 7-10
Ammonia (Tables 9-10) 11-12
B. Metric Units
Participate (Tables 11-14) ....'. 13-16
Fluoride (Tables 15-18) 17-20
Ammonia (Tables 19-20) ..... 21-22
•I'll. DISCUSSION OF RESULTS. 23
IV. PROCESS DESCRIPTION AND OPERATION ........ 24-27
Figure 1 - Normal Superphosphate Process ..... 26
Figure 2 - Ammoniator-Granulator Process ..... 27
V. SAMPLING AND ANALYTICAL PROCEDURE ........ 28
VI. LOCATION OF TRAVERSE POINTS 29-32
Figure 3 - Inlet of Superphosphate Scrubber 29
Figure 4 - Outlet of Superphosphate Scrubber 30
Figure 5 - Inlet of Ammoniator Scrubber . 31
Figure 6 - Outlet of Ammoniator Scrubber 32
-------
.INTRODUCTION
From June 18-22, 1973, the Environmental Protection Agency
tested the emissions from International Minerals and Chemicals
in Americus, Georgia. Test data were collected for the purpose of .
setting standards for phosphate fertilizer plants. Tests were conducted
at the inlet and the outlet of the venturi scrubbers for the normal
superphosphate plant and the ammoniator-granulator plant. The NSP
plant was tested for particulates and fluorides. The ammoniator-granulator
was tested for particulates, fluorides, and ammonia. The plan also
called for particle sizing tests to be run at both of the outlets using
the Brinks Model B impactor. However, because of the high moisture
content in the outlets, it was not possible to test for particle size.
The test team consisted of members from the EPA and contractors from
Environmental Science and Engineering.
Also present at the test site were members from the State of Georgia.
They were present to perform parallel tests with the EPA at the NSP
scrubber outlet. They wanted to obtain comparative data with the EPA for
particulates and fluorides at each of the test sites. However, after the
presurvey the EPA decided it would not be possible for both crews to be
present anywhere except at the NSP scrubber outlet. The State did parallel
particulate tests with the EPA but cancelled parallel fluoride tests
because of malfunction in this test equipment.
-------
SUMMARY OF RESULTS
-------
TABLE 1 - Particulate
Superphosphate Scrubber Inlet
(Enqlish)
Run Hinber • " • '" ' ' ' 1 2 ''• '••. • • 3
Data 6-19-73 6-19-73 6-20-73
Volume of Gas Sampled - DSCFa 50.28 49.25 ; 50.36
Percent Moisture by Volume 8.7 6.3 11.1
Average Stack Temperature - °F 130 . . 130 130
Stack Volumetric Flow Rate - DSCFMb 4856 4876 5250
Stack Volumetric Flo;/ Rate - ACFMC 6041 5911 . - 6704
Percent Isokinetic 105.6 103.0 97.8
Feed Rate - ton/hr 20 20 20
Particulates - probe, cyclone,
and .filter catch
mg
gr/DSCF ;
gr/ACF •
lb/hr~ - -
1b/ ton- feed
Particulates - total catch
mg
gr/DSCF •
gr/ACF
Ib/hr
Ib/ton feed
3679
1.1-3
0.905
46.90
2.34
4473.4
1.37
1.10
57.02
2.85
7980.6
2.50
2.06
104.3
5.21
8495.9
2.66
2.19
111.0
5.55
3680.5
1.13
0.881
50.65
2.53
4557.1
1.39
1.09
62.71
3.14
Percent iir.pinger catch 17.8 6.1 19.2
a Dry standard cubic f=?et at 70°F, 29.92 in. Hg.
b Dry standard cubic feet per minute at 70°F, 29.92 in. Ho.
c Actual cubic fe^t per minute
-------
TABLE 2 - Particulate
Superphosphate Scrubber Outlet
(English)
Run number . .1 2 '3
,. ^ . .
Date 6-19-73 , 6-19-73 6-20-73
Volume of Gas Sampled - DSCFa 69.75 69.66 64.23
Percent floisture by Volume 12.7 13.6 14.8
Average Stack Temperature - °F 123.2 125.6 128.7
Stack Volumetric Flow Rate - DSCFM5 4949 4724 4622
Stack Volumetric Flov/ Rate - ACFMC 6324 6124 6T09 -
Percent Isokinetic 99.1 103.7 97.7
Feed Rate - ton/hr 20 20 20
Particulates - probe, cyclone, ' . •
^ and filter catch
mg . ; • ;'..-.' • ' ' • • •;
gr/DSCF
gr/ACF^
1b/hr~ "" •
Ib/ton feed
Partlculates - total catch
mg
gr/DSCF ::•
gr/ACF ;
Ib/hr
Ib/ton feed .
Percent impinger catch 62.6 65.2 59.2
163.6
0.0361
0.0283
1.53
0.0766
437.2
'0.0965
0.0755
4.10
0.205
220.3
0.0487
0.0375
1.97
0.0986
633.6
' 0.140i:
0.1080
5.67
0.0986
294.0
0.0705
0.0533
2.79
0.1396
719.9
0.1726
0.1305
6.84
0.140
a Dry standard cubic fact at 70°F, 29.52 in. Hg.
b Dry standard cubic feet per minute at 70°F, 29.92 in. Ho.
c Actual cubic fe^t per minute
-------
TABLE 3 - Parti oil ate •
Ammoniator Scrubber Inlet
(English)
Run flumber 1 2 ' '3
Date 6-19-73 6-19-73 6-20-73
Volume of Gas Sampled - DSCFa 85.58 70.01 88.48
Percent Moisture by Volume 8.6 8.5 7.8 .
Average Stack Temperature - °F 121.1 121.4 123.0
Stack Volumetric Flow Rate - DSCFMb 6222 5576 6690
Stack Volumetric Flov/ Rate - ACFMC 7637 6838 8237
Percent Isokinetic . 105-6 107-2
a Dry standard cubic f-et at 70°F, 29.92 in. l!g.
b Dry standard cubic feet per minute at 70°F, 29.92 in. Hg.
c Actual cubic fe^t per minute
Feed Rate - ton/hr 30 .30 30
Parti culates - probe, cyclone,
and filter catch .
n>g .
gr/DSCF
lb/hr~ - .
Ib/ton feed
Participates - total catch
mg-
gr/DSCF
gr/ACF .
Ib/hr :
Ib/ton feed .
Percent iir.pingnr cntch 4.6 2.5 2.6
9542.4
1.717
1.398
91.58
3.05
9997.7
'1.799
1.465
95.95
3.20
8168.3
1.797
1.464
85.87
2.86
8381.4
1.844
1.502
88.11
2.94
10570.2
1.840
1.493
105.5
3.52
10850.4
1.888
1.533
108.3
3.61
-------
TABLE 4 - Particulate
Ammoniator Scrubber Outlet
(English)
Run number
Date
Volume of Gas Sampled - DSCFa
Percent Moisture by Volume
Average Stack Temperature - °F
Stack Volumetric Flow Rate - DSCFM
Stack Volumetric Flow Rate - ACFMC
Percent Isokinetic
1
3
6-19-73
90.40
6.4
no
5280
5934
91.3
6-19-73
112.45 '
6.4
no
7475
8403
80.2
6-20-73
112.48
5.9
115
7197
8274
90.8
Feed Rate - ton/hr
Partlcul a tes - probe, cyclone,
and filter catch
30
30
30
gr/DSCF
gr/ACF
1b/hr~ "" . '
Ib/ton -feed
Participates - total catch
ing
gr/DSCF
gr/ACF
Ib/hr
Ib/ton feed
Percent inipinger catch
57.80
0.00985
0.00875
0.45
0.0148
137.30
0.02339
0.02080
1.06 .
0.0353
37.60
0.00515
0.00458
0.33
0.0110
95.20
' 0.01304
0.01159
0.84
0.0278
93.70
0.01178
0.01024
0.73
0.0242
175.20
0.02203
0.01915
1.36
0.0453
57.9
60.5
46.5
Dry standard cubic fset at 70°F, 29.92 in. Hg.
b Dry standard cubic feet per minute at 70°F, 29.92 in. Hg,
c Actual cubic fe?t per minute
-------
TABLE 5 - Fluoride
' Superphosphate Scrubber Inlet
(English)
Run [lumber
Date
Volune of Gas Sampled - DSCFa
Percent Moisture by Volume .
Average Stack Temperature -.°F
Stack Volumetric Flow Rate - DSCFMb
Stack Volumetric Flow Rate - ACFMC
Percent Isokinetic
Feed Rate - ton/hr
Soluble Fluoride
mg ' . ' / ,' ;'•' -
gr/DSCF :
gr/ACF
lb/hr~ "
Ib/ton feed
Total Fluoride
«* ' . : .- -.- :
gr/DSCF
gr/ACF . . -., ,
Ib/hr
Ib/ton feed ;
» •• .
1
6-20-73
44.30
12.1
130
4576
5911
98.4
20
11,600
4.03
3.12
158.0
11,816
V.ll
3.18
161.2
. • • •
2 '
6-21-73
. 46,89
9.8
130
4608
5801
103.4
20
8,990
2.95
2.34
116.5
>9,140
3.00
2.38
118.5
• • •:. •
a Dry standard cubic faet at 70°F, 29.92 in. Hg.
b Dry standard cubic feet per minute at 70°F, 29.92 in. Hg,
3
6-21-73
42.59
8.8
130
4514
5620
95.9
20
6,350
2.30
1.85
89.0
7,300
2.64
2.12
102.1
c Actual cubic fe^t per minute
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TABLE 6 - Fluoride
Superphosphate Scrubber Outlet
. (English)
Run f!umber • i 2 ' ... .'3
Date 6-20-73 6-21-73 6-21-73
Volume of Gas Sampled - DSCFa 52.60 49.13 51.54
Percent Moisture by Volume 15.4 14.9 15.7
Average Stack Temperature - °F 133.3 128.9 130.7
Stack Volumetric Flow Rate - DSCFMb 3863 . 3510 3702
Stack Volumetric Flow Rote - ACFMC 5181 4645 ' 4954
Percent Isokinetic 95-7 . 99.1 97.9
Feed Rate - ton/hr 20 20 20
Sol ubl e F1 uori de ;"
rcg .
gr/DSCF
^
lb/hr~ "
lb/ ton 'feed
Total Fluoride
gr/DSCF
gr/ACF
Ib/hr
Ib/ton feed
397; 3
O.T16
0.0864
3.84
0.1.92
408.4
0.120
0.0894
3.97
0.198
299.3
0.0938
0.0707
.:'. 2.82
0.141
306.0
. 0.0959
0.0724
2.88
0.144
174.8
0.0522
0.0389
1.66
0.083
176.4
0.0527
0.0393
1.67
0.084
- a Dry standard cubic fset at 70°F, 29.92 in. Mg.
b Dry standard cubic feet per minute at 70°F, 29.92 in. Hg.
c Actual cubic fe?t per minute .
8
-------
Run Number
TABLE 7 - -Fluoride
Ammoniator Scrubber Inlet
(English)
2
Date
Volume of Gas Sampled - DSCFa
Percent Moisture by Volume
Average Stack Temperature - °F
Stack Volumetric Flow Rate - DSCFH
Stack Volumetric Flov/ Rate - ACFHC
Percent Isokinetic
6-21-73
30.48
9.3
111.9
7942
9801
104.4
6-21-73
30.81
11.2
118.1
7989
10,049
103,4
Feed Rate - ton/hr
30
30
Soluble Fluoride
mg • • '.
gr/DSCF
gr/ACF
lb/hr~ ~ .
Ib/ton feed
Total Fluoride
mg
gr/DSCF
gr/ACF
Ib/hr
Ib/ton feed
12.5
0.00632
0.00519
0.430
0.143
30.9
0.0156
0.0128
1.06
0.0353
12.6
0.00630
0.00501
0.431
0.0144
50.8
0.0254
0.0202
.1.74
0.0579
Dry standard cubic f:>et at 70°F, 29.92 in. Hg.
5 Dry standard cubic feet per minute at 70°F, 29.92 in. Hg.
Actual cubic fe?t per minute
-------
Run Number
TABLE 8 - Fluoride .
Ammo, iator Scrubber Outlet
(English)
1
,c
Date
Volume of Gas Sampled - DSCFa
Percent Moisture by Volume
Average Stack Temperature - °F
Stack Volumetric Flow Rate - DSCFM
Stack Volumetric Flow Rate - ACFf
Percent Isokinetic
Feed Rate - ton/hr
Soluble Fluoride
mg
gr/DSCF
gr/ACF
lb/hr~
Ib/ton'feed
Total Fluoride
mg
gr/DSCF
gr/ACF
Ib/hr
Ib/ton feed
6-20-73
75.79
4.5
120
6549
7484
79.2 & 84.8C
30
2.36
0.000480
0.000420
0.0269
0.000900
2.67
0.000543
0.000475
0.0305
0.00102
2
6-21-73
130.47
5.9
120
7717
8950
89.9
30
0.48
0.0000567
0.0000488
0.00375
0.000125
1 .70
0.000201
0.000173
0.0133
0.000443
3
6-21-73
110.63
6.6
120
7472
8731
76.7
30
0.96
0.000134
0.000115
0.00858
0.000286
1.54
0.000214
0.000183
0.0137
0.000457
a Dry standard cubic fset at 70°F, 29.92 in. Mg.
b Dry standard cubic feet per minute at 70°F, 29.92 in. Ho.
c Actual cubic fe2t per minute .•
j . . . • .. . -•. . ., ....•,,..
Separate calculations in two portions of test due"to nozzle change.
10
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TABLE 9 - Ammonia
Ammom'ator Scrubber Inlet
(English)
Run Number
Date
Volume of Gas Sampled - DSCFa
Percent Moisture by Volume
Average Stack Temperature - °F
Stack Volumetric Flow Rate - DSCFMb
Stack Volumetric Flow Rate - ACFMC
Percent Isokinetic
Feed Rate - ton/hr
Ammonia
mg
gr/DSCF
gr/ACF
Ib/hr
Ib/ton feed
1
6-21-73
29.95
11.5
120.2
7439
9389
109.5
30
7,300
3.75
2.97
239
7.97
2
6-22-73
25.51
9.4
112.3
6585
7992
108.7
30
9,800
5.92
4.87
334
11.1
3
6-22-73
24.11
13.1
-119.9
6487
8318
101.1
30
4,900
3.13
2.44
174
5.80
a Dry standard cubic feet at 70°F, 29.92 in. Hg.
Dry standard cubic feet per minute at 70°F, 29.92 in. Hg.
c Actual cubic feet per minute.
11
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TABLE 10 - Ammonia
Ammoniator Scrubber Outlet
(English)
Run Number
Date 6-21-73 6-22-73 6-22-73
Volume of Gas Sampled - DSCFa 63.79 67.53 47.54
Percent Moisture by Volume 7.56 7.05 , 8.15
Average Stack Temperature - °F 120 120 120
Stack Volumetric Flow Rate - DSCFM5 7444 7600 7520
Stack Volumetric Flow Rate - ACFMC 8793 8904 8926
Percent Isokinetic 91.1 94.4 69.6
Feed Rate 30 30 30
Ammonia
mg . 4000 4000 4600
gr/DSCF 0.966 0.912 . 1.49
gr/ACF 0.817 0.778 1.25
Ib/hr ... 61.6 59.4 96.0
Ib/ton feed 2.05 1.98 3.20
a Dry standard cubic feet at 70°F, 29.92 in. Hg.
Dry standard cubic feet per nv
c Actual cubic feet per minute.
b Dry standard cubic feet per minute at 70°F, 29.92 in. Hg.
12
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TABLE 11 - Particulate
Superphosphate Scrubber Inlet
(Metric)
Run^ -Number
Date - - •
Volume of Gas Sampled - Mm3 ^
Percent Moisture by Volume
Average Stack Temperature - °C
o
Stack Volumetric Flow Rate - Nnr/min.
Stack Volumetric Flow Rate - m /min.
Percent Isokinetic .
Feed Rate - Mton/hr
Particulates .- probe, cyclone,
and filter catch
mg
mg/Nm .
nig/ni
kg/hr :
kg/Mton
Particulates - total catch
mg
mg/Nm
mg/m
kg/hr
kg/Mton
Percent impinger catch
1
6-19-73
1.42
8.7
54.4
138 .
171
105.6
18.2
3679.0
2578.4
2071.5
21.27
1.17
4473.4
3135.2
2518.8
25.87
1.43
17.8
2
6-19-73
1 .39
6.3
54.4
138
167
103.0
18.2
7980.6
5710.9
4707.8
47.31
2.61
8495.9
6079.7
5011.8
50.36 .
2.78
3 -
6-20-73
1.43
11.1
54.4
149
190
97.8
18.2
3680.5
2575.6
2015.8
22.97
1.27
4557.1
3189.0
2495.9
28.44
1.57
6.1
19.2
Dry normal cubic meter at 21.1°C, 760mm Hg.
Dry normal cubic meters per minute at 21.1°C, 760mm Hg.
Actual cubic meters per minute
13
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TABLE 12 - Particulate
Superphosphate Scrubber Outlet
(Metric)
. Run Number 1 2 3
Date - 6-19-73 6-19-73 6-20-73
Volume of Gas Sampled - Mm3- ^ 1.98 1.97 1.82
Percent Moisture by Volume 12.7 13.6 14.8
Average Stack Temperature - °C 50.7 52.0 53.7
Stack Volumetric Flow Rate - Nm3/min. ^ 140 . .134
a Dry normal cubic meter at 2T.10C, 760mm Hg.
K
Dry normal cubic maters per minute at 21.1°C, 760mm Hg.
c Actual cubic meters per minute
Stack Volumetric Flow Rate - m3/min. 179 173 <' 173
Percent Isokinetic . 99.1 103.7 , 97.7
Feed Rate - Mton/hr
Particulates - probe, cyclone,
and filter catch
mg
mg/Nm
rcg/m , .
kg/hr
kg/Mton
Particulates - total catch
mg
mg/Nm
mg/m
kg/hr
kg/Mton
Percent impinger catch 62.6 65.2 59.2
163.6
8266
64.65
0.70
0.0383
437.2
220.9
172.8
1.86
0.102
220.3
111.4
85.91
0.89
0.0493
633.6
320.5
247.1
2.57
0.142
294.0
.161.3
; 122.0
1.27
0.0698
719.9
395.0
298.7
3.10
0.171
14
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TAHLE 13 - Particulate
Ammoniator Scrubber Inlet
- (Metric)
B3 (a)
Run Number
Date
Volume of Gas Sampled - Nnf
Percent Moisture by Volume
Average Stack Temperature - °C
Stack Volumetric Flow Rate - Mr,
/min.
Stack Volumetric Flow Rate - m/nrih.
Percent Isokinetic
- — Feed Rate - Mton/hr
Particulates - probe, cyclone,
and filter catch
mg
mg/Nm
. mg/m
kg/hr .
kg/Mton
Particulates - total catch
. • mg . •
O • •
mg/Nni ' "'
mg/m
kg/hr
kg/Mton
Percent impinger catch
(b)
(c)
1
6-19-73
2.42
8.6 .
49.5
176
216
105.6
27.3
9542.4
3930
.3200
41.54
1.53
9997.7
4117
3352
43.52
1.60
4.6
2
6-19-73
1.98
8.5
49.7
158
194
107.2
27.3
8168.3
4111
3350
38.95
1.43
8381.4
4219
3438
39.96
1.47
3
6-20-73
2.51
7.8
50.6
189
233
101.6
27.3
10570.2
4210
3417
47.85
1.76
10850.4
4322
3508
49.12
1.80
2.5
2.6
Dry normal cubic meter at 21.1°C, 760mm Hg.
Dry normal cubic meters per minute at 21.1°C, 760mm Hg.
c Actual cubic meters per minute
15
-------
TAPLE 14 - Particulate
Ammoniator Scrubber Outlet
• (Metric)
Run. Number 1 2 3
Date 6-19-73 6-19-73 6-20-73
Volume of Gas Sampled - Mm3 'a' 2.56 3.18 3.47
Percent Moisture by Volume 6.4 . 6.4 5.9
Average Stack Temperature - °C 43.3 43.3 46.1
Stack Volumetric Flow Rate - Nin3/min. 149 .212 204
Stack Volumetric Flow Ra;te - m3/min. ^ T68 238 234
Percent Isokinetic 91.3 80.2 90.8
Feed Rate - Mton/hr 27.3 27.3 27.3
Particulates - probe, cyclone, .
and filter catch
tug
mg/Nm
mg/m . '•..'•
kg/hr
kg/Mton
Pairticulates - total catch
mg .
mg/Nm . .'' ^-
mg/m
kg/hr : .
kg/Hton
Percent impinger catch 57.9 60.5 46.5
57.80
22.53
20.03
0.20
0.0074
137.3
53.52
47.59
0.48
0.0176
37.60
11.78
10.48
0.15
0.0055
95.20
29.83
26.53
0.38
0.0139
93.70
26.96
23.44
0.33
0.0121
175.2
50.41
43.82
0.62
0.0226
Dry normal cubic meter at 21.1°C, 760mm Hg.
.Dry normal cubic meters per minute at 21.1°C, 760mm Hg.
c Actual cubic meters per minute
16
-------
TABLE 15 --Fluoride
Superphosphate Scrubber Inlet
'(Metric)
Run Number
Date'
O ( \
Volume of Gas Sampled - Nm * '
Percent Moisture by Volume
Average Stack Temperature - °C
Stack Volumetric Flow Rate - Nni3/nn'n. ^b
~~~o . . . / \
Stack Volumetric Flow Rate - m /min. v '
Percent Isokinetic . .
t-.-. ' •
- ' • '•.?'
>? ' p '
„_.._„'.. Feed Rate - Mton/hr
Soluble Fluoride
mg
•. - mg/Nm . '•
. • ng/m ._.,. '
kg/hr
kg/Mton
Total Fluoride
mg
mg/Nm
mg/m
kg/hr
kg/Mton
1
6-20-73
1.25
12.1
54
) 129.5
167.2
98.4
18.2
11,600
9,221
7139
71.7
4.0
11,816
9,404
7,276
73.2
4.0
2
6-21-73
1.33
9.8
54
130.4
164.2
103.4
18.2
8,990
6,750
5354
52.9
2.9
>9,140 .
6rt f A
,864
5445
53.8
2.9
3
6-21-73
1.21
8.8
54
127.7
159.0
95.9
18.2
6,350
5,262
4233
40.4
2.2
7,300
6f\Af\
,040
4851
46.4
2.5
a Dry normal cubic meter at 21.1°C, 760mm Hg.
. Dry normal cubic meters per minute at 21.1°C, 760mm Hg,
c Actual cubic meters per minute
1?
-------
TABLE 16 - Fluoride
Superphosphate Scrubber Outlet
(Metric)
Run Number
Date
Volume of Gas Sampled - Nm3 ^
Percent Moisture by Volume
Average Stack Temperature - °C
Stack Volumetric Flow Rate - Nni3/min.
'Stack Volumetric Flow Rate - m /min.
Percent Isokinetic
Feed Rate - Mton/hr
Soluble Fluoride
mg
mg/Nm
mg/m
kg/hr
kg/Mton
Total Fluoride
mg
mg/Nm .
mg/m
kg/hr
kg/Mton
a Dry normal cubic meter at 21.1°C, 760mm Hg.
.Dry normal cubic maters per minute at 21.1°C, 760,11m Hg,
1
6-20-73
1.49
15.4
56.3
109.3
146.6
95.7
18.2'
397.3
265
198
1.74
0.096
408.4
275
205
1.80
0.099
2
6-21-73
1.39
14.9
53.8
99.34
131.5
99.1
18.2
299.3
215
162
1.28
0.070
306.0 .
219
165
1.31
0.071
3
6-21-73
1.46
15.7
54.8
104.8
140.2
97.9
18.2
174.8
119
89.0
0.754
0.042
176.4
121
89.9
0.758
0.042.
c Actual cubic meters per minute
18
-------
TABLE 17 - Fluoride
Ammoniator Scrubber Inlet
(Metric)
Number
Date
O f ' \
Volume of Gas Sampled - Nm ^ •
Percent Moisture by Volume
Average Stack Temperature - °C
Stack Volumetric Flow Rate - Nr.i3/min. ^
Stack Volumetric Flow Rate - m /min.
Percent Isokinetic
(c)
6-21-73
0.863
9.3
44.4
224.8
211A
104.4
3
6-21-73
0.872
11.2
47.8
226.1
284.4
103.4
Feed Rate - Mton/hr
27.3
27.3
Soluble Fluoride
mg
mg/Nm
ng/m
kg/hr
kg/Mton
Total Fluoride
mg
mg/Nm
mg/m
kg/hr
kg/Mton
12.5
14.5
11.9
0.195
0.0071
30.9
35.7
29.3
0.481
0.018
12.6
14.4
11.4
0.195
0.0072.
50.8
58.1
46.2
0.790
0.030
Dry normal.cubic meter at 21.1°C, 760mm Hg.
Dry normal cubic meters per minute at 21.1°C, 760mm Hg.
Actual cubic meters per minute
19
-------
TABLE 18 - Fluoride
Ammoniator Scrubber Outlet
(Metric)
Run Number .
Date
3 fa)
Volume of Gas Sampled - Mm v '
Percent Moisture by Volume
Average Stack Temperature - °C
Stack Volumetric Flow Rate - fta/min,
™"o .
Stack Volumetric Flow Rate - m/min.
Percent Isokinetic .
Feed Rate - Mton/hr
Soluble Fluoride
mg
mg/Np
;mg/m
kg/hr
kg/Mton
Total Fluoride
mg
mg/Nm
mg/m
kg/hr
. kg/Mton
(b)
1
6-20-73
1.38+0.760
4.5
49
185.3
211.8
79. 2+84. 8d
27. 3-'
2.36
1.10
0.961 -
61.5
0.00045
2.67
1.24
1.09
69.8
0.00051
2
6-21-73
3.68
5.9
49
.218.4
253.3
89.9
27.3
0.48
0.130
0.112
8.58
0.000062
1.70
0.460
0.396
30.4 f.
0.00022
3
6-21-73 -
3.12
6.6
49
211.5
247.1
76.7
27.3
0.96
0.307
0.263
19.6
0.000143
1.54
0.490
0.419
31.3
0.00023
Dry normal cubic meter at 21.1°C, 760mm Hg. .
.Dry normal cubic meters per minute at 21.1°C, 760mm Hg.
Actual cubic meters per minute
Separate calculations in two portions of test due to nozzle change.
:<.*
20
-------
TABLE 19 - Ammonia
Ammoniator Scrubber Inlet
(Metric)
Run Number 1 2 3
Date 6-21-73 6-22-73 6-22-73
Volume of Gas Sampled - Nm3 ^ 0.848 0.722 0.682
Percent Moisture by Volume 11.5 9.4 13.1
Average Stack Temperature * °C 49.0 44.6 48.8
Stack Volumetric Flow Rate - Nm3/min.^b^ 210.5 186.4 183.6
Stack Volumetric Flow Rate - m3/min/c^ 265.7 226.1 235.4
Percent Isokinetic 109.5 108.7 101.1
Feed Rate - Mton/hr 27.3. 27.3 27.3
Ammonia
mg
mg/Nm
mg/m
kg/hr
kg/Mton
7,300
8580
6795
108.5
4.0
9,800
13,545
11J43
151.6
5.6
4,900
7161
5583
79.0
2.9
Dry normal cubic meter at 21.1°C, 760 mm Hg.
Dry normal cubic meters per mini
c Actual cubic meters per minute.
Dry normal cubic meters per minute at 21.1°C, 760 mm Hg.
21
-------
TABLE 20 - Ammonia
Ammoniator Scrubber Outlet
(Metric)
Run Number
Date
Volume of Gas Sampled - Nm3'^
Percent Moisture by Volume
Average >Stack Temperature - °C
•J /L \
Stack Volumetric Flow Rate-Nm /min. '
Stack Volumetric Flow Rate - m3/min.'c'
Percent Tsokinetic
Feed Rate - Mton/hr
Ammonia
mg
mg/Nm
mg/m
kg/hr
kg/Mton
1
6-21-73
1.81
7.6
49
210.7
248.8
91.1
27.3
4,000
2,210
1,869
28.0
1.1
2
6-22-73
1.91
7.1
49
215.1
252.0
94.4
27.3
4,000
2,087
1,780
27.0
1.0
3
6-22-73
1.35
8.2
49
212.8
252.6
69.5
27.3
4,600
3,409
2,860
43.6
1.6
.
a Dry normal cubic meter at 21.1°C, 760 mm Hq.
Dry normal cubic meters per minute at 21.1°C, 760 mm Hg.
c Actual cubic meters oer minute.
22
-------
. DISCUSSION OF RESULTS \
It was possible to monitor the velocity head only at the NSP
scrubber outlet. At the ammoniator scrubber outlet, the stack pressure
was too high to allow a continuous reading of velocity. At both of the
scrubber inlets, the pitot tubes were constantly being plugged .because
of the high particulate concentration. In order to get isokinetic flow,
a preliminary traverse was done just prior to each test run and these values
of velocity head were used.
i
At the ammoniator scrubber outlet, a suitable length of tygon tubing
was used to connect the sampling probe to the impinger box while doing the
vertical traverse. This was done because there was no other way to sample
the vertical port. This left a length of about five feet between the
probe and the impinger box which was unheated. During the horizontal;
traverse, the probe was connected directly to the impinger box. Vertical
and horizontal sampling was done for the particulate and the fluoride tests
but only horizontal sampling was done for ammonia.;
Because of the location of the ammonia scrubber inlet duct, it could
only be sampled across one diameter, that being the horizontal diameter.
Also, at the ammoniator scrubber inlet, the probe plugged often. This made
it necessary to interrupt sampling to wash out the probe. The probe first
plugged with ten minutes remaining in run number 2 for particulates. The
contractors were told to end run 2 at that point. The probe plugged more
frequently during run number 3 particulates but the run was completed.
23
-------
PROCESS DESCRIPTION AND OPERATION
The IMC Rainbow Division's, Americus, Georgia, plant produces
several grades of NPK fertilizer. During the tests, the plant was
manufacturing mainly the product grade 5-10-15; i.e., 5% nitrogen (N2),
10% (APA) available phosphoric acid expressed as $2®$* anc* "^ potassium
expressed as KJD. This product is made by mixing raw materials in a
reaction vessel, known as an ammoniator, with subsequent drying 'of the
granules.
The normal superphosphate is produced in the plant by reacting
phosphate rock and sulfuric acid.
Gases from the ammoniator are treated in a high-pressure Venturi ;
scrubber which removes ammonia, fluorides, and particulate. The presence
of the ammonia is due to the fact that anhydrous ammonia is used to react
with the phosphate part of superphosphate. Since the phosphate might not
react with all the ammonia, sulfuric acid is added to pick up the ammonia
in excess.
Gases from the normal superphosphate are heated in two Schuette and
Koerting scrubbers in series for removal of particulates and fluorides.
24
-------
Run number 1 for fluorides was voided because the probe was plugged
every three minutes. Beginning with run number 2 for fluorides, the
nozzle -diameter was changed from .25 to .1875 inches and the sampling
time was reduced from two hours to one hour. Whenever the probe
plugged, sampling was interrupted and the probe was washed with
distilled water. The washings were saved for analysis.
At the NSP scrubber inlet, the probe became plugged. At the
midpoint of each run, it was necessary to wash the probe with distilled
water. The wash was saved as part of sample to be analyzed.
Run number 2 for fluorides had to be interrupted temporarily because
the plant had to shut down at the ammoniator because of an acid leak.
The plant was down for about fifteen minutes. Later, the plant went
down because the acid line was plugged. It was down for about two hours.
Five test runs, all at the ammoniator outlet, were less than 90 percent
isokinetic. Runs 1, 2, and 3 for fluorides, Run 3 for ammonia, and Run 2
for particulate all were under isokinetic because of difficulty in maintaining
the desired sample flow rate.
On June 20, 1973, the Brinks Model B Cascade impactor was used to
determine particle size distribution at the ammoniator scrubber outlet.
At first, the test was run for fifteen minutes isokinetically. The
impactor was disassembled and nothing was caught. The impactor was later
run. for thirty minutes at an underisokinetic rate. Again, nothing was obtained.
The reason for getting nothing in the impactor was because the stack gas
was moist and the nozzle plugged.
25
-------
Sampling
Points
H2S04
P2°5
Phosphate
Rock
Reactor
to
CO
Inlet
NSP Product
1st Stage
Scrubber
2nd Stage
Scrubber
Holding Tank
Stack gases
Outlet
Figure 1. Normal Superphosphate Process
-------
H2S04
NH,
Feed
(NSP Product)
Inlet
Ammoniatbr-
Granulator
Gas
Product to
Cooler-Drier
to
Venturi
Scrubber
Spent H20
Sampling
Points
Outlet
Fan
Stack
Gas
Figure 2. Ammoniator-Granulator Process
-------
SAMPLING AND ANALYTICAL PROCEDURE
Participate tests were run in accordance with Method 5 as
described in the August 17, 1971, Federal Register.
Fluoride tests were run in accordance with tentative Method 13,
included in Appendix F. the sample is captured in a modified Method 5
train and analyzed by the SPADNS-Zirconium Lake Method.
Ammonia tests were run according to the method described in
Appendix F. The sample is captured in a modified Method 5 train, ;
in a sulfuric acid solution. .
Any departures from these methods are described in the "Summary
and-Discussion of Results."
28
-------
Distance to nearest upstream disturbance: 10 feet
Type of disturbance: bend
Distance to nearest downstream disturbance:
Type of disturbance: junction
Inside diameter of duct: 29 inches
Number of traverse points: 44 -
3 feet
Figure 3
Location of Traverse Points
Inlet of Superphosphate Scrubber
29
-------
Distance to nearest upstream disturbance: 80 inches
Type of disturbance: junction
Distance to nearest downstream disturbance: 70 feet
Type of disturbance: stack outlet
Inside diameter of duct: 23 inches
Number of traverse points: 20
Figure 4
Location of Traverse Points
Outlet of Superphosphate Scrubber
30
-------
Distance to nearest upstream disturbance: 6 feet
Type of disturbance: fan
Distance to nearest downstream disturbance: 6 feet
Type of disturbance: ammoniator
Inside diameter of duct: 24 inches
Number of traverse points: 12
Figure'5
Location of Traverse Points
Inlet of Ammoniator Scrubber
31
-------
Distance to nearest upstream disturbance: 30 feet
Type of disturbance: elbow
Distance to nearest downstream disturbance: 5 feet
Type of disturbance: damper
Inside diameter of duct: 20 inches
Number of traverse points: .,}2
'
Figure 6
Location of Traverse Points
Outlet of Ammoniator Scrubber
32
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