Emission Testing Report EMB Test No.: 73-FRT-16 KAISER AGRICULTURAL CHEMICALS, INC. Reigelwood, North Carolina Prepared by Roger 0. Pfaff Project Officer Environmental Protection Agency Office of Air Quality Planning and Standards Research Triangle Park, North Carolina 27711 ------- TABLE OF CONTENTS . • i "•, . • •. ."-"-.--•'• ' ' " • v Page Number(s) I. INTRODUCTION 1-2 II. SUMMARY AND DISCUSSION OF RESULTS . ... . . . . . '.'. . '• 3-13 III. PROCESS DESCRIPTION AND OPERATION '•'••' 14-15 Figure 1 - Process Diagram Showing Test Sites 15 IV. SAMPLING AND ANALYTICAL PROCEDURES ,. 16-18 Figure 2 - Location of Traverse Points - Inlet ..... 17 Figure 3 - Location of Traverse Points - Outlet .... 18 ------- INTRODUCTION i Under the Clean Air Act as amended the Environmental Protection Agency is responsible for establishing Federal performance standards for new stationary sources which contribute significantly to air pollution or cause or contribute to the endangerment of public health or welfare. Phosphate fertilizer plants have been included in a listing of such sources. The Office of Air Quality Planning and Standards establishes performance standards from emission data gathered from the best emission control systems which have been shown to be operable and economically feasible. The granulated NPK fertilizer plant at Kaiser Agricultural Chemicals in Reigel wood, N. C., was determined to be a well controlled facility. The Emission Measurement Branch conducted source tests at this plant from May 14 to May 19, 1973. The testing was performed by Roy F. Westbn, Inc., under contract to EPA. , The original tests program called for the identical tests at the following locations: 1) Inlet to normal superphosphate scrubber 2) Outlet of normal superphosphate scrubber 3) Inlet to granulator scrubber : 4) Outlet of granulator scrubber Because of fugitive acid mist fumes due to process problems, ar.d because -of.frequent and long shutdowns, testing at the normal superphosphate plant had to be cancelled. 1 ------- In the granulation process, emissions from the granulator are controlled by a venturi water scrubber. Emissions from the dryer-cooler are vented to the atmosphere after passing through a cyclone. Three particulate, one fluoride, and one ammonia test were performed at the inlet and outlet of the venturi scrubber. ------- SUMMARY AMD DISCUSSION OF RESULTS All inlet tests were run simultaneously with the corresponding outlet tests. P205 analyses were obtained from the fluoride tests and are not separate test runs. Ammonia tests were run within the same time period as the fluoride tests. Comments Run 1 particulate: One impinger in the inlet test train had to be changed during the run due to clogging. Both tests were stopped 10 minutes early due to a plant shutdown. Fluoride and ammonia tests: One impinger in the outlet fluoride test was clogged momentarily. The fluoride tests were stopped 15 minutes short due to an ammonia leak in the plant. ------- Summary of Particulate Results at Inlet . English Units Run liurnber Date Volume of Gas Sampled - DSCFa Percent Moisture by Volume Average Stack Temperature - °F Stack Volumetric Flow Rate - DSCFM1 Stack Volumetric Flow Rate - ACFMC Percent Isokinetic Percent Excess Air Percent Opacity Feed Rate - ton/hr Particylates - probe, cyclone, and" filter catch mg gr/DSCF gr/ACF lb/hr~ ~ Ib/ton feed • Pg.r.tic»lates - total catch mg gr/DSCF - . . gr/ACF Ib/hr Ib/ton feed , Percent impinger cntch . ..,.1: , 5-16-73 ' :67.83 ; ; 4.o: .90. 9 ' 3820 4131. ' 101.0 .36.0. 273.6 0.05211 0.05738 , 2.03 0.0565 . 418-2 0.09494 0.08770 3.11 0.0864 . 34.6 .2 . 5-16-73 71.19 . 1 4.1 ; 9S..6 : 3763 4131 '100.9 • :36.o ". 196.7 0.04255 ; 0,03872 1.37 0.0381 .,' 509.6. " 0.11023 " 0.10032 3.56 0.0990 61.4 . • '- ' 3 • 5-17-73 . 72.07 7.2 103.7 3629 4129 105.6 , ', ' ' . / ' •"" ' 36.0 1081.3 0.23106 . - 0.20300 7.19 0.200 . 1458.4 0.31164 0.27379 9.69 0.269 25.9 3 Dry standard cubic f-jet at 70°F, 29._92 "in. Hg. Dry standard cubic feet per minute at 70°F, 29.92 in. Hg Actual cubic fe-jt per minute ------- Summary of Participate Results at .Inlet Metric Units '. ': ... Run Number ..... Date • •': Q f \ Volume of Gas Sampled - Mm '%a' Percent Moisture by Volume Average Stack Temperature - °C Stack Volumetric Flow Rate - Nm3/min. Stack Volumetric Flow Rate - m /min. ••Percent •rs-ok'tnet-vc Percent Excess Air Percent Opacity Feed Rate - Mton/hr Particulates - probe, cyclones and filter catch mg rag/Mm - mg/m kg/hr kg/Mton Particulates - total catch mg mg/Nm mgfm kg/hr kg/Mton Percent impinger catch nJ-/1 -;•:' ;' 5-1 6-73 •;.ri,92 .4,0 V32,7 D) 108 117 ; TOI.O 32.7 273.6 142.1 131.3 0.92 0.0282 418.2 217.3 200.7 1.41 0.0432 34.6 ... ; •••'•. 2. •••••; •'5-16-73 .[•''•• 2.02" ' 4.1 .37.0 : 107 ''. 117 •'.100.9 32.7 196.7 ' 97.4 ' 88.60 0.62 '0.0191 " 509.6 252;2^ 229.6 1.61 0.0494 61.4 •':r:;;>v3 ,; . 5-17-73 ..'.: " .2.04 '7^2 ' 39.8 . ^103 ; ; ''• 117 105.6 . 32.7 1031 '.3 528.8 464.5 • .,3.2.6 . .0.0998 1458.4 713.2 .626.5 4:.40 0.1346 ; 25.9 Dry normal cubic meter at 21.1°C, 76"Cinm Hg. Dry normal cubic meters per minute at 21.1°C, 760mm Hg, Actual cubic meters per minute ------- Summary of Particulate Results af English Units Run Number Date Volume of Gas Sampled - DSCFa Percent Moisture by Volume Average Stack Temperature - °F Stack Volumetric Flov; Rate - DSCFH Stack Volumetric Flov/ Rate - ACFHC Percent I sokinetic Percent Excess Air Percent Opacity Feed Rate - ton/hr PartlculatGs - probe, cyclone, and filter catch nig , . . • gr/DSCF gr/ACF lb/hr~ Ib/ton feed • Particulates Outlet - total catch gr/DSCF gr/ACF Ib/hr • lb/ton feed Percent.impinger catch ...l : . 5-16-73 107.72 3.7 81.9 4061 4307 92.6 36.0 92.6 0.01324 0.01248 .0.46 0.0128 t ,293.7 '0.04199 0.03957 1.46 0.0406 68.5 .2 5-16-73 108.16 3.1 105.0 3868 4252 95.5 36.0 61.4 0.00874 0.00795 0.29 0.00805 262.3 0.03735 0.03396 1.24 0.0344 76.6 3 5-17-73 106.52 .9.3 119.9 3346 4033 108.6 36.0 773.9 0.1119 0.09280 3.21 0.08915 905.6 0.1309 0.1086 3.76 .0.104 14.5 a Dry standard cubic f.-jet at 70°F, 29,9? in. Hg. Dry standard cubic feet per minute at 70°F, 29.92 in. Ho, c Actual cubic f'e?t per minute ------- Summary of Particulate Results at Outlet . Metric Units Run Number Date '• .;••• ...'.. Volume of Gas Sampled - Nm ^ Percent Moisture by Volume Average Stack Temperature - °C Stack Volumetric Flow Rate - Nrn3/min. Stack Volumetric Flow Rate - m3/min. '' 'Percent I-sokinoetic . Percent Excess Air . Percent Opacity . Feed Rate - Hton/hr Particulates - probe, cyclone, and filter catch mg . mg/Nm - • .. ng/m . . . . kg/hr kg/Mton . . '-;•'. PaHi cul ates - total catch mg .' .." ' .' ••'. mg/Nm • . r 3 mg/m . . . • . kg/hr ' ' .. , kg/Hton Percent impinger catch -.;, .V : '5-16-73 : 3.05' ;.3.7 27.7 r L. \ ^ 115 :) 122 .92 ,-6. . 32.7 92.6 30.29 28.55 0.21 0.00640 293.7 96.08 : 90.54 0.66 0.0203 68.5 . ,. •.•-..- 2 •; .5-16-73 - : : 3.06 : 3.1 40.6 , no 120 '-' ' 95.5 ;.. '. '..'.' -•"• ...'•:' i '-- '. 32.7 61.4 20.00 18.20 0.13 0.00403 262.3 85.46 77.72 0.56 0.0172 76.6 3: 5-17r73 3.02 9.3 48.8 95 114 108.6 32.7 773.9 256.04 212.4 1.46 . 0.0446 905.6 299.61 248.5 1.70 0.0522 14.5 Dry normal cubic meter at 21.1°C, 76'0mtn Hg. Dry" normal cubic meters per minute at 21.1°C, 760mm Hg. Actual cubic meters per minute ------- Summary of Ammonia Results English Units - Location 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 -Inlet ,5-19-73 ,37.32 3.7 82.6 4197 4438 94.4 36.0 Outlet 5-19-73 56.88 3 .'9 83.8 3868 4106 TOO.O 36.0 Ammoni a mg gr/DSCF gr/ACF Ib/hr Ib/ton feed 4.90 :0.00202 0.00192 :'•: 0.07 0.00202 4.30 0.00116 0.00109 0.04 0.00107 Dry standard cubic feet at 70°F, 29.92 in. Hg. 'Dry standard cubic feet per minute at 70°F, 29.92 in. Ha. "Actual cubic feet per minute. ------- Summary of Ammonia Results Metric Units Location Date Volume of Gas Sampled - Nm3 ^ Percent Moisture by Volume Average Stack Temperature - °C Stack Volumetric Flow Rate - Nm /min. 3 Stack Volumetric Floy/ Rate - m / min. Percent Isokinetic Feed Rate Inlet Outlet (b) (c) '5-19-73 1.09 3.7 28.1 119.0 126.0 94.4 32.7 5-19-73 1.69 : 3.9 28.8 110.0 116.0 100.0 32.7 Ammonia mg 3 mg/Nm mg/m kg/hr kg/Mton 4.9 4.63 4.37 0.03 0.00101 4.3 2.66 2.51 0.02 0.00054 Dry normal cubic meter at 21.1°C, 760 mm Hg. .Dry normal cubic meters per minute at 21.1°C, 760 mm Hg. ^Actual cubic meters per minute. ------- Summary of Fluoride Results *» English Units Location Date Volume of Gas Sampled - DSCFa Percent Moisture by Volume : Average Stack Temperature - °F . Stack Volumetric Flow Rats - DSCFMb Stack Volumetric FTov/Rate - ACFHC Percent Isokinetic ,::, . Percent Excess Air . Percent Opacity Feed Rate - ton/hr Soluble fluorides . Inlet 36.0 Outlet 5-19-73 ; 67.55 - :;;4.o 84.4 . 4322 4600 96.0 . 5-19-73 - 95;22 3.7 .82.1 4025 4251 ; ;-;9i.3 36.0 gr/DSCF gr/ACF lb/hr~ Ib/ton feed Total fluorides nig gr/DSCF gr/ACF Ib/hr Ib/ton feed 3.1 ' 0.00071 0.00067 0.03 0.00073 . 3.35 ; 0.00076 '0.00071 .: 0.03. 0.00079 . '':• 3.4 0.00055 0.00052 0.02 0.00053 . : :• 3.4 0.00055 .0.00052 0.02 0.00053 Dry standard cubic f-»et at 70°F, 29.,92 'in. l!g. Dry standard cubic feet per minute at 70°F, 29.92 in. Hg, Actual cubic f'e^t per minute 10 ------- Summary of Fluoride Results Metric Units .3 (a) Location Date Volume of Gas Sampled - Nm" Percent Moisture by Volume Average Stack Temperature - °C Stack Volumetric Flow Rate - Nrn3/min Stack Volumetric Flow Rate - m3/min. .Re.rGen.t Isok.inetic Percent Excess Air . . Percent Opacity Feed Rate - Mton/hr Inlet Outlet 5-19-73 1.91 •'4.0 29.1 122 130 96.0 .5-19-73 . 2.70 3.7 27.8 114 120 91.3 32.7 32.7 Soluble Fluorides mg ng/m kg/hr kg/Mton .Total Fluorides mg mg/Nm mg/m kg/hr kg/Mton 3.1 1.62 1.51 0.01 0.00036 3.35 1.75 • 1.64 0.01 0.00039 3.4 1.26 1.19 0.01 0.00026 3.4 1.26 1.19 0.01 0.00026 Dry normal cubic meter at 21.1°C, 76Crnni Hg. Dry normal cubic meters per minute at 21.1°C, 760mm Hg. Actual cubic meters per minute n ------- Summary of P205 Results English Units Location Date Volume of Gas Sampled - DSCFa Percent Moisture by Volume Average Stack Temperature - °F Stack Volumetric Flow Rate - DSCFM1 Stack Volumetric Flow Rate - ACFMC Percent Isokinetic Percent Excess Air Percent Opacity Feed Rate - ton/hr Inlet .Outlet 5-19-73 67.55 " 4.0 . 84.4 4322 4600 96.0 5-19-73 95.22 .3.7 82.1 4025 4251 91.3 '• 36.0 36.0 Soluble gr/DSCF gr/ACF_ 1b/hr~ Ib/ton feed Total P2'05 gr/DSCF gr/ACF Ib/hr Ib/ton feed 3.5 0.00080 0.00075 0.03 ; 0.00082 6.7 0.00153 0.00144 ' O.OG 0.00157 1.4 0.00023 0.00021 0.01 0.00022 1.4 0.00023 0.00021 0.01 0.00022 Dry standard cubic f:>et at 70°F, 29.9?. in. tig. Dry standard cubic feet per minute at 70°F, 29.92 in. Hg. Actual cubic fe:-t per minute 12 ------- Summary of ?2®5 Metric Units Location- ,3 (a) Date Volume of Gas Sampled - Nm" Percent Moisture by Volume Average Stack Temperature - °C Stack Volumetric Flow Rate - Nm3/min. Stack Volumetric Flow Rate - m3/min. "Percent rs-ok'tnetvc Percent Excess Air Percent Opacity Feed Rate - Mton/hr Inlet 32.7 Outlet 5-19-73 . 1.91 4.0 29.1 122 130 ,.9,6....D . .5-19-73 2.70 3.7 .27.8 114 120 .91.3 32.7 Soluble P205 mg mg/n kg/hr kg/Hton -Total P. ng mg/Nm mg/m kg/hr kg/Mton .3.5 1.83 1.72 0.01 0..00041 6.7 3.50 3.28 0.03 0.00079 1.4 0.52 0.49 0.0037 0.00011 1.4 0.52 : 0.49 0.0037 0.00011 Dry normal cubic meter at 21.1°C, 76"0mm Hg. .Dry normal cubic meters per minute at 21.1°C, 760mm Hg. .,, c Actual cubic me tars per minute 13 ------- PROCESS DESCRIPTION AND OPERATION The plant produces several grades of NPK fertilizer. Two of the major grades are 3-9-9 and 15-15-30 ( % N - % P205 - % K20). A variety of raw materials containing the basic nutrients nitrogen, phosphorous, and potassium are mixed in a granulator. The wet granules are conveyed to a gas-fired dryer cooler, which dries the wet granules, then cools the product. The product is then stored. Gases from the dryer-cooler are.sent to a dry cyclone which removes some of the particulate for recycling. The gases from the cyclone are vented to the atmosphere. Gases from the granulator are controlled by a venturi water scrubber using recirculated water. . 14 ------- Product Figure 1 Process Diagram Shov/ing Test Sites ------- SAMPLING AMD ANALYTICAL PPxOCEDURES , . , . Particulate tests were run using EPA Method 5 particulate train and procedures as published in the Federal Register, August 17, 1971, except that the imninger v/ater v/ash is evaporated to dryness after organic extraction and weighed. . . . \ . . - Fluoride tests were run in accordance with Method 13 for fluorides (See Appendix F). Sampling equipment and procedures are similar to that of Method 5 except that the filter is in the rear of the sampling train and is a paper filter. Fluoride analysis is by the SPADNS Zirconium Lake Method. Ammonia tests were run usinq the method outlined in Appendix F. The method is similar to Method 5 except that the impinger solution is 0.1 N HoSO* and only the impingers are analyzed for ammonia. 16 ------- Distance to nearest uostrearc disturbance: 2 ft. (0.8 diameters) Type of disturbance: Duct entrance (closed) Distance to nearest downstrean disturbance: 6 in. (0.2 diameters) Type of disturbance: Bend Number of traverse points: 48 . •••'. 30 "ID. X Figure 2 . Location of Traverse Points - Inlet 17 ------- Distance to nearest upstreamr-disturbance: :'-6,fti. (3_ diameter) Type of disturbance: Storage tank Distance to nearest downstream disturbance: 40 ft. (20. diameter) Type of disturbance: Stack outlet •Number -of traverse -poi-nts.: 40 . Figure 3 , Location of Traverse Points- Outlet 18 ------- |