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

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                          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

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                           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

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     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.

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                  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.

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                    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

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                    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

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                   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

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                   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

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                        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.

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                         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.

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                          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

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                        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

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                            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

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                              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

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                   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

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Product
                       Figure 1
          Process  Diagram Shov/ing Test Sites

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                 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

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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

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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

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