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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