Emission Testing Report
EMB Test No.: 73-FRT-6
SWIFT AGRICULTURAL CHEMICALS, INC.
Birmingham, Alabama
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
Page Number(s)
I. INTRODUCTION . 1-2
II. SUMMARY AND DISCUSSION OF RESULTS .3-14
III. PROCESS DESCRIPTION AND OPERATION ......... 15-17
Figure 1 - Process Flow Diagram 16
Figure 2 - Test Sites 17
IV. SAMPLING AND ANALYTICAL PROCEDURES .18
V. LOCATION OF SAMPLING SITES 19-21
Figure 3 - Test Site 1 . -• 20
Figure 4 - Test Site 3 21
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INTRODUCTION
Under the Clean Air Act, as amended, the Environmental Protection Agency
is responsible for establishing Federal performance standards for new station-
ary sources whrch -contribute -significant'ly "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 per-
formance 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 Swift Agricultural Chemicals in Birmingham,
Alabama, was determined to be a well controlled facility. The Emission
Measurement Branch conducted source tests at.this plant from April 30 to
May 3, 1973. The testing was performed by Environmental Engineering, Inc.,
under contract to EPA. Tests were performed at the outlet of the control
system, which consists of the following equipment in series:
1) a low pressure water spray chamber
2) a venturi water scrubber.
Gases cleaned by the system are from the ammoniator, granulator, dryer,
and cooler, all of which are part of the same granulation process. There are
no other major air pollution sources in the process, and all gas streams
from the process are scrubbed by the same system. Gases from the dryer
and cooler pass through cyclones before entering the scrubbers.
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Test runs at the outlet of the system were as follows:
1)3 fluoride
2) 2 particulate
3) 2 ammonia.
One test run for fluorides was performed on the gas entering the
.scrubbers from the ammoniator-granulator.
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SUMMARY AND DISCUSSION OF RESULTS
Test results for ?2®5 were obtained from the same test runs as
fluoride results. The samples were analyzed for both pollutants.
Therefore, in this discussion, references to fluoride test runs are
-appltca'bTe to P^ results "as well.
Fluoride tests 2 and 3 at the outlet were run simultaneously to
save time because of the frequency of plant shutdowns.
Only two particulate and ammonia tests were run instead of the normal
three because of a time shortage caused by frequent plant shutdowns.
COMMENTS
Fluoride test at granulator outlet: This test was run simultaneously with
Run 1 for fluorides at the venturi outlet. Sampling was stopped for
about 10 minutes at one point due to a plant shutdown. The filter
on the granulator test plugged and was changed twice. Only one traverse
was used at this test site due to space limitations around the duct.
Run 2 and 3 for fluorides: The filters in both tests were replaced twice
during the run. Testing was ended 25 minutes early due to a plant
shutdown.
Run 1 particulate: Run 1 for ammonia was taken during the same time period.
Both tests were discontinued for 1 hour due to plant equipment problems.
The venturi water recirculation system was not working properly for
an unknown portion of the test.
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Run 2 particulate: Run 2 for ammonia was taken during the same time
period. The venturi water pump was shut off for several unknown
periods.of time during the test. The particulate test only was
discontinued for 2.5 hours due to a power failure. Both tests
• • . "'•'.. •
were run to completion. ..-,:.. , .,;-, : : ...
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Summary of Particulate Tests at, Outlet
English Units
Run flumbsr
Date
Volume of Gas Sampled - DSCFa
Percent Moisture by Volume
Average Stack Temperature - °F
Stack Volumetric Flow Rate - DSCFM1
Stack Volumetric Flow Rote - ACFMC
Percent Isokinetic
Percent Excess Air
Percent Opacity
Feed Rate - ton/hr
Parti culatss - probe, cyclone,
and filter catch
mg
gr/DSCF
gr/ACF . ' •
lb/hr~ "
lb/to>i feed
Participates - total catch
gr/DSCF '
gr/ACF
Ib/hr .
Ib/ton feed
Percent ircpir.gor cntch
1
5-2-73
62.56
10.3
127.5
26,300
33,100
98.3
5-3-73
64.14
7.5
133.5
28,400
35,000
93.2
25.0
25.0
85.5
0.02105
0.01672
4.75
0.190
200.8
0.04943
0.03926
11.15
0.446
352.3
0.08459
0.06872
20.62
0.825
448.3
0.10764
0.08745
26.23.
1.05
57.4
21.4
0 Dry standard cubic f'let at 70°F, 29.92 in. Hg.
Dry standard cubic feet per minute at 70°F, 29.92 in. Hg,
c Actual cubic fe?t per minute
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Summary of Particulate Tests at Outlet
' . Metric Units .
Run Numbej" . . . '. • '.1 •...."••.2
Date ': ; . 5-2-73 ; : 5-3-73
Volume of Gas Sampled - Mm3 ^ . 1-77 .1.82
/Percent Moisture by Volume . '10.3 7.5
Average Stack Temperature - °C 53.1 56.4
Stack Volumetric Flow Rate - Nm3/min. (b) 745 805
Stack Volumetric Flow Rate - m3/min. ^ ' 938 . 991
•Percent ,I.so-ki.n.etlc . ,'. . 98.3' 93.2
Percent Excess Air . , . •
Percent Opacity
Feed Rate - Mton/hr . 22'7 22*7
. Particulates - probe, cyclone, .
. and fiIter catch - . '
mg - . 85.5 352.3
. mg/fte3 - .•• ' . ' 48.17 193.57
ng/m3 38.34 157.26
kg/hr 2.15 . 9.35
kg/Mton . •'.••'• 0.09495 0.4123
Particulates - total catch
mg . .;'.-' 200.8 .448.3
mg/Nm3 113.12 246.32
mg/m3 89.85 200.12
kg/hr . .,';'• 5.06 . 11.9
kg/Hton '..'.' . 0.2230 0.5246
Percent impinger catch 57.4 21.4
a Dry normal cubic meter at 21.1°C, 760mm Hg.
Dry normal cubic maters per minute at 21.1°C, 760mm Hg.
c Actual cubic meters per minute
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Summary of Ammonia Tests at Outlet
English Units
Run Number
Date
Volume of Gas Sampled - DSCFa
Percent Moisture by Volume
Average Stack Temperature - °F
Stack Volumetric Flow Rate - DSCFMfc
Stack Volumetric Flow Rate - ACFMC
Percent Isokinetic
Feed Rate - ton/hr
5-2-73
33.99
8.7
129.7
'26,100
32,400
107.5
25.0
5-3-73
. 35.95
5.9
,"1.37.8
28,000
34,100
, 106.2
'25.0
Ammonia
mg
gr/DSCF
gr/ACF
Ib/hr
Ib/ton feed
1.10
0.00050
0.00040
0.1.1
0.00446
0.8
0.00034
0.00028
0.08
0.00329
Dry standard cubic feet at 70°F, 29.92 in. Hg.
Dry standard cubic feet per minute at 70°F, 29.92 in. Hg.
Actual cubic feet per minute.
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Summary of Ammonia Tests at Outlet
Metric Units
Run Number 1 2
Date 5-2-73 5-3-73
Volume of Gas Sampled - Nm3 ^ . . . . 0.96 1.02
Percent Moisture by Volume 8.7 5.9
Average Stack Temperature - °C 54.3 58.8
^ / L \
Stack Volumetric Flov/ Rate - Nm /min. v ; 740 792
Stack Volumetric Flow Rate - m /min. 918 966
Percent Isokinetic . 107;5 106.2
Feed Rate - Mton/hr 22.7 22.7
Ammonia
mg 1.1 0.8
mg/Nm3 1.14 0.78
mg/m " 0.92 . . 0.65
kg/hr 0.05 0.04
kg/Mton 0.00223 0.00164
a 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.
8
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Summary of Results - Fluoride Tests"at Outlet
English Units
Run number
,c
Data
Volume of Gas Sampled - DSCFa
Percent Moisture by Volume
Average Stack Temperature - °F
Stack Volumetric Flow Rate - DSCFM
Stack Volumetric Flow Rate - ACF!
Percent Isokinetic
Percent Excess Air
Percent Opacity
Feed Rate - ton/hr
-Soluble Fluorides
rag
gr/DSCF
gr/ACF
lb/hr~
Ib/ton feed
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton feed
1
5-1-73
61.69
8.4
m-,8
27,600
33,100
92.0
25.0
3.1
0.00077
0.00065 .
0.18
0.00733
3.3
0.00082
0.00068
.0.20
0.00781
2
5-1-73
49.60
. 9.2
111.5
28,400
34,300
• 89.9
25.0
1.8
0.00056
0.00046
0.14
0.00545
1.8
. 0.00056
0.00046
0.14.
0.00545 .
. .3
5-1-73
' .; 52.05
9.0
115.0
27,000
32,700
107.2
- • " ..' ,
. 25.0
1.5
0.00044
0.00037
. 0.10
0.00410
3.4
0.00101
0.00083
0.23
0.00930
c< 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. Hg.
c Actual cubic fe?t per minute
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Summary of Results - Fluoride Tests at Outlet
Metric Units • .. ..
»»
,3 (a)
Run Number
Date
Volume of Gas Sampled - Nm
Percent Moisture by Volume
Average Stack Temperature - °C
Stack Volumetric Flow Rate - M
Stack Volumetric Flow Rate - m /min
"Percent Ts'o'kinet'ic
Percent Excess Air
Percent Opacity
Feed Rate - Mton/hr
Soluble Fluorides
(b)
mg
mg/fte3 -
ng/m
kg/hr
kg/Mton
Total Fluorides
mg
mg/Nm
mg/m ,
kg/hr
kg/Mton
. . 1 . ;
5-1-73 ..
:}.7S
8.4
44.3
783
937
. 92 ..0
22.7
3.1
1.77
1.48
0.08
0.00367
3.3
1.89
. 1.58
. 0.09
0.00390
;'.;'• 2
5-1-73 :
, 1.40
'9.2
44.2
805
972
.'.". -89.9
22.7
1.8
1.28
1.06
0.06
0.00272
' 1.8
. 1.28
1.06
0.06
0.00272
. .' , 3
5-1-73
1.47
9.0
46.1
763
. 925
107.2
22.7
1.5
1.02
0.89
0.05
•0.00205
3.4
2.30
1.90
0.11
0.00465
Dry. normal cubic meter at 21.1°C, 760tnm Hg.
Dry normal cubic meters per minute at 21.1°C, 760mm Hg.
c Actual cubic meters-per minute ,.
10
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Summary of P205 Tests at Outlet
English Units
Run Number
Date
Volume of Gas Sampled - DSCFa
Percent 'loisture by Volume
Average Stack Temperature - °F
Stack Volumetric Flow Rate - DSCFM*
Stack Volumetric Flow Rate - ACFHC
Percent Isokinetic
Percent Excess Air
Percent Opacity
Feed Rate - ton/hr
.Soluble P205"
mg
gr/DSCF
gr/ACF
lb/hr~ "
Ib/ton feed
Total P205
rcg
gr/DSCF
gr/ACF
.lb/hr
Ib/ton feed
1
5-1-73
61.69
8.4
111.8
27,600
33,100
92.0
25.0
6.5
0100162
0.00135
0.38
0.0153
12.0
0.00300
0.00250
0.71
0.0284
2
5-1-73
49.60
9.2
111.5
28,400
34,300
89.9
25.0
1.6
0.00050
0.00046
0.12
0.00484
.1.7
0.00053
: 0.00041
0.13
0.00514
3
5-1-73
52.05
9.0
115.0
27,000
32,700
107.2
25.0
6.0
0.00178
0.00146
0.41
0.0164
36.0
0.01065
0.00877
2.46
0.0984
a Dry standard cubic f-iet at 70°F, 29.92 in. Hg.
b Dry standard cubic feet per minute at 70°F, 29.92 in. Ho,
c Actual cubic fet-t oer minute
11
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Summary of P205 Tests at Outlet
Metric Units
3 l>
Run Number
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 Isok.ine.tic
Percent Excess Air
Percent Opacity
Feed Rate - Mton/hr
Sol'uble P00C
2 b
mg
mg/Nm -
mg/m
kg/hr
kg/Mton
Total P20,
mg
mg/Nm
mg/m
kg/hr
kg/Mton
1
5-1-73
1.75
8.4
44.3
783
937
92.0
22.7
6.5
3.71
3.10
0.17
0.00769
12.0
6.86
5.72
0.32
0.01419
2
5-1-73
1.40
9.2
44.2
805
972
89.9
22.7
1.6
1.14
0.94
0.05
0.00242
1.7
1.21
1.00
0.06
0.00257
3
5-1-73
1.47
9.0
46.1
763
925
107.2
22.7
6.0
4.06
3.35
0.19
0.00820
36.0
24.37
20.09
1.12
0.04923
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
12
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Summary of Results - Fluoride and P205 Tests at Granulator Outlet
English Units
Sample Type
Date
Volume of Gas Sampled - DSCFa
Percent t'.oisture 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
Fluoride
5-1-73
93.26
5.5
103.5
5475
6369
97.0
25.0
P2°5
-Soluble
mg
gr/DSCF
gr/ACF
lb/hr~ "
lb/to:i feed
Total
5.9
0.00097
0.00084
0.05
0.00183
1 23.7
0.00391
0.00336
0.18
0.00735
ng
gr/DSCF
gr/ACF
Ib/hr
Ib/ton feed
5.9
0.00097
0.00084
. 0.05
0.00183
26.5
0.00438
0.00377
0.21
0.00822
Dry standard cubic fset at 70°F, 29.92 in. Mg.
Dry standard cubic feet per minute at 70°F, 29.92 in. Hg.
Actual cubic fe:-t per minute
13
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Summary of Results - Fluoride and P205 Tests.at Granulator Outlet
Metric Units . .
B3 (a)
Sample Type
Date
Volume of Gas Sampled - Nnf
Percent Moisture by Volume
Average Stack Temperature - °C
Stack Volumetric Flow Rate - Nm3/min.
Stack Volumetric Flow Rate - m /min.
Percent Isokinetic ..
Percent Excess Air
Percent Opacity
Feed Rate - Mton/hr
Fluoride
P2o5
5-1-73
'-:•'-. 2.64'
5.5
39.7
: 155
180
97.0
22.7
Soluble
mg
mg/m
kg/hr
kg/Mton
Total
mg
3
mg/Nm
r 3
mg/m
kg/hr
kg/Mton
5.9
2.23
1.92
0.02
0.00092 .
23.7
8.96
7.70
' 0.08
0.00367
5.9 .
2.23
1.92
0.02
0.00092
26.5.
10.01
8.61
0.09
0.00411
Dry normal cubic meter at 21.1°C, 760mm Hg.
Dry normal cubic meters per minute at 21.1°C, 760mm Hg.
Actual cubic n.eters per minute
14
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PROCESS DESCRIPTION AND OPERATION . '
The plant produces several grades of NPK fertilizer. Two of the major
grades are 8-8-8 and 5-10-15 ( % N- % P205- % K20). A variety of raw materials
containing the basic nutrients nitrogen, phosphorous, and potassium are mixed
in the granulator. The wet granules are conveyed to a gas-fired dryer, and
finally to a cooler.
Gases from the dryer and cooler are vented to separate cyclones, then
to the first stage scrubber. The granulator is exhausted directly to
the scrubber. The first stage scrubber is a Heil No. 729 low pressure
water scrubber. Water is recirculated from a waste pond.
A 150 hp fan conveys the gas from the first scrubber to a Heil venturi
scrubber. Water is recirculated through the venturi scrubber.
A 100 hp fan transports scrubbed gas from the venturi through a stack
to the atmosphere.
15
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DK.Y
:kicL, DAP, TSP,
STORAGE
N.H3— ~^-r
FUE.I.
PRioP.
•STOP-A^E
":.M x v
CJBANULATIN5
DC.YE.R.
COOL.EG.
4
_ . Ml
A.ND
WAT EG
5T&AM
bOI LEf^
CVCLONE
C.ECII2CULAT1HO
POND
T
TO 4 Frz^f/i
SUPERPHOSPHATE
CYCLONE
W5IL-V . IO"£>.P.
NEIL. 720 MOD!FI£D
3206PM
Figure 1
Process Flow Diagram
16
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Site 2
Site .3=-
•til
To C
Figure 2
Test Sites
17
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" • " SAMPLING AND ANALYTICAL PROCEDURES • • . . :'
Particulate tests were run using EPA Method 5 particulate train
and procedures as published in the Federal Register, August 17, 1971,
except that the impinger water wash 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 using the method outlined in Appendix F. •
The method is similar to Method 5 except that the impinger solution is
0.1 N H^SO* and only the impingers are analyzed for ammonia. . .-
18
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. LOCATION OF SAMPLING SITES
Simultaneous sampling at three sampling sites was originally
planned.
Site 1 is the inlet to the first stage scrubber from the ammoniator-
granulator. Inlets from the dryer and cooler could not be sampled due to
poor locations.
Site 2 is between the first stage and second stage scrubbers. All
gas streams pass through the first stage scrubber and into the second
stage scrubber past site 2.
Site 3 is the outlet of the second stage scrubber in the stack
leading to the atmosphere. This is the final outlet of all gas streams.
Due to clogging problems in the Run 1 fluoride test, sampling was
discontinued at site 1 after this first test. Site 2 was never
sampled due to high water and ammonia concentrations coupled with high
pressure, posing both a safety and a technical problem.
19
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Distance to nearest upstream disturbance - 160 in. (JO. diameters)
Type of disturbance - Granulator
Distance to nearest downstream disturbance - 30 in. (2_diameter)
Type of disturbance - Bend . ,
Figure 3
'Test Site 1
20
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Distance to nearest upstream disturbance - 30 ft. (9. diameter)
Type of disturbance - Fan
Distance to nearest downstream disturbance - 12 ft. (3_ diameter)
Tvoe of disturbance - Stack outlet
i. o.
C
* 5
t
H
•
3
«
2 .
k>
s
«
f
o
3
«
Z
«
Figure 4
Test Site 3
21
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