xvEPA
United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 79-NHF-10
November 1979
Air
Ammonium Nitrate
Emission Test Report
C. F. Industries
Harrison, Tennessee
-------
REPORT ON
PROCESS EMISSIONS TESTS
AT THE CF INDUSTRIES. INC,.
AMMONIUM NITRATE FERTILIZER PLANT
IN HARRISON, TENNESSEE
Thomas M. Bibb
EPA Project Manager
Clyde E. Riley
EPA Technical Manager
EPA Contract #68-02-2820
Work Assignment #12
TRC Project No. 0988-E80-30
Willard A. Wade, III, P.E.
Project Manager
Reed W. Cass
Project Engineer
June 25, 1980
-------
TRC-Environmental Consultants, Inc.
Willard A. Wade III, P.E.
Project Manager
June 25, 1980
-------
Note: Mention of trade names or commercial products in this
publication does not constitute endorsement or recommendation
for use by the Environmental Protection Agency.
-------
PREFACE
The work herein was conducted by personnel from TRC-Environmental
Consultants, Inc., (TRC), the GCA/Technology Division (GCA), CF Industries,
Inc., (CFI), Harrison, Tennessee, and the U.S. Environmental Protection
Agency (EPA).
The scope of the work issued under EPA Contract No. 68-02-2820, Work
Assignment No. 12 was under the supervision of the TRC Project Manager, Mr.
Willard A. Wade, III. Mr. Reed W. Cass of TRC served as Project Engineer and
was responsible for summarizing the test and analytical data in this report.
Analysis of the samples was performed at the CFI Harrison, Tennessee plant
under the direction of Ms. Margaret Fox and at the TRC labs in Wethersfield,
Connecticut under the direction of Ms. Joanne J. Marchese.
Mr. Tim Curtin of GCA was responsible for monitoring the process
operations during the testing program. GCA personnel were also responsible
for preparing Section 3.0 (Process Description and Operations) and Appendix M
of this report.
Members of CF Industries, Inc., Harrison, Tennessee whose assistance and
guidance contributed greatly to the success of the test program include Mr.
Fred W. Lockemann, Manager Engineering, Mr. John Turner, Process Engineer,
and Mr. Richard Westmoreland, Special Problems Chemist.
Mr. Eric A. Noble, Office of Air Quality Planning and Standards,
Industrial Studies Branch, EPA, served as Test Process Project Engineer and
was responsible for coordinating the process operation monitoring.
Mr. Clyde E. Riley,, Office of Air Quality Planning and Standards,
Emission Measurement Branch, EPA, served as Technical Manager and was
responsible for coordinating the emission test program.
ii
-------
TABLE OF CONTENTS
Preface
SECTION
1.0 INTRODUCTION
1.1 Background
1.2 General Process Description
1.3 Measurement Program
1.3.1 Prill Tower Scrubber
1.3.2 Prill Cooler Scrubber
1.3.3 Neutralizers
1.3.4 Evaporators
1.3.5 Product Sampling and Analysis
1.3.6 Ambient Air Measurements
1.3.7 Clean-up Evaluation and Audit Samples . . .
1.4 Description of Report Sections
2.0 SUMMARY OF RESULTS
2.1 Prill Tower Scrubber
2.2 Prill Cooler Scrubber
2.3 Neutralizer Scrubbers
2.4 Evaporators
2.5 Particle Size Test Data
2.6 Visible Emissions
2.7 Scrubber Water Analysis Data
2.8 Scrubber Pressure Drop Measurements
2.9 Integrated Gaseous Bag Samples
2.10 Ambient Air Measurements
2.11 Product Samples
3.0 PROCESS DESCRIPTION AND OPERATION
3.1 Process Equipment
3.2 Emission Control Equipment
3.3 Production Rate Monitoring
3.4 Production and Control Equipment Monitoring .
3.5 General Plant Operation
4.0 LOCATION OF SAMPLING POINTS
4.1 Prill Tower
4.1.1 Scrubber Inlet - Ammonium Nitrate Sampling.
4.1.2 Scrubber Outlet - Ammonium Nitrate Sampling
4.1.3 Particle Size Tests at Scrubber Inlet . . . .
4.1.4 Scrubber Pressure Drop Measurements
4.1.5 Scrubber Liquor Sampling
11
PAGE
1
1
2
4
4
5
5
6
6
7
7
7
8
8
17
24
42
47
47
50
50
58
58
58
65
65
69
71
74
78
79
79
76
76
82
82
82
-------
TABLE OF CONTENTS (Continued)
SECTION PAGE
4.2 Prill Cooler 85
4.2.1 Scrubber Inlet - Ammonium Nitrate Sampling ... 85
4.2.2 Scrubber Outlets - Ammonium Nitrate Sampling . . 85
4.2.3 Particle Sizing Tests at Scrubber Inlet 88
4.2.4 Scrubber Pressure Drop Measurements 88
4.2.5 Scrubber Liquor Sampling 88
4.3 Neutralizers 88
4.3.1 Scrubber Inlet - Ammonium Nitrate Sampling ... 88
4.3.2 Scrubber Outlets - Ammonium Nitrate Sampling . . 89
4.3.3 Scrubber Pressure Drop Measurements 89
4.3.4 Scrubber Liquor Sampling 93
4.4 Evaporators 93
4.4.1 Calandria Concentrator Outlet Sampling 93
4.4.2 Calandria and Air-Swept Falling-Film Evaporator
Combined Outlet 93
4.5 Visible Emissions Observation Locations 95
4.6 Product Sampling 100
4.7 Ambient Air Measurements 100
5.0 SAMPLING AND ANALYSIS METHODS 97
5.1 EPA Reference Methods Used in This Program .... 97
5.2 Ammonium Nitrate Sampling and Analysis 103
5.2.1 Sampling Methods 103
5.2.1.1 Prill Tower Scrubber and Prill Tower Cooler
Scrubber 103
5.2.1.2 Neutralizer Scrubbers 105
5.2.1.3 Evaporators 108
5.2.2 Sample Recovery and Preparation 109
5.2.3 Sample Analysis 110
5.3 Ammonia Sampling and Analysis 112
5.3.1 Sampling, Sample Recovery and Sample Preservation 112
5.3.2 Sample Analysis 112
5.4 Magnesium Sampling and Analysis 113
5.4.1 Sampling, Sample Recovery and Sample Preparation 113
5.4.2 Sample Analysis 115
5.5 Insoluble Particulate 115
5.6 Particle Size Distribution Tests 115
5.7 Integrated Gaseous Bag Sampling 116
5.8 Visible Emissions 117
5.9 Scrubber Pressure Drop Measurements 117
5.10 Scrubber Liquor Sampling and Analysis 118
5.11 Ambient Air Measurements 118
5.12 Process Sample Collection and Analysis 119
-------
LIST OF APPENDICES
APPENDIX
A Computer Printout Test Results for Ammonium Nitrate,
Ammonia, Magnesium and Insoluble Particulate
A-l Prill Tower Scrubber Test Runs
A-2 Prill Cooler Scrubber Test Runs
A-3 Neutralizer Scrubber Test Runs
A-4 Calandria Evaporator Test Runs
A-5 Combined Calandria and Air-Swept Falling-Film Evaporator
Test Runs
B Sample Equations and Example Calculations
C Field Data Sheets for Ammonium Nitrate Tests
C-l Prill Tower Scrubber Field Data Sheets
C-2 Prill Cooler Scrubber Field Data Sheets
C-3 Neutralizer Scrubbers Field Data Sheets
C-4 Calandria and Combined Calandria and Air-Swept Falling-Film
Evaporator Field Data Sheets
D Sampling Logs
D-l Daily Summary Log
D-2 Field Laboratory Notebook
E Cyclonic Flow Measurement Information
F Particle Size Tests
F-l Discussion of Particle Size Testing
F-2 Particle Size Test Results
F-3 Particle Size Field Data Sheets
F-4 Laboratory Weighing Data
G Integrated gaseous bag sampling
H Visible Emissions Results
H-l Visible Emissions Data Tables
H-2 Visible Emissions Recertification Certificate
H-3 Visible Emissions Observation Locations
H-4 Guidelines for EPA Method 9
H-5 Visible Emissions Field Data Sheets
I Ambient Air Temperature, Relative Humidity and" Barometric
Pressure Measurements
J Sampling Train Calibration Data
J-l Sampling Orifice Calibrations
J-2 Nozzle Measurements
J-3 Pitot Tube Calibrations
K Scrubber Liquor Sampling Data
-------
LIST OF APPENDICES (Continued)
APPENDIX
L Scrubber Pressure Drop Data
M Process Operations Log
N Process Sampling and Product Analysis
0 Sampling and Analytical Procedures
0-1 Summary of Sampling and Analysis Methods
0-2 EPA Ammonium Nitrate and Ammonia Reference Method Procedures
Used on This Program
0-3 In-Stack Orifice Method Development
P Chemical Laboratory Data
P-l Laboratory Data Summaries
P-2 TRC Chemical Laboratory Notebook
Q Audit Sample Analysis Results
R Cleanup Evaluation Results
S Project Participants
T Scope of Work
-------
LIST OF FIGURES
FIGURE PAGE
1-1 Flow Diagram of Ammonium Nitrate Production
at CF Industries, Inc., Harrison, Tennessee 3
2-1 Opacity Readings on the Prill Tower Scrubber Outlet
at CF Industries, Inc., Harrison, Tennessee 49
3-1 High Density Ammonium Nitrate Production at
CF Industries, Inc., Harrison, Tennessee 66
3-2 Ammonium Nitrate Solution Production and Concentration Line,
at CF Industries, Inc., Harrison, Tennessee 67
4-1 General Layout of Ammonium Nitrate Process Facilities
at CF Industries, Inc., Harrison, Tennessee 80
4-2 Prill Tower Scrubber Inlet Sampling Location
at CF Industries, Inc., Harrison, Tennessee 81
4-3 Prill Tower Scrubber Outlet Sampling Location
at CF Industries, Inc., Harrison, Tennessee 83
4-4 Scrubber Liquor Sampling Locations
at CF Industries, Inc., Harrison, Tennessee 84
4-5 Prill Cooler Scrubber Inlet Sampling Location
At CF Industries, Inc., Harrison, Tennessee 86
4-6 Prill Cooler Outlet Sampling Location (West and East)
at CF Industries, Inc., Harrison, Tennessee 87
4-7 Neutralizer No. 1 Scrubber Inlet Sampling Location
at CF Industries, Inc., Harrison, Tennessee 90
4-8 Neutralizer No. 1 Scrubber Outlet Sampling Location
at CF Industries, Inc., Harrison, Tennessee 91
4-9 Neutralizer No. 2 Scrubber Outlet Sampling Location
at CF Industries, Inc., Harrison, Tennessee 92
4-10 Calandria Evaporator Sampling Location
at CF Industries, Inc., Harrison, Tennessee 94
4-11 Combined Calandria and Air-Swept Falling-Film Evaporator
Sampling Location at CF Industries, Inc., Harrison, Tennessee 96
-------
LIST OF FIGURES (Continued)
FIGURE PAGE
4-12 Prill Tower Scrubber Visible Emissions Observation Location
at CF Industries, Inc., Harrison, Tennessee 97
4-13 Prill Cooler Scrubber Visible Emissions Observation Location
at CF Industries, Inc., Harrison, Tennessee 98
4-14 Neutralizer Scrubber Visible Emissions Observation Locations
at CF Industries, Inc., Harrison, Tennessee 99
5-1 Modified EPA Particulate Sampling Train
August 18, 1977 Federal Register 104
5-2 Typical In-Stack Orifice and Nozzle Assembly 107
-------
LIST OF TABLES
TABLE PAGE
2-la Summary of Ammonium Nitrate and Insoluble Particulate
Measurements on Gases Entering and Exiting the Prill Tower
Scrubber at CF Industries, Inc., Harrison, Tennessee
(English) 9
2-lb Summary of Ammonium Nitrate and Insoluble Particulate
Measurements on Gases Entering and Exiting the Prill Tower
Scrubber at CF Industries, Inc., Harrison, Tennessee
(Metric) 10
2-2 Summary of Ammonium Nitrate and Insoluble Particulate
Measurements on Gases Entering the Prill Tower Scrubber
at CF Industries, Inc., Harrison, Tennessee 11
2-3 Summary of Ammonium Nitrate and Insoluble Particulate
Measurements Exiting the Prill Tower Scrubber at
CF Industries, Inc., Harrison, Tennessee 12
2-4a Summary of Ammonia and Calculated Ammonium Nitrate
Measurements on Gases Entering and Exiting the Prill
Tower Scrubber at CF Industries, Inc., Harrison, Tennessee
(English) 13
2-4b Summary of Ammonia and Calculated Ammonium Nitrate
Measurements on Gases Entering and Exiting the Prill Tower
Scrubber at CF Industries, Inc., Harrison, Tennessee
(Metric) 14
2-5 Summary of Ammonia, Calculated Ammonium Nitrate and
Calculated Excess Ammonia Measurements on Gases Entering
the Prill Tower Scrubber at CF Industries, Inc., Harrison,
Tennessee 15
2-6 Summary of Ammonia, Calculated Ammonium Nitrate and
Calculated Excess Ammonia Measurements on Gases Exiting the
Prill Tower Scrubber at CF Industries, Inc., Harrison, Tennessee 16
2-7a Summary of Magnesium Measurements on Gases Entering and
Exiting the Prill Tower Scrubber at CF Industries, Inc.,
Harrison, Tennessee
(English) 18
2-7b Summary of Magnesium Measurements on Gases Entering and
Exiting Prill Tower Scrubber at CF Industries, Inc.
Harrison, Tennessee
(Metric) 19
-------
LIST OF TABLES (Continued)
TABLE PAGE
2-8a Summary of Ammonium Nitrate and Insoluble Particulate
Measurements on Gases Entering and Exiting the Prill Cooler
Scrubber at CF Industries, Inc., Harrison, Tennessee
(English) 20
2-8b Summary of Ammonium Nitrate and Insoluble Particulate
Measurements on Gases Entering and Exiting the Prill Cooler
Scrubber at CF Industries, Inc., Harrison, Tennessee
(Metric) 21
2-9 Summary of Ammonium Nitrate and Insoluble Particulate
Measurements on Gases Entering the Prill Cooler Scrubber
at CF Industries, Inc., Harrison, Tennessee 22
2-10 Summary of Ammonium Nitrate and Insoluble Particulate
Measurements on Gases Exiting the Prill Tower Scrubber
at CF Industries, Inc., Harrison, Tennessee 23
2-lla Summary of Ammonia and Calculated Ammonium Nitrate
Measurements on Gases Entering and Exiting the Prill
Cooler Scrubber at CF Industries, Inc., Harrison,
Tennessee (English) 25
2-llb Summary of Ammonia and Calculated Ammonium Nitrate
Measurements on Gases Entering and Exiting the Prill Cooler
Scrubber at CF Industries, Inc., Harrison, Tennessee
(Metric) 26
2-12 Summary of Ammonia, Calculated Ammonium Nitrate and
Calculated Excess Ammonia Measurements on Gases Entering
the Prill Cooler Scrubber at CF Industries, Harrison, Tennessee 27
2-13a Summary of Ammonia, Calculated Ammonium Nitrate and
Calculated Excess Ammonia Measurements on Gases from the
Prill Cooler Scrubber East Outlet at CF Industries, Inc.,
Harrison, Tennessee 28
2-13b Summary of Ammonia, Calculated Ammonium Nitrate and
Calculated Excess Ammonia Measurements on Gases from the
Prill Cooler Scrubber West Outlet at CF Industries, Inc..,
Harrison, Tennessee 29
2-14a Summary of Ammonium Nitrate and Insoluble Particulate
Measurements on Gases Entering and Exiting Neutralizer No. 1
Scrubber at CF Industries, Inc., Harrison, Tennessee
(English) 30
-------
LIST OF TABLES (Continued)
TABLE PAGE
2-14b Summary of Ammonium Nitrate and Insoluble Particulate
Measurements on Gases Entering and Exiting Neutralizer No. 1
Scrubber at CF Industries, Inc., Harrison, Tennessee
(Metric) 31
2-15 Summary of Ammonium Nitrate and Insoluble Particulate
Measurements on Gases Entering Neutralizer No. 1 Scrubber
at CF Industries, Inc., Harrison, Tennessee 32
2-16 Summary of Ammonium Nitrate and Insoluble Particulate
Measurements on Gases Exiting Neutralizer No.l Scrubber
at CF Industries, Inc., Harrison, Tennessee 33
2-17 Summary of Ammonium Nitrate and Insoluble Particulate
Measurements on Gases Exiting Neutralizer No. 2 Scrubber
at CF Industries, Inc., Harrison, Tennessee 34
2-18a Summary of Ammonia and Calculated Ammonium Nitrate
Measurements on Gases Entering and Exiting Neutralizer No. 1
Scrubber at CF Industries, Inc., Harrison, Tennessee
(English) 36
2-18b Summary of Ammonia and Calculated Ammonium Nitrate
Measurements on Gases Entering and Exiting Neutralizer No. 1
Scrubber at CF Industries, Inc., Harrison, Tennessee
(Metric) 37
2-19 Summary of Ammonia, Calculated Ammonium Nitrate and
Calculated Excess Ammonia Measurements on Gases Entering
the Neutralizer No. 1 Scrubber at CF Industries, Inc.,
Harrison, Tennessee 38
2-20 Summary of Ammonia, Calculated Ammonium Nitrate and
Calculated Excess Ammonia Measurements on Gases Exiting
Neutralizer No. 1 Scrubber at CF Industries, Inc.,
Harrison, Tennessee 39
2-21 Summary of Ammonia, Calculated Ammonium Nitrate and
Calculated Excess Ammonia Measurements on Gases Sampled
at 200% Isokinetic Exiting Neutralizer No. 2 Scrubber at
CF Industries, Inc., Harrison, Tennessee 40
2-22 Summary of Ammonia, Calculated Ammonium Nitrate and
Calculated Excess Ammonia Measurements on Gases Sampled
at 50% Isokinetic Exiting Neutralizer No. 2 Scrubber at
CF Industries, Inc., Harrison, Tennessee 41
-------
LIST OF TABLES (Continued)
TABLE PAGE
2-23 Summary of Ammonium Nitrate and Insoluble Particulate
Measurements on Gases Exiting the Calandria Evaporator
at CF Industries, Harrison, Tennessee 43
2-24 Summary of Ammonium Nitrate and Insoluble Particulate
Measurements on Combined Gases Exiting both the Calandria
Evaporator and the Air-Swept Falling-Film Evaporator at
CF Industries, Inc., Harrison, Tennessee 44
2-25 Summary of Ammonia, Calculated Ammonium Nitrate and
Calculated Excess Ammonia Measurements on Gases Exiting
the Calandria Evaporator at CF Industries, Inc., Harrison,
Tennessee 45
2-26 Summary of Ammonia, Calculated Ammonium Nitrate and
Calculated Excess Ammonia Measurements on Combined
Gases Exiting both the Calandria Evaporator and the Air-
Swept Falling-Film Evaporator at CF Industries, Harrison,
Tennessee 46
2-27 Summary of Insoluble Particulate, Ammonium Nitrate
Particulate and Ammonia Calculated Mass Flowrates
from the Air-Swept Falling-Film Evaporator at CF Industries,
Inc., Harrison, Tennessee 48
2-28 Summary of Measurements on the Prill Tower Scrubber Liquor
at CF Industries, Inc., Harrison, Tennessee 51
2-29 Summary of Measurements Made on Prill Cooler Scrubber Liquor
at CF Industries, Harrison, Tennessee 52
2-30 Summary of Measurements Made on the Neutralizer No. 1
Scrubber Inlet Liquor at CF Industries, Inc., Harrison,
Tennessee 53
2-31 Summary of Pressure Drop Measurements Made Across the
Prill Tower Scrubber at CF Industries, Inc., Harrison, Tennessee 54
2-32 Summary of Pressure Drop Measurements Made Across the
Prill Cooler East Scrubber at CF Industries, Harrison,
Tennessee 55
2-33 Summary of Pressure Drop Measurements Made Across the
Prill Cooler West Scrubber at CF Industries, Inc., Harrison,
Tennessee 56
2-34 Summary of Pressure Drop Measurements Made Across the
Neutralizer No. 1 Scrubber at CF Industries, Inc., Harrison,
Tennessee 57
-------
LIST OF TABLES (Continued)
TABLE PAGE
2-35 Summary of Ambient Air Measurements at the Prill Tower
at CF Industries, Inc., Harrison, Tennessee 59
2-36 Summary of Ambient Air Measurements Made at the Prill
Cooler at CF Industries, Inc., Harrison, Tennessee ... 60
2-37 Summary of Ambient Air Measurements Made at the
Neutralizers and Evaporators at CF Industries, Inc.,
Harrison, Tennessee 61
2-38 Summary of Sieve Analysis and Bulk Density Measurements
on the Solid Product Sampled Before Entering the Prill Cooler
at CF Industries, Inc., Harrison, Tennessee 63
2-39 Summary of Sieve Analysis and Bulk Density Measurement on
the Solid Product Leaving the Prill Cooler (Before Screening)
at CF Industries, Inc., Harrison, Tennessee 64
3-1 Average Values of Neutralizer and Evaporator Operating
Parameters During Emissions Testing 75
3-2 Average Values of Prill Tower Operating Parameters During
Prill Tower Emissions Testing 76
3-3 Average Values of Prill Tower and Prill Cooler Operating
Parameters During Cooler Emissions Testing 77
5-1 Comparison of Ammonia Analysis Results from Emissions Tests
at CF Industries, Inc., Harrison, Tennessee 114
-------
1.0 INTRODUCTION
1.1 Background
WJ
Section ^r of the Clean Air Act of 1970 charges the Administrator of the
U.S. Environmental Protection Agency (EPA) with the responsibility of
establishing Federal standards of performance for new stationary sources which
may significantly contribute to air pollution. When promulgated, these
standards of performance for new stationary sources (SPNSS) are to reflect the
degree of emission limitation achievable through application of the best
demonstrated emission control technology. EPA utilizes emission data,
obtained from controlled sources in the particular industry under
consideration, as a partial basis for SPNSS.
EPA's Office of Air Quality Planning and Standards (OAQPS) selected the CF
Industries, Inc., ammonium nitrate manufacturing plant at Harrison, Tennessee
as a site for an emission test program. This plant produces ammonium nitrate
for industrial and fertilizer use, and is considered to employ process and
emission control technology representative of high density ammonium nitrate
solution production, concentration, prilling and rotary drum cooling
processes. The test program was designed to provide a portion of the emission
data base required for SPNSS for the processes associated with the production
of ammonium nitrate.
EPA engaged TRC to measure ammonium nitrate and ammonia concentrations and
mass flowrates; particle size distributions; and plume opacities. All
measurements made at this facility were performed during times of normal
operation of the ammonium nitrate production process, as described in Section
3.0, Process Description and Operations.
-1-
-------
The measurement program was conducted at the CF Industries, Inc., ammonium
nitrate manufacturing facility in Harrison, Tennessee during the weeks of May
7 through May 11 and June 18 through June 22, 1979. The emissions tests
performed May 8 - 11, 1979 were designed to characterize and quantify
uncontrolled emissions from the solids production process (Prill Tower and
Prill Cooler) and to determine control equipment efficiency. The emissions
tests performed June 19 - 22, 1979 were designed to characterize and quantify
uncontrolled emissions from the solution production process (neutralizers and
evaporators) and to determine emission control efficiency.
1.2 General Process Description
Figure 1-1 presents a flow diagram of the production process, described
very basically as follows:
Nitric acid and ammonia are fed to two parallel
neutralizers, from which an 85% ammonia nitrate (AN)
solution flows into a common surge tank. The AN solution
then passes through a two-stage evaporator where it is
concentrated to greater than 99%. A magnesium nitrate
additive is added between the first evaporator (Calandria
Concentrator) and the second evaporator (Air-Swept
Falling-Film Evaporator). The 99+ percent solution is
then pumped to the top of the Prill Tower, through which
AN droplets fall countercurrent to an induced air flow.
The solid prill product is collected at the bottom of the
tower and is conveyed to a rotary drum cooler where it is
cooled and dried. After screening, correctly-sized prills
are conveyed to storage bins.
The air flow through the Prill Tower is directed to a Koch
valve tray scrubber. The rotary drum cooler exhaust air
stream is divided into two separate streams, each of which
enters a separate spray chamber scrubber. The air exiting
each spray chamber is again divided into two streams, each
of which enters a separate cyclonic separator. The four
separator outlets are then combined into two. Emissions
vented from each of the neutralizers are driven by the
-2-
-------
TO ATMOSPHERE
A
I
CYCLOHIC SEPARATORS
VENTURI
SCRUBBERS ,
i
I
I
i
£
*
BUTTERFLY VALVE
1
NEUTRALIZE NEUTRALJZERl
L_J U-J©(
AS .
AIR FL01
< >
'BALANCE
I VENT
I
X; „«
/ ] «•
ess AN
SURGE TANK
/
\
\
94X AN
ess
ADDITIVE
PRODUCTION
1
CALANDRIA
CONCENTRATOR
AIR-SWEPT
rALUNG-FILN
EVAPORATOR
J/c
JCDt -I
cs
s
EAST NEST
PRILL
TOWER
^
TO ATMOSPHERE
i*
r
t
r-,.-----=i
-------
internal operating pressure of the neutralizers through
venturi-cyclonic separator scrubbers. Emissions venting
from the evaporators are normally ducted to the Koch valve
tray scrubber along with the Prill Tower emissions; for
this testing program, however, evaporator emissions were
vented directly to the atmosphere.
1.3 Measurement Program
The measurement program was conducted at the CF Industries, Inc., ammonium
nitrate manufacturing facility in Harrison, Tennessee, during the weeks of May
7 - 11, and June 18 - 22, 1979. TRC personnel were responsible for sampling
and analyzing process emissions; concurrently, GCA was responsible for
monitoring pertinent process operation parameters.
Several of the test runs at the neutralizers were discontinuous due to
excessive amounts of water in the gas streams. These interruptions are
indicated in the Daily Summary Logs contained in Appendix D.
The components of the measuring program were as follows.
i
1.3.1 Prill Tower Scrubber
Ammonium Nitrate, Ammonia and Magnesium in Gas Stream
Three runs of concurrent inlet and outlet tests were performed in
accordance with prescribed EPA methods.
Particle Size Distribution in Gas Stream
Three test runs on the inlet gas stream were performed with a cascade
impactor in accordance with the impactor manufacturer's procedures.
Visible Emissions
The opacity of the Prill Tower scrubber exhaust plume was monitored
for approximately seven hours during the May testing period.
Scrubber Liquor Evaluation
Samples of the inlet and outlet scrubber liquor were collected
periodically during each test run. The temperature and pH of the
-4-
-------
samples were measured, and the samples were subsequently analyzed for
ammonium nitrate, ammonia and undissolved solids.
Pressure Drop Across Scrubber
The gas pressure drop across the scrubber was measured periodically
during each test run.
1.3.2 Prill Cooler Scrubber
Ammonium Nitrate and Ammonia in Gas Stream
Three test runs were performed on the single common inlet to the
spray chamber scrubbers and on the two cyclonic separator outlets.
Visible Emissions
The opacities of the two Prill Cooler scrubber system exhaust plumes
were monitored simultaneously for three hours during the May testing
period.
Particle Size Distribution in Gas Stream
Three test runs on the inlet gas stream were performed with a cascade
impactor in accordance with the impactor manufacturer's procedures.
Scrubber Liquor Evaluation
Samples of the common inlet and common outlet scrubber liquor were
collected periodically during each test run.
Pressure Drop Across Scrubber
The gas pressure drops across the scrubber (measured with two
manometers from the common scrubber system inlet to both of the
scrubber system outlets) were measured periodically during each test
run.
1.3.3 Neutralizers
Ammonium Nitrate and Ammonia in Gas Streams
Three runs of concurrent inlet and outlet tests were performed on
Neutralizer No. 1 scrubber, and three separate runs were performed on
the outlet of Neutralizer No. 2 scrubber. EPA test methods for high
water-content gas streams were followed.
Visible Emissions
The combined opacity of the two neutralizer scrubber plumes was
monitored for three hours during the June test period.
-5-
-------
Scrubber Liquor Evaluation
Samples of the Neutralizer No. 1 scrubber inlet liquor were collected
periodically during the three test runs.
Pressure Drop Across Scrubber
The gas pressure drop across the Neutralizer No. 1 scrubber was
measured periodically during the test runs.
Integrated Gaseous Bag Samples
Bag samples of the Neutralizer No. 1 inlet gas stream were analyzed
for C02 and 02- One bag sample was taken during each of the
three test runs.
1.3.4 Evaporators
Ammonium Nitrate and Ammonia in Gas Streams
Three test runs on the Calandria outlet and three test runs on the
combined Calandria and Air-Swept Falling-Film Evaporator outlet were
performed.
1.3.5 Product Sampling and Analysis
Prill Tower
The ammonium nitrate (AN) feed melt to the Prill Tower and the solid
AN prills from the tower were sampled and analyzed.
Prill Cooler
The solid AN prills from the cooler before screening were sampled and
analyzed.
Neutralizer
The 85% AN feed from Neutralizer No. 1 to the surge tank was sampled
and analyzed.
Evaporators
The 85% AN feed from the surge tank to the Calandria, the 94% AN feed
from the Calandria to the Air-Swept Falling-Film . (ASFF) Evaporator,
and the 99% AN feed from the ASFF evaporator to the Prill Tower were
sampled and analyzed.
-6-
-------
1.3.6 Ambient Air Measurements
Ambient air temperature, relative humidity and barometric pressure
measurements were taken periodically during the Prill Tower, Prill Cooler,
Neutralizer and Evaporator test runs. Measurements were made in the immediate
vicinity of the process involved.
1.3.7 Clean-up Evaluation and Audit Samples
The sampling train was assembled and charged as if ready to perform a test
for ammonium nitrate (AN) and ammonia. The unexposed impinger contents were
<>
then recovered, prepared and analyzed according to procedure in order to
establish background/contamination levels of AN and ammonia.
Audit samples from EPA and from CFI were analyzed for ammonia and nitrate
after both the May and June testing periods in order to assess the accuracy of
the analysis procedures.
1.4 Description of Report Sections
The remaining sections of this report cover Summary of Results (Section
2.0), Process Description and Operations (Section 3.0), Location of Sampling
Points (Section 4.0), and Sampling and Analytical Methods (Section 5.0).
Descriptions of methods and procedures, field and laboratory data, and
calculations are presented in the various appendices, as noted in the Table of
Contents. Appendix R contains the results of the clean-up evaluations
performed on the sampling train equipment, and Appendix Q contains the results
of audit sample analyses.
-7-
-------
2.0 SUMMARY OF RESULTS
This section presents the results of emissions tests performed at the CF
Industries Inc./ Harrison, Tennessee, ammonium nitrate manufacturing plant in
May and June 1979. During this testing program, the gas and water streams
entering and exiting the prill tower scrubber, prill cooler scrubber and
neutralize scrubbers, and the gas streams from the Calandria and air-swept
falling-film evaporators, were sampled and analyzed. The process product was
also sampled periodically during the emissions tests and analyzed.
2.1 Prill Tower Scrubber
The ammonium nitrate and insoluble particulate measurements made on the
prill tower scrubber inlet and outlet gas stream samples are shown in Tables
2-1 (combined inlet and outlet), 2-2 (inlet) and 2-3 (outlet). The average
total particulate (ammonium nitrate plus insoluble particulate) removal
efficiency is 46.9 percent.
The ammonia measurements made on the inlet and outlet gas stream samples
are shown in Tables 2-4 (combined inlet and outlet), 2-5 (inlet) and 2-6
(outlet). The average ammonia removal efficiency is 83.7 percent. Tables 2-5
and 2-6 also show a parameter labelled excess ammonia. Assuming that nitrate
is the limiting factor in the conversion of ammonia and nitric acid to
ammonium nitrate, excess ammonia is calculated by subtracting the ammonia
(presumably) combined with the measured nitrate from the total measured
ammonia.
The anomalously low ammonia measurements in Run 3 are probably due to the
fact that the ammonia injection mechanism on the prill tower was off during
this run. Consequently the Run 3 ammonia data are not included in the
averages.
-8-
-------
TABLE 2-la (ENGLISH)
SUMMARY OP AMMONIUM NITRATE AND INSOUIBI.E PART1CUUTE MEASUREMENTS
ON GASES ENTERING AND EXITING TUB PRILL TOWER SCRUBBER
AT C l; INDUSTRIES, INC., HARRISON, TENNESSEE
vo
I
RUN NUMBER
DATE
LOCATION
VOUJME OP CAS SAMPLED (USCF)3
PERCENT MOISTURE BY VOLUME
AVERAGE STACK TEMPERATURE ( E) ,
STACK VOLUMETRIC FLOW3ATE (DSCFM)
PERCEW ISOKfNETIC
PERCENT OPACITY
PRODUCTION RATE (TONS/HOUR)
INSOLUBLE PARTICUIATE
RUN 1
Total SampJe Weight (Mil li grains)
Gra i ns/DSCF
Pounds/hour
Pounds/Ton
Collection Efficiency (Percent)
AMMONIUM NITRATE PARTICULATEC
Total Sample Weight (Milligrams)
Grains/DSCF'
Pounds/Hour
Pounds/Ton
Collection Efficiency (Percent)
TOTAL PARTI CULATE; INSOLUBLE
NITRATE
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
Collection Efficiency (Percent)
05-08-79
INLET
OUTLET
12.79
0.003004
6.638
0.3161
5.52
0.000837
1.904
0.0907
71.3
133.52
0.03136
69.29
3.299
101.14
0.01535
34.88
1.661
49.7
RUN 2
05-08-79
INLET OUTWIT
RUN 3
AVERAGE
4.97
0.001191
2.592
0.1234
11.47
0.001700
3.842
0.1830
<0
124.36 101.55
0.02979 0.01506
64.83 34.02
3.087 1.620
47.5
05-09-79
INLET
OUTLET
65.7
2.049
93
257800
99.3
21.0
101.7
3.033
96
265200
108.4
12.8
21.0
64.42
2.466
91
253900
98.9
21.0
104.1
2.56
95
263700
110.8
15.2
21.0
65.86
2.542
91
258500
99.3
21.3
98.95
2.874
91
268500
103.5
17.2
21.3
0.52
0.000122
0.270
0.0127
1.95
0.000304
0.700
0.0329
<0
45.5
INLET
OUTLET
65.33
2.352
92
256700
99.2
21.1
101.58
2.822
94
265800
107.6
15.1
21.1
6.09
0.001439
3.165
0.1500
6.31
0.000959
2.184
0.1035
31.0
134.81
0.03159
69.99
3.286
106.30
0.01658
38.16
1.792
130.90
0.03092
68.02
3.224
103.00
0.01565
35.64
1.688
47.6
146.31
0.03436
75.93
3.615
106.66
0.01618
36.78
1.752
51.6
129.33
0.03097
67.42
3.210
113.02
0.01675
37.85
1.802
43.9
135.33
0.03171
70.26
3.299
108.25
0.01688
38.85
1.824
44.7
136.99
0.03236
71.19
3.378
109.31
0.01661
37.82
1.793
46.9
a Dry standard cubic feet € 68 E, 29.92 inches llg
b Dry standard cubic feet per minute
c Specific ion electrode analysis method. This method measures nitrate (NOj-); Ammonium Nitrate (mg) = Nitrate (mg) X 80/62.
-------
TABLE 2-lb (Metric)
SUMMARY OF A^MONIUM NITRATE AND INSOLUBLE PARTICUIATE MEASUREMENTS
ON GASES ENTERING AND EXITING TIE PRILL TOWER SCRUBBER
AT C F INDUSTRIES, INC.,
HARRISON, TENNESSEE
O
I
RUN NUMBER
DATE
LOCATION
VOLUME OF GAS SAMPLED (W m3)3
PERCENT MOISTURE BY VOLUME
AVERAGE STACK TEMPERATURE (°C) .
STACK VOLUMETRIC FLOWRATE (DN m3/nun)°
PERCENT ISOKINETIC
PERCENT OPACITY
PRODUCTION RATE (Mg/Uour)
INSOLUBLE PARTICULATE
Total Sample Weight (Milligrams)
Grams/DN m3
Kg/lbur
Kg/Mg
Collection Efficiency (Percent)
AMMONIUM NITRATE PARTICULATEC
Total Sample Weight (Milligrams)
Grams/DN m3
Kg/Hour
Kg/Mg
Collection Efficiency (Percent)
TOTAL PARTICULATE :
INSOLUBLE 6 AMMONIUM NITRATE
Total Sample Weight (Milligrams)
Grams/DN m3
Kg/I four
Kg/Mg
Collection Efficiency (Percent)
Run 1
05-08-79
Inlet
Outlet
Run 2
05-08-79
Inlet Outlet
Run 3
05-09-79
Inlet Outlet
1.861
2.049
34
7300
99.3
19.1
2.880
3.033
36
7510
108.4
12.8
19.1
1.824
2.466
33
7190
98.9
19.1
2.948
2.56
35
7470
110.8
15.2
19.1
1.865
2.542
33
7320
99.3
19.3
2.802
2.874
33
7600
103.5
17.2
19.3
71.3
<0
Inlet
Outlet
1.850
2.352
33
7270
99.2
19.2
2.877
2.822
35
7530
107.6
15.1
19.2
12.79
0.006873
3.011
0.1581
5.52
0.001916
0.864
0.0454
4.97
0.002725
1.176
0.0617
11.47
0.003890
1.743
0.0915
0.52
0.000279
0.122
0.0064
1.95
0.000696
0.318
0.0165
6.09
0.00329
1.436
0.0750
6.31
0.00219
0.991
0.0518
31.0
133.52 101.14 124.36 101.55 134.81 106.30 130.90 103.00
0.07175 0.03512 0.06816 0.03446 0.07228 0.03794 0.07075 0.03585
31.43 15.82 29.41 15.43 31.75 17.31 30.86 16.16
1.650 0.831 1.544 0.811 1.643 0.896 1.612 0.844
49.7 47.5 45.5 47.6
146.31
0.07862
34.44
1.808
106.66
0.03702
16.68
0.876
51.6
129.33
0.07086
30.58
1.605
113.02
0.03832
• 17.17
0.902
43,9
135.33
0.07256
31.87
1.650
108.25
0.03862
17.62
0.912
44.7
136.99
0.07404
32.29
1.689
109.31
0.0380]
17.16
0.896
47.6
a Dry normal cubic meters 8 20 C, 760 mm llg .
b Dry normal cubic meters per minute.
c Specific Ion Electrode Analysis method. This method measures nitrate (N03-); Ammonium Nitrate (mg) = Nitrate (mg) x 80/62.
-------
TABLE 2-2
SUMMARY OF ANMONIUM NITRATE AND INSOUIBI.E PART1CU1.ATE MEAS1JRP.MENTS
ON CASK ENTERING 'HIP, TRILL TOWT.R SCRUBBER AT
C P INDUSTRIES, INC., HARRISON, TENNESSEE
RUN NUMBER
DATE
VOLUME Ol; C-AS SAMl'I.ED (lXSCP)a
PERCENT MOISTURE BY V01AJME
AVERAGE STACK TEMPERATURE (-°l;) .
STACK VOLUMETRIC FIX)W RATE (DSCIM)
PERCENT ISOKINETIC
PRODUCTION RATE (TONS/HOUR)
INSOLUBLE PARTICUIATE
Total Siiinple Weight (Milligrams)
Grains/nSCI-
Pounds/Hour
Pounds/Ton
AMMONIUM NITRATE PAKTICULATE C
Total Sample Weiglit (Milligrams)
Gr;iins/nSCI:
Pounds/Hour
Pounds/Ton
TOTAL PART1CULATE: INSOLUltLE AND
AMNJONUIM'NITRATE
Total Siiinple Weight (Milligrnnis)
Gralns/RSCP
I'ounds/llour
Pounds/Ton
PERCI-NI' PARTICUUTE CATCH*
RUN 1
05-08-79
65.70
2.049
93
257,800
99.3
21.0
12.79
0.003004
6.638
133.52
0.03130
69.29
3.299
146.31
0.03436
75.93
3.615
8.7
RUN 2
05-08-79
64.42
2.466
91
253,900
98.9
21.0
4.97
0.001191
2.592
124.36
0.02979
64.83
3.087
129.33
0.03077
67.42
3.210
3.8
RUN 3
05-09-79
65.86
2.542
91
258,500
99.3
21.3
0.52
0.000122
0.270
134.81
0.03159
69.99
3.286
135.33
0.03171
70.26
3.299
0.38
AVERAGE
65.33
2.352
92
256,700
99.2
21.1
6.09
0.001439
3.165
130.90
0.03092
68.02
3.224
136.99
0.03236
71.19
3.378
4.4
3 Dry standard cuhic feet @ 68°P, 29.92 inches Hfi.
3 Dry standard cubic feet per minute @ 68°P, 29.92 inches llg.
Specific Ion Electrode analysis method. This method measures nitrate (NO^-); Ammonium nitrate (nig) = nitrate (ing) X 80/62.
* (Insoluble Particulate/Total Particulatc) X 100.
-------
TABLE 2-3
SllfMARY OF ANMONIUM NITRATE AND INSOIUBLE PARTICULATE MEASUREMENTS
ON GASES EXITING TIE PRILI, TOWER SCRUBBER AT
C F INDUSTRIES, INC., HARRISON, TENNESSEE
RUN NUMBER
DATE
VOLUME OF GAS SAMPLED (DSCF)a
PERCENT MOISRIRE BY VOLUME
AVERAGE SFACK TEMPERATURE (°F)
STACK VOLUMETRIC FI.OW RATE
PERCF.NF ISOKINETIC
PRODUCTION RATE (TONS/HOUR)
INSOLUBLE PARTICULATE
Total Sample Weight (Milligrams)
Grains/l)SCI!
Pounds/Hour
Pounds/Ton
ANMONIUM NITRATE PARTICULATE C
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
TOTAL PARTIQ1LATE: INSOLUBLE AND
ANMONIUM NITRATE
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
PERCENT PARTTCULATE CATCH *
RUN 1
05-08-79
101.70
3.033
96
265200
108.4
21.0
5.52
0.000837
1.904
0.0907
101.1.4
0.01535
34.88
1.661
106.66
0.01618
36.78
1.752
5.2
RUN 2
RUN 3
AVERAGE
05-08-79
104.10
2.560
95
263700
110.8
21.0
11.47
0.001700
3.842
0.1830
101.55
0.01506
34.02
1.620
05-09-79
98.95
2.874
91
268500
103.5
21.3
1.95
0.000304
0.700
0.0329
106.30
0.01658
38.16
1.792
101.58
2.822
94
265800
107.6
21.1
6.31
0.000959
2.184
0.1035
103.00
0.01565
35.64
1.688
113.02
0.01675
37.85
1.802
10.1
108.25
0.01688
38.85
1.824
1.8
109.31
0.01661
37.82
1.793
5.8
Dry standard cubic feet % 68°F, 29.92 inches llg.
°
Dry standard cubic feet per mjnute @ 68F, 29.92 inches llg.
c Specific 'on Electrode analysis method. This method measures nitrate (NOj-); ammonium nitrate (mg) = nitrate (nig) X 80/62.
* (Insoluble Particulate/Total Particulate) X 100.
-------
TABLE 2-4a (English)
SUMMARY OF AMMONIA AND CALCULATED AMMONIUM NITRATE MEASUREMENTS
ON GASES ENTERING AND EXITING THE PRILL TOWER SCRUBBER AT
C F INDUSTRIES, INC., HARRISON, TENNESSEE
RUN NUMBER
DATE
LOCATION
VOLUME OP GAS SAMPLED (DSCF)a
PERCENT MOISTURE BY VOIUME
AVERAGE STACK TEMPERATURE (°F) .
STACK VOLUMETRIC F1X3WRATE (DSCFM)
PERCENT 1SOKINETIC
PRODUCTION RATE (TONS/HOUR)
AMWN1A DATA c
Total Sample Weight (Milligrams)
Graiiis/DSCP
Pounds/I tour
Pounds/Ton
Collection Efficiency (Percent)
AMMONIUM NITRATE CAJ.Q1LATED
FROM AMMONJA?
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
Collection Efficiency (Percent)
Run 1
05-08-79
INLET
65.70
2.049
93
257,800
99.30
21.0
2372
0.55715
1231.1
58.62
83.4
11162
2.6218
5793.4
275.9
83.4
OUTLET
101.70
3.033
96
265,200
108.4
21.0
593
0.08998
204.5
9.74
2791
0.4235
962.7
45.8
Run 2
05-08-79
INLET OUTLET
64.42
2.466
91
253,900
98.86
21.0
104.10
2.560
95
263,700
110.8
21.0
2330
0.55816
1214.7
57.85
10965
2.6267
5716.5
272.2
84.7
554
0.08212
185.6
8.84
2607
0.3865
873.7
41.60
Run 3
05-09-79
INLET OUTLEf
65.86
2.542
91
258,500
99.25
21.3
98.95
2.874
91
268,500
103.5
21.3
114.5
0.02683
59.4
2.79
539
0.1263
279.8
13.1
<0
84.7
199.4
0.03110
71.6
3.36
938
0.1463
336.7
15.8
INLET
OUTLET
65.33
2.352
92
256,700
99.14
21.2
101.58
2.822
94
265,800
107.6
21.2
2351
0.5S535
1221.8
57.63
11064
2.6135
5749.5
271.2
83.7
574
0.08721)
198.7
9.40
<0
83.7
2701
0.4104
934.9
4'1.15
a Dry standard cubic feet @ 68 F, 29.92 inches llg.
b Dry standard cubic feet per minute.
c Specific Ion Electrode analysis method.
d Ammonium nitrate (ing) = Ammonia (ing) x 80/17.
e Ammonia and Ammonium nitrate averages include only Runs 1 and 2.
-------
TABLE 2-11) (Metric)
SUMMARY OF AMMONIA AND CALCULATED AMMONIUM NITRATE MEASUREMENTS
ON GASES ENTERING AND EXITING 'nil: PRILL TOWER SCRUBBER
AT C.l: INDUSTRIES, INC.,
IIAKUlSON, TENNESSEE
RUN NUMBER
DATE
IjOCATlON
VOLUME OF GAS SAMPLED (DNm3)
PERCENT MOISTURE BY VOLUME
AVERAGE STACK TEMPERATURE
STACK VOLUMETRIC FLOWRATE
PERCKNI1 ISOKINET1C
I PRODUCT!1 ION RATE (Mg/Hour)
I AMMONIA DATAC
Total Sample Weight (Milligrams)
Grams/DNin3
Kg/Hour
KB/MB
Col lection Efficiency (Percent)
A>MONIUM NITRATE CALCULATED FROM
AMWNIA~a
Total Sample Weight (Milligrams)
Grams/DNm3
Kg/Hour
Kg/Mg
Collection Efficiency (Percent)
RUN 1
05-08-79
RUN 2
05-08-79
RUN 3
05-09-79
AVERAGE1
INLET
OUTLET
INLET
OUTLET
INLET
OUrLET
11162
5.999
2628
137.95
2791
0.9690
436.7
22.9
83.4
10965
6.010
2593
136.11
84.7
2 607
0.8843
396. 3
20.80
539
0.2890
126.9
6.55
<0
938
0.3347
152.7
7.9
INLET
arnirr
*)•
(°c) 3
ligrams)
;rcent)
1.861
2.049
,h 3"
inn)1 7300
99.3
19.1
2372
1.275
558.4
29.31
2.880
3.033
36
7510
108.4
19.1
593
0.2059
92.76
4.87
83.4
1.824
2.466
33
7190
98.9
19.1
2330
1.277
551.0
28.92
2.948
2.560
35
7470
110.8
19.1
554
0.1879
84.21
4.42
84.7
1.865
2.542
33
7320
99.3
19.3
114. S
0.06139
26.94
1.40
<0
2.802
2.874
33
7600
103.5
19.3
199.4
0.07116
32.48
1.68
1.850
2.352
33
7270
99.1
19.2
2351
1.271
554.2
28.82
83.7
2.877
2.822
35
7530
107.6
19.2
574
0.1995
90.12
4.69
11064 2701
5.980 0.9389
2608 424.1
135.6 22.07
83.7
Dry normal cubic meters @ 20C, 760 mm llg.
Dry normal cubic meters per minute.
Specific Ion Electrode Analysis method.
Ammonium nitrate (nig) = Ammonia (mg) X 80/17.
Ammonia and ammonium nitrate averages include only Runs 1 and 2.
-------
TABLE 2-5
SUMMARY OF AMMONIA, CAIjCULATED AMMONIUM NITRATE AND CALCULATED EXCESS AMMONIA MEASURt-MENTS
ON GASES ENTERING '11 IE PRILL TOWT.R SCRUBBER AT
C F INDUSTRIES, INC., HARRISON, TENNESSEE
Ln
I
RUN NUMBIiR
DATE
VOLUME 01; GAS SAMPLED (DSCF)a .
STACK VOLUMETRIC FIjOW RATE (DSCFM)
PRODUCTION RATE (TONS/HOUR)
AMMONIA C
Total Sample Weight (Milligrams)
Grains C.DSGF)
Pounds/Hour
Pounds/Ton
AMMONIUM NITRATE CALCULATED
FRCM AMMONIAC
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
EXCESS AMMONIA e
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
RUN 1
05-08-79
65.70
257800
21.0
2372
0.55715
1231.1
58.62
11162
2.6218
5793
275.9
234-1
0.5506
1217
57.95
RUN 2
05-08-79
64.42
253900
21.0
2330
0.55816
1214.7
57.85
10965
2.6267
5716
272.2
2304
0.5520
1202
57.22
RUN 3
05-08-79
65.86
258500
21.3
114.5
0.02683
59.4
2.79
539
0.1263
280
13.1
85.8
0.0201
44.55
2.092
AVERAGE'
65.33
256700
21.1
2351
0.55535
1221.8
57.63
11064
2.6135
5749
271.2
2323
0.5488
1207
57.21
a
b
c
d
c
f
Dry standard cubic feet e 68 F, 29.92 inches Mj',.
Dry standard cubic feet per minute @ 68°F, 29.92 inches Mg.
Specific Ion Electrode analysis method.
Ammonium nitrate (mg) = ammonia (mg) X 80/17.
Excess Ammonia = {(Aiiinonium nitrate calculated from ammonia) - (AmmoniiDii nitrate measured directly, from Table 2-2)1 X 17/80.
Ammonia, calculated ammonium nitrate and excess ammonia averages are calculated from RIIPS 1 and 2 only.
-------
TABLE 2-6
SUMMARY OP AMMONIA, CALCULATED ANMONIIW NITRATE AND CAU1ILATED EXCESS ANMONIA MEASUREMENTS
ON CASES EXITING W: PRILL TOWEU SCRimUER AT
C F INDUSTRIES, INC., HARRISON, TENNESSEE
RUN NUMBER
DATE
VOLUME OP GAS SAMPLED (DSCF) a .
STACK VOUJMETRIC FIXW RATE (DSCFM) D
PRODUCTION RATE (TONS/HOUR)
AMMONIA
Tot;il Sample Weight (Milligrams)
Grains/USCF
Pounds/Hour
Pounds/Ton
AMMONIUM NITRATE CALCULATED
FROM Alt-lONlA e
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
EXCESS AMMONIA f
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
RUN 1
05-08-79
101.70
265200
21.0
SIE C NESSLER d
593 552
0.08998 0.08376
204.5 190.4
9.74 9.07
RUN 2
05-08-79
104.10
263700
21.0
SIE NI-SSLER
554 473
0.08212 0.07012
185.6 158.4
8.84 7.54
RUN 3
05-09-79
98.95
268500
21.3
SIE NI-SSLER
199.4 204.6
0.03110 0.03191
71.6 73.4
3.36 3.45
AVERAGE
101.58
265800
21.1
K
SIE NESSLER
574
0.08720 0
198.7
9.40
513
.07794
177.6
8.38
2791
0.4235
962.7
45.8
572
0.08680
197.3
9.40
2598
0.3942
896.1
42.7
531
0.08057
182.2
8.72
2607
0.3865
873.7
41.6
532
0.07886
178.3
8.48
2226
0.3300
745.9
35.5
456
0.06760
152.8
7.28
938
0.1463
336.7
15.8
177
0.02760
63.53
2.98
963
0.1502
345.7
16.2
182
0.02838
65.32
3.07
2701
0.4104
934.9
44.15
552
0.08386
191.1
9.05
2414
0.3667
835.5
39.4
492
0.07475
170.3
8.07
Dry standard cubic feet § 68 F, 29.92 inches I IK .
Dry standard cuhic feet per minute § 68 F, 29.92 inches IIg .
Specific Ion 13ectrocle analysis method.
Nessler (with preliminary distillation) analysis method.
Ammonium nitrate (mg) = Ammonia (mg) X 80/17.
Excess Ammonia = {(Ammonium nitrate calculated from ammonia) - (Ammonium Citrate measured directly, from Tahle 2-3)} X 17/80.
Ammonia, calculated ammonium nitrate and excess ammonia averages are bused on Runs 1 and 2 only.
-------
The magnesium measurements made on the inlet and outlet gas streams are
t
shown in Table 2-7. The average magnesium removal efficienty is 72.4 percent.
The scrubber outlet samples were analyzed for ammonia by the specific ion
electrode (SIE) method and the Nessler method. The SIE analyses were done at
the CFI laboratory within 48 hours after samples were taken and the Nessler
analyses were done at TRC within 10 days of sampling. For this reasonf and to
facilitate comparisons with inlet data resulting from SIE analyses alone, the
SIE ammonia data are considered the primary data for all data presented in
Section 2.0. Discussions of all analysis methods are contained in Section
5.0, Sampling and Analysis Methods.
The isokinetic percentages for the prill tower scrubber outlet test runs 1
and 2 are relatively high (108% and 111% respectively). The reasons for this
are not evident and can probably be attributed to a contistent operator
error. The effect on the amount of particulate matter sampled is not
considered significant.
2.2 Prill Cooler Scrubber
The ammonium nitrate and insoluble particulate measurements made on the
prill cooler scrubber inlet and two outlets are shown in Tables 2-8 (inlet and
combined outlets) 2-9 (inlet) and 2-10 (each outlet). Because the flow rates
in the two scrubber outlet stacks were not equal to each other, averages
weighted by flowrate were calculated for some combined outlet parameters shown
in Table 2-8. The average total particulate removal efficiency was 90.3
percent.
-17-
-------
TABLE 2-7a (ENGLISH)
SUMMARY OP MAGNESIUM MFAS1IREMF.NTS ON CASKS
ENTERING AMU EXITING THE PRILL TOWER SCRUBBER
AT C 1- INIXJSI'IUES, INC.,
HARRISON, TENNESSEE
GO
I
RUN NUMBER
L1ATI:
IJOCATION
VOLUME OF GAS SAMPLED (DSCr)a .
SI'ACK VOUJMETRIC FLOWRATE (DSCIM)
PRODUCTION RATE (TONS/IOUR)
TOI'AI. MAGNESIUM0
Total Sample Wcjght (Milligrams)
C-rains/DSCF
Pounds/Hour
Pounds/Ton
Collection Efficiency (Percent)
RUN 1
05-08-79
INLET OUTLET
RUN 2
05-08-79
INLET oururr
Q
RUN 5
05-09-79
INLET OUl'LI-T
AVERAGE
INLI-T
65.70
257800
21.0
1.164
0.0002734
0.6041
0.02877
81
101.70
265200
21.0
0.3204
0.00004862
0.1105
0.00526
.7
64.42
253900
21.0
0.3826
0.00009165 0.
0.1995
0.00950
68.8
104.10
263700
2L.O
0.1856
.00002751
0.06218
0.00296
65.86
258500
21.3
0.4958
O.OC01162
0.25747
0.01209
53
98.95
268500
21.3
0.3345
0.00005217
0.12007
0.00564
.3
65.33
256700
21.1
0.6808
0.0001596
0.35116
0.01664
72
101.58
265800
21.1
0.2802
0.00004256
0.09696
0.00460
.4
a Dry standard cubic feet @ 68 F, 29.92 inches llg
b Dry standard cubic feet per minute
c Analyzed by atomic absorption
-------
TABU; 2-7b (Metric)
SUMMARY OF MAGNESIUM MEASUREMENTS ON CASES
ENTERING AND EXITING PRILL TOWER SCRUBBER
AT C F INDUSTRIES, INC,,
VD
I
RUN NUMBER
DATE
LOCATION
VOLUME OP GAS SAMPLED (DN m3)a ,
STACK VOLUMETRIC FLOWRATE (DN m3/min)
PRODUCTION RATE (Mg/lbur)
TOTAL MAGNESIUM0
Total Sample Weight (Milligrams)
Granis/DN in3
Kg/Hour
Kg/Mg
Col lection Efficiency (Percent)
a Dry normal cubic meters @ 20°C, 760 mm llg
b Dry normal cubic meters per minute
c Analyzed by atomic absorption
IIARRSION, TENNESSEE
Riui
1
OS-08-79
Inlet
1.861
7300
19.1
1.161
0.0006256
0.2740
0.01138
81.
Outlet
2.880
7510
19.1
0.3201
0.0001113
0.0501
0.00263
7
' Rim
2
05-08-79
Inlet
1.821
7190
19.1
0.3826
0.0002097
0.0905
0.00175
68
Outlet
2.918
7170
19.1
0.1856
0.00006295
0.0282
0.00118
.8
Run
3
Averaj
je
05-09-79
Inlet
1.865
7320
19.3
0.1958
0.0002659
0.1168
0.00605
53.
Outlet
2.802
7600
19.3
0.3315
0.0001191
0.0515
0.00282
3
Inlet
1.850
7270
19.2
0.6808
0.0003652
0.1593
0.00832
72.1
Outlet
2.877
7530
19.2
0.2802
0.0000971
0.0110
0.00230
-------
TABLE 2-8a (ENGLISH)
SUMMARY OF AMMONIUM NITRATE AND INSOLUBLE PARTICULATE MEASUREMENTS
ON CASES ENTERING AND EXITING THE PRILL COOLER SCRUBBER
AT C F INDUSTRIES, INC., HARRISON, TENNESSEE
RUN NUMBER
DATE
LOCATION
VOLUME 01' GAS SAMPLE (DSCF)a
PERCENT MOISTURE BY VOLUME*
AVERAGE STACK TEMPERATURE (°F)*
STACK VOLUMETRIC FLOWRATE (DSCFM)'5
PERCENT ISOKINETIC
( PRODUCTION RATE (TONS/HOUR)
Ni
-------
TABLE 2-8b (Metric)
SUMMARY OF AMMONIUM NITRATE AND INSOUJBLE PARTIOJI.ATE MEASUREMENTS
ON GASES ENTERING AND EXITING 'HIE PRILL COOLER SCRUBBER AT
C F INDUSTRIES, INC.,
HARRISON, TENNESSEE
I
ho
RUN NUMBER
DATE
LOCATION .
VOUIME OF GAS SAMPLED (ON m3)3
PERCENT MOISTURE BY VOLUME*
AVERAGE STACK TEMPERA1URG (°C)* h
STACK VOLUMETRIC FLOWRATE (DN mVmin)
PERCENT ISOKINETIC
PRODUCTION RATE (Mg/llour)
1NSOUJBI.E PARTICULATE
Total Sample Weiglit (Milligrams)
Grams/UN m3*
Kg/I bur
Kg/Mg
Collection Efficiency (Percent)
AMMONIUM NITRATE PARTICULATEC
Total Sample Weight (Milligrams)
Grams/DN in3 *
Kg/Hour
Kg/Mg
Collection Efficiency (Percent)
TOTAL PARTiailATE: INSQUIBI..E AND
AMMONIUM NITRATE
Total Sajnple Weight (Milligrams)
Grams/UN in1*
Kg/Hour
Kg/Mg
Collection Efficiency (Percent)
Run 1
Run 2
05-10-79
Inlet
1.483
1.879
62
896
99.3
19.1
5.08
0.00343
0.1843
0.00965
415.4
0.2803
15.07
0.791
420.48
0.2837
15.25
0.801
Combined
Outlets
4.936
2.290
48
974
97.8
19.1
7.83
0.001329
0.0777
0.00408
57.7
94.94
0.02222
1.299
0.0682
91.4
102.77
0.02354
1.377
0.0723
9.1.0
05-11-79
Inlet
1.462
1.447
63
881
99.6
19.1
2.46
0.001682
0.0890
0.00467
407.6
0.2787
14.74
0.774
410.06
0.2805
14.83
0.779
Combined
Outlets
4.944
3.182
46
953
100.7
19.1
6.62
0.001057
0.0605
0.00317
32.1
149.90
0.03613
2.067
0.1085
86.0
156.52
0.03718
2.126
0.1117
85.7
Run 3
05-11-79
Combined
Inlet Outlets
1.436
0.7S5
63
878
98.2
18.8
4.44
0.00309
0.1629
0.00868
472.1
0.3286
17.32
0.923
<0
4.829
2.428
48
939
101.7
18.8
20.10
0.00396
0.2229
0.01187
71.72
0.01S40
0.867
0.04618
95.0
476.54
0.3318
17.49
0.931
93.8
91.82
0.01936
1.090
0.0581
Inlet
1.460
1.360
63
885
99.0
19.0
3.99
0.00272
0.1451
0.00766
431.7
0.2956
15.70
0.828
435.69
0.2984
15.85
0.836
Combined
Outlets
4.903
2.634
48
956
100.1
19.0
11.52
0.002101
0.1204
0.00635
17.0
105.52
0.02467
1.414
0.0746
91.0
117.04
0.02677
1.535
0.0810
90.3
a Dry normal cubic meters @ 20 C, 760 mm llg
b Dry normal cubic meters per minute
c Specific Ion Electrode Analysis method. This method measures nitrate (NO^-); ammonium nitrate (ing) = nitrate (nig) x 80/62.
* Combined outlet values are weighted averages (weighted by flowrate). Separate outlet values are shown in Table 2-10.
-------
TABLE 2-9
SUMMARY OF AMMONIUM NITRATE ANI) INSOLUBLE PARTICUIATE MEASUREMENTS
ON GASES ENTERING Tlir: I'lUI.L COOLER SCRUBBER
AT C l: INDUSTRIES, INC.,
HARRISON, TENNESSEE
t-o
N3
I
RUN NUMBER
DATE
VOI.UMT. Ol: GAS SAMPLED (DSCF) 3
PERCENT MOISTURE BY VOLUME
AVERAGE STACK TEMPERATURE ( '0 i
STACK VOLUMETRIC FLjOW RATE (DSCFM)
PERCENI' ISOKINiri'lC
PRODUCTION RATE (Tons/Hour)
INSOLUBLE PARTICULATI-
Total. Sample Weight (Milligrams)
Grains/USCF
Poi 11 ids/Hour
Pounds/Ton
ANMONHIM WTRATE PARTICUIAFE c
Total Sample Weight (Milligrams)
Grains/USCF
Pounds/Hour
Pounds/Ton
TOI'AI. PAUT1CUIAI13: INSOUJBLE
ANT)
NITRATE
Total Siunple Weight (Milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
PERCENT PARTICUUVTE CATOI *
RUN 1
05-.10-79
52.35
1.879
143
31650
99.3
5.08
0.00150
0.'1063
0.0193
415.4
0.1225
33.22
420.48
0.1240
33.63
1.21
RUN 2
05-11-79
51.63
1.447
144
31120
99.6
2.46
0.000735
0.1961
0.00934
407.6
0.1218
32.50
410.06
0.1226
32.69
0.60
RUN 3
05-11-79
50.72
0.755
145
31020
98.2
4.44
0.00135
0.3592
0.01735
472.1
0.1436
38.19
476.54
0.1450
38.55
0.93
AVERAGE
51.57
1.360
144
31260
99.0
3.99
0.00119
0.3199
0.01531
431.7
0.1292
34.62
435.69
0.1304
34.94
0.92
. Dry standard cubic feet e 68 F, 29.92 inches llg.
Dry standard cubic feet per minute.
Specific Ion Electrode analysis method. This method measures nitrate (N03-); ammonium nitrate (ing) = nitrate (ing) X 80/62.
* (Insoluble pnrticulate/Total participate) X 100.
-------
TABLE 2 10
SUMMARY OP AMMONIUM NITRATE AND INSOUIBI.E PART1CULATE MEASUREMENI'S
ON GASES EXITING TIIE PRll.L COOLER SCRUBBER
AT C P INDUSTRIES, INC.,
HARRISON, TENNESSEE
R1IN NUMBER
DATE
SCRUBBER OUTLET
VOLIIMI! OP GAS SAMPLED (I)SCP) a
PERCENT ^D1SI1UIU:, BY VOLUME
AVERAGE STACK TEMPERATURE ( F)
STACK VOLUMETRIC FIjOWRATli (DSCIM)
PERCENT 1SOKINETIC
PRODUCTION RATH (TONS/HOUR)
INSOLUBLE PARTICUIAI'E
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
ANMONHIM NITRATE PAirflCULATE C
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
TOTAL PARTICUIJVTE: INSOLUBI-E
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
PliRCI-KP PART ICUI ATI; (WTO I *
RUN 1
05-10-7'J
RlIN 2
05-11-79
RUN 3
AVERAGE
05-11-79
55.98
n.01378
2.126
0.1012
1.84
Wl-ST
EAST
Wl-ST
EAST
WIST
46.79
0.00647
0.9101
0.0433
14.53
97.40
0.02346
3.559 .
0.1695
0.40
59.12
0.00826
1.130
0.0538
10.54
36.38
0.00890
1.339
0.0647
16.33
55.44
0.00797
1.065
0.0515
25.54
I-AST
63.25
0.01542
2.346
0.1122
3.87
WF.ST
62.70
2.296
1.14
18000
96.8
21.0
1.03
0.000254
0.03911
0.00186
54.95
0.01352
2.087
0.09938
111.60
2.284
122
16410
98.8
21.0
6.80
0.000940
0.13226
0.00630
39.99
0.00553
0.7778
0.03704
64.08
3.713
110
17700
100.7
21.0
0.39
0.000094
0.01426
0.00068
97.01
0.02336
3.544
0.16876
110.50
2.593
119
15960
100.7
21.0
6.23
0.000870
0.11902
0.00567
52.89
0.00739
1.011
0.04814
63.10
2.360
115
17550
103.3
20.7
5.94
0.001453
0.21857
0.01056
30.44
0.00744
1.119
0.05406
107.40
2.504
122
15590
100.1
20.7
14.16
0.002035
0.27193
0.01314
41.28
0.00593
0.7924
0.03828
63.29
2.790
113
17750
100.3
20.9
2.45
0.000598
0.09098
0.00435
60.80
0.01483
2.256
0.10794
109.83
2.460
121
15990
99.9
20 . 9
9.07
0.001274
0.17461
0.00835
44.72
0.00628
0.8607
0.04118
53.79
0.00756
1.036
0.04%
16.86
a Dry standard cubic feet @ 68°F, 29.92 inches Mg
Dry standard cubic feet per minute. *
c Specific Ion Electrode Analysis method. This method measures nitrate (NO,-); ammonium nitrate (nig) = nitrate (ing) X 80/62.
* (Insoluble particulatc/Total Participate) X 100.
-------
In Table 2-10 the west outlet insoluble particulate concentrations are
about twice those from the cast. This difference is magnified in the
calculated percent particulate catch by the fact that the east outlet ammonium
nitrate concentration is more than twice that of the west outlet. The reasons
for these differences between the east and west outlets are not evident.
The ammonia measurement data for the inlet and two outlet gas stream
samples are shown in Tables 2-11, 2-12 and 2-13. The average ammonia removal
efficiency was 79.0 percent.
2.3 Neutralizer Scrubbers
Ammonium nitrate and insoluble particulate data for the neutralizer No. 1
scrubber inlet and outlet gas stream samples are shown in Tables 2-14, 2-15
and 2-16. The average total particulate removal efficiency was 93.7 percent.
Two special tests were performed on the neutralizer No. 2 outlet only:
simultaneous test runs at 200% isokinetic and 50% isokinetic were run at
single points in order to determine if deviations from strict isokinetic
sampling techniques in a high water content gas stream (such as these
neutralizer scrubber outlets) affect the sampling results. The ammonium
nitrate and insoluble particulate data for these special tests are shown in
Table 2-17. Because of the scatter of the data, no definite conclusions on
the effects of the anisokinetic sampling can be drawn.
The leak check of the sampling train after the first inlet run revealed a
significant leak; as a result the Run 1 inlet sample volume and flowrate are
not included in the averages (Tables 2-14 and 2-15) . The second and third
runs leak-checked satisfactorily, but the calculated percent isokinetics are
high for these two runs. These high isokinetics may be due to a slight error
in the calculated in-stack calibration factor.
-24-
-------
TABLE 2-lla (English)
SUMMARY Ol: AMMONIA AND CALC1IIATED AMMONIUM NITRATE MEASUREMENTS
ON CASES ENTERING AND EXITING 'HIE PRILL COOLER SCRUBBER
AT C F INDUSmiES, INC.,
IIAR1USON, TENNESSEE
I
ro
ui
I
RUN NUMBER
DATE
LOCATION
VOLUME OF CAS SAMPLED (DSCIr)a
PERCENT MOISTURE BY VOLUME*
AVERAGE STACK Tl-MPERATUUE (°1:)*
STACK VOLUMETRIC PIXDWRATE (DSCFM)"
PERCENT I SDK INET!C
PRODUCTION RATE (TONS/HOUR)
ANM)NIAC
Total Sample Weight (Milligrams)
Grains/nSCI*
Pounds/I bur
Pounds/Ton
Collection Efficiency (Percent)
AMMONIUM NITRATE CALCUUTED
FROM AMMONIAC
Total Sample Weight (Milligrams)
Grains/USCr*
Pounds/I lour
Pounds/Ton ».
Collection Efficiency (Percent)
Run 1
Run 2
Run 3
05-10-79
Inlet
52.35
1.879
143
31650
99.3
21.0
Combined
aitlet
174.30
2.290
118
34410
97.8
2.1.0
05-10-79
Inlet
51.63
1.447
144
31120
99.6
21.0
Combined
Outlet
174.58
3.182
114
33660
100.7
21.0
05-10-79
Inlet
50.72
0.755
145
31020
98.2
20.7
Combined
Outlet
170.50
2.428
118
33140
101 .7
20.7
Inlet
51.57
1 . 360
144
31260
99.0
20 . 9
Combined
Outlet
173.12
2.634
117
33740
100.1
20 . 9
86.2
0.02541
6.894
0.3283
42.0
0.00383
1.130
0.0538
83.6
98.7
0.02950
7.869
0.3747
75.3
76.5
0.00730
1.947
0.09270
116.4
0.03479
9.280
0.4483
72.4
0.00659
1.872
0.0904
79.8
100.4
0.03004
8.050
0.3889
63.6
0.00590
1 . 70(>
0.0810
79.0
405.6
0.1196
32.44
1.545
197.6
0.01802
5.315
0.253
83.6
464.5
0.1388
37.03
1.764
360.0
0.0344
9.176
0.437
75.3
547.8
0.1637
43.68
2.110
340.7
0.03101
8.809
0.426
79.8
472.5
0.1414
37.89
1.830
299 . 3
0.0277(>
8.028
0.3841
79.0
a Dry standard cubic feet @ 68°P and 29.92 inches Mg.
b Dry standard cubic feet per minute.
c Specific Ion Electrode Analysis method.
d Aiinnoniun nitrate (nig) = Ammonia (mg) x 80/17.
* Combined outlet values are weighted averages (weighted by flowrate). Separate outlet values are shown in Table 2-13.
-------
TABLE 2-lib (Metric)
SUNMARY OF AMMONIA AN1) CALCULATED AMMONIUM NITRATE MEASUREMENTS
ON GASES ENTERING AND EXITING THE PRILL COOLER SCRUBBER AT
C F INDUSTRIES, INC.,
HARRISON, TENNliSSEE
RUN NUMBER
DATE
LOCATION
VOUJME OF GAS SAMPLED (DN m3)3
PERCENT MOISTURE BY VOUWE*
AVERAGE STACK TEMPERATURE (°Q* .
STACK VOLUMETRIC FLOWRATE (DN m3/min)
PERC13JT ISOKINETIC
PRODIICriON RATE (Mg/Hour)
AMMONIA0
Total Sample Weight (Milligrams)
Grams/DN in3*
Kg/lbur
^ KB/MS
o\ Collection Efficiency (Percent)
1
ANMONIUM NITRATE CALCUIATED
FROM AMMONIAd
Total Sample Weight (Milligrams)
Grams/DN m3*
Kg/lbur
Kg/Mg
Col lection Efficiency (Percent)
a Dry normal cubic meters 0 20 C, 760
Run
1
05-10-79
Inlet
1.483
1.879
62
896
99.3
19.1
86.2
0.05814
3.127
0.1642
83,
405.6
0.2737
14 . 71
0.773
83,
mm llg.
Combined
Outlets
4.936
2.290
48
974
97.8
19.1
42.0
0.00876
0.513
0.0269
.6
197.6
0.04123
2.411
0.127
.6
Run 2
05-10-79
Inlet
1.462
1.447
63
881
99.6
19.1
98.7
0.06750
3.569
0.1874
75.3
464.5
0.3176
16.80
0.882
75.3
Combined
Outlets
4.944
3.182
46
953
100.7
19.1
76.5
0.01670
0.883
0.0464
360.0
0.0787
4.162
0.219
Run 3
Avera
ge
05-10-79
Inlet
1.436
0.755
63
878
98.2
18.8
116.4
0.07960
4.209
0.2242
79.8
547.8
0.3746
19.81
1.055
79.8
Combined
Outlets
4.829
2.428
48
939
101.7
18.8
72.4
0.01508
0.849
0.0452
340.7
0.07096
3.996
0.213
Inlet
1.460
1.360
63
885
99.0
19.0
100.4
0.06873
3.651
0.1945
79.
472. S
0.3235
17.19
0.915
79.
Combined
Outlets
4.903
2.634
48
956
100.1
19.0
63.6
0.01350
0.774
0.0408
0
299.3
0.06352
3.642
0.1921
0
b Dry normal cubic meters per minute.
c Specific Ion Electrode Analysis method.
d Ammonium nitrate (mg) = Ammonia (ing) x 80/17.
* Combined outlet values are weighted averages (weighted by flowrate). Separate outlet values are shown in Table 2-13.
-------
TABLE 2-12
SUMMARY OP AIWONIA, CA1.CUIATEU AMMONIUM NITRATE AND CALCINATED
EXCESS AMMONIA MEASUREMENTS ON liASES
ENTERING Tl IE PRILL CHOI Jill SCRUBBER AT
C P INDUSTRIES, INC.,
HARRISON, TENNESSEE
Run 1
Run 2
Run 3
05-10-79
52.35
31650
21.0
86.2
0.02541
6.894
0.3283
05-11-79
51.63
31120
21.0
98.7
0.02950
7.869
0.3747
05-11-79
50.72
31020
20.7
116.4
0.03479
9.280
0.4483
51.57
31260
20.9
100.4
0.03004
8.050
0.3889
RUN NUMBER
DATE
VOI.UMI! 01: CAS SAMPLED (DSCP)a .
STACK VOUJMETR1C I'LOWRATE (DSCPM)
PROW ICI1 ION HATH (TONS/1101110
TOTAL AMMONIA0
Total Sample Weight (Milligrams)
Grains/1 )SCF
Pounds/1 lour
Pounds/Ton
AMMONIUM NITRATE CALCUI.ATI.iD
FROM AMMONIA J
Total Sample Weight (Milligrams)
Grains/USCr
Pounds/I bur
Pounds/Ton
EXCESS AMMONIA0
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/1 lour
Pounds/Ton*"
a Dry standard cubic feet @ 68°P, 29.92 inches llg.
b Dry standard cubic feet per minute.
c Specific Ion Electrode Analysis method.
d Anaiionium nitrate (nig) = Ammonia (ing) X 80/17.
e Excess Ammonia = {(Ammonium nitrate calculated from ammonia) - (Ammonium nitrate measured directly, from Table 2-9)} X 17/80.
f Averages include only Runs 2 and 3.
405.6
0.1196
32.44
1.545
-2.08
464.5
0.1388
37.03
1.764
12.09
0.003613
0.9639
0.0459
547.8
0.1637
43.68
2.110
16.09
0.004900
1.3017
0.0629
472.5
0.1414
37.89
1.830
f
14.09 f
0.00421.6.
1.1297 f
0.0541
-------
TABLE 2-13a
SUMMARY OF AMMONIA, CALCULATED AMMONIUM NITRATE ANI) CALCUUTED EXCESS AMMONIA MEASURIiMENTS
ON GASES FROM THE PRILL COOLER SCRUBBER EAST OUTLET
AT C F INDUSTRIES, INC.,
HARRISON, TENNESSEE
NJ
CO
I
RUN NUMBJiR
I1ATI-
VOLllMi; OF CAS SAMPLED (DSCF) a
STACK VOLllNB-TRfC FLOW RATE (DSCFM)
PRODUCTION RATE (TONS/HOUR)
TOTAL AMMONIA
Total Sample Weight (Milligrams)
Crains/DSCF
Pounds/Hour
Pounds/Ton
AMMONIUM NITRATE CALCULATED
" FROM AMMONIA e
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
i-.xciiss AMMONIA f
Total Sample Weight (Milligrams)
f.rains/DSCF
Pounds/Hour
Pounds/Ton
RUN 1
05-10-79
62.70
18000
21.0
SIE C NESSLER d
16.9 13.9
0.004159 0.003421
0.6417 0.5278
0.03056 0.02513
RUN 2
05-11-79
64.08
17700
21.0
RUN 3
AVKKACE
SIE
N15SLER
36.9 34.1
0.008887 0.008212
1.348 1.246
0.06419 0.05933
05-11-79
63.10
17550
20.7
Sin NESSLER
27.4 22.0
0.006701 0.005380
1.008 0.8093
0.04870 0.03910
63.29
17750
20.9
SIE
27.0
0.006584
1.002
0.04794
NESSLER
23.3
O.OOS681
0.8643
0.04135
79.5
0.01957
3.019
0.1438
5.22
0.00129
0.1990
0.00948
65.4
0.01610
2.484
0.1183
2.22
0.00055
0.0849
0.00404
173.6
0.04181
6.342
0.3020
16.28
0.00392
0.5947
0.02832
160.5
0.03865
5.864
0.2792
13.49
0.00325
0.4931
0.02348
128.9
0.03152
4.742
0.2291
20.92
0.00512
0.7702
0.03721
103.5
0.02531
3.808
0.1839
15.52
0.00380
0.5716
0.02761
127.1
0.03100
4.715
0.2256
14.09
0.00344
0.5234
0.02504
109.6
0.02672
4.066
0.1945
10.37
0.00253
0.3849
0.01842
Dry standard cubic feet @ 68 F, 29.92 inches llg.
llry standard cubic feet per minute.
Specific Ion Electrode Analysis method.
Nessler (with preliminary distillation) analysis method.
Ammonium nitrate (ing) = Ammonia (nig) X 80/17.
F.xcess Ammonia = {(Ammonium nitrate calculated from ammonia) - (Ammonium nitrate measured directly, from Table 2-10)1 X 17/80.
-------
I
fO
WIN NIIMBHR
DATE
VOLUME OP GAS SAMPLED (OSCF)a .
STACK "VOLUMETRIC FLOWUATB (DSCFM)
1'ROnilCTTON RATR (TONS/IIOUR)
TOI'Al. ANHONIA
Total Simple Weight (Milligrams)
r.rains/DSCP
Pounds/I lour
Pounds/Ton
AMMONIUM NITRATE CALCULATED
FROM
Total Sample Weight (Milligrams)
Grai ns/l)SCF
Pounds/Hour
Pounds/Ton
EXCESS AMMONIAf
Total Sample Weight (Milligrams)
Urains/DSCF
Pounds/Hour
PoiinJs/Ton
TABLE 2-13b
SUMMARY OF AMMONIA, CALCULATED AMMONIUM NITRATE AND CALCULATED
EXCESS AMMONIA MEASUREMENTS ON GASES FROM THE
PRILL COOLER SCRUBBER VEST OUTLET AT
C
Run 1
F INDUSTRIES, INC.,
HARRISON, TENNESSEE
Run 2
Run 3
05-10-79
111.60
16410
21.0
SIE0 NESSLERd
25.1 23.4
0.003471 0.003236
0.4882 0.4552
0.02325 0.02168
05-11-79
110.50
15960
21.0
SIE NUSSLER
39.6 35.6
0.005530 0.004972
0.7565 0.6802
0.03602 0.03239
05-11-79
107.40
15590
20.7
SIE NESSLER
45.0 38.7
0.006466 0.005561
0.8640 0.7431
0.04174 0.03590
109.83
15990
20.9
SIE
36.6
0.005143
0.7049
0.03373
NESSLER
32.6
0.004581
0.6279
0.03004
118.1
0.01633
2.297
0.10938
16.6
0.00230
0.3235
0.01540
110. 1
0.01522
2.141
0.10195
14.9
0.00206
0.2898
0.01380
186.4
0.02603
3.561
0.16957
28.4
0.00397
0.5431
0.02586
167.5
0.02339
3.200
0.15238
24.4
0.00341
0.4665
0.02221
211.8
0.03043
4.066
0.19643
36.2
0.00520
0.6949
0.03357
182.1
0.02617
3.497
0.16894
29.9
0.00430
0.5746
0.02776
172.2
0.02420
3.317
0.15871
27.1
0.00381
0.5222
0.02499
153.4
0.02155
2.954
0.14134
23.1
0.00325
0.4454
0.02131
a Dry standard cubic feet e 68°P, 29.92 inches Hg.
b Dry standard cubic feet per minute.
c Specific Ion Electrode Analysis method .
d Messier (with preliminary distillation) analysis method.
e Annnoniinn nitrate (mg) = ammonia (mg) x 80/17
f Excess ammonia = I (Ammonium nitrate calculated from ammonia) - (ammonium nitrate measured directly, from Table 2-10)1 x 17/80.
-------
TABU: 2-14a (English)
SUMMARY OP AMMONIIM NITRATE AN1J INSOLUBLE PARTICUIATE MEASUREMENTS
ON GASES ENTERING AND EXITING NEUTKAI.1ZER NO. 1 SCRUBBER AT
C F INDUSTRIES, INC.,
HARRISON, TENNESSEE
I
LO
O
RUN NUMBER
DATE
LOCATION
VOLUME OF GAS SAMPLED (DSCF)a
PERCENT MOISTURE BY VOLUME
AVERAGE STACK TEMI'ERATURE (°F) .
STACK VOLUMETRIC FljOWUATE (DSCFM)
PERCENT ISOKINETIC
PRODUCriON RATE (TONS/I CUR)
INSOLUBLE PARTICULATE
Total Sample Weight (Milligrams)
Crains/DSCF
Pounds/I bur
Pounds/Ton
Collection Efficiency (Percent)
AMMONIUM NITRATE PARI'1CULATEC
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/lbur
Pounds/Ton
Collection Efficiency (Percent)
TOTAL PARTiqilATE: INSOLUBLE
AND AMMONIUM NITRATE
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/I tour
Pounds/Ton
Collection Efficiency (Percent)
Run 1
06-19-79
Inlet
0.329
99.53
269
27.85
92.74
11.3
129.51
6.075
1.450
0.12832
6344
297.6
71.04
6.2867
6474
303.7
72.50
6.4159
Outlet
6.582
94.23-
213
378.3
110.1
11.3
75.88
0.1779
0.5987
0.05299
58.7
474
1.111
3.739
0.33088
94.7
549.9
1.289
4.338
0.38388
Run 2
06-20-79
Inlet
t
4.568
94.43
275
315.6
113.7
11.5
69.49
0.2348
0.6352
0.05523
6890
23.28
62.98
5.4765
6960
23.51
63.60
5.5304
Outlet
5.484
95.01
212
302.1
114.9
11.5
97.75
0.2751
0.7356
0.06397
<0
387
1.089
2.912
0.25326
95.4
484.8
1.364
3.647
0.31715
Run 3
06-20-79
Inlet Outlet
4.200
95.24
270
260.7
126.6
11.4
53.03
0.1948
0.4353
0.03818
7474
27.46
61.36
5.3825
5.814
94.85
210
326.3
112.8
11.4
99.39
0.2638
0.7615
0.06680
<0
353
0.9370
2.704
0.23723
95.6
7527
27.66
61.81
5.4219
452.4
1.201
3.467
0.30416
Inlet
4.384*!
94.84d
271
288.2d
120.2d
11.4
84.01
0.2957
0.7305
0.06408
6903
24.30
60.03
5.2658
6987
24.59
60.74
S.3281
Outlet
5.960
94.70
212
335.6
112.6
11.4
91.01
0.2357
0.7012
0.06151
4.0
405
1.049
3.121
0.27378
94.8
496.0
1.284
3.H20
0.33507
94.0
94.3
94.4
93.7
a Dry standard cubic feet 3 68°F, 29.92 inches llg.
b Dry standard cubic feet per minute.
c Specific Ion Electrode Analysis method.
d These averages include only Runs 2 and 3 due to high sampling train leak rate during Run 1.
* Averages include all three runs except for parameters identified by d.
Grains/DSCF, pounds/hour and pounds/ton are calculated from average Total Sample Weights.
-------
TABLE 2-l4b (Metric)
SUMMARY OF AMMONIUM NITRATE AND INSOLUBI.E PARTICULATE MEASUREMENTS
ON GASES ENTERING AND EXITING NEUTRALIZER NO. 1 SCRUBBER AT
C P INDUSTRIES, INC.,
HARRISON. TENNESSEE
WIN NUMBER
DATE
LOCATION
VOLUME OP GAS SAMPLED (DN m3)3
PERCENT MOISniRE BY VOUJME
AVERAGE STACK TEMPERATURE ( C) h
STACK VOLUMETRIC FIjOWUATE (DN m3/min)
PERCENT 1SOKINETIC
PRODUCTION RATE (Mg/ltour)
Rim 1
06-19-79
Inlet
Outlet
Run 2
06-20-79
Inlet
Outlet
Run 3
06-20-79
Inlet Outlet
Inlet
Outlet
0.0093
99.53
132
0.7887
92.7
10.2
0.1864
94 . 23
101
10.71
110.1
10.2
0.1294
94.43
135
8.938
113.7
10.5
0.1553
95.01
100
8.555
114.9
10.5
0.1189
95.24
132
7.383
126.6
10.4
0.1647
94.85
99
9.241
112.8
10.4
0.1242?
94.84"
133
8.162^
120. 2d
10.4
0.1688
94.70
100
9.502
112.0
10.4
INSOLUBLE PARTICU1ATES
Total Sample Weight (Milligrams)
Grams/DN m3
Kg/Hour
Kg/Mg
Collection Efficiency (Percent)
AMMONIUM NITRATE PAHTICU1ATEC
Total Sample Weight (Milligrams)
Graiiis/DN m3
Kg/I lour
Collection Efficiency (Percent)
TOTAL PAKT1CULATE: INSOLUBLE
AND AMMONIUM NITRATE
Total Sample Weight (Milligrams)
Grams/ DN m3
Kg/I lour
Kg/Mg
Collection Efficiency (Percent)
129.51
13.90
0.6577
0.06416
6344
681.0
32.22
3.1434
75.88
0.4071
0.2716
0.02650
58.7
474
2.542
1.696
0.16542
94.7
69.49
0.5372
0.2881
0.08762
6890
53.27
28.57
2.7383
97.75
0.6295
0.3337
0.03199
<0
387
2.492
1.321
0.l26(-3
95.4
53.03
0.4457
0.1975
0.01909
7474
62.83
27.83
2.6913
99.39
0.6036
0.3454
0.03340
<0
353
2.144
1.226
0.11862
95.6
84.01
0.6766
0.3314
0.03204
6903
55.60
27.23
2.6329
91.01 '
0.5393
0.3182
0.1)3076
4.0
405
2.400
1.416
0.1.Y><>3
94.8
6474
694.9
32.89
3.2080
549.9
2.949
1.967
0.19193
94.0
6960
53.79
28.85
2.7652
484.8
3.121
1.654
0.15859
94.3
7527
63.29
28.04
2.7110
452.4
2.748
1.573
0.15208
94.4
6987
56.26
27.55
2.6641
496.0
2.938
1.733
0.16758
93.7
a Dry normal cubic meters e 20 C, 760 mm llg.
b Dry normal cubic meters per minute.
c Specific Ion Electrode Analysis method.
d These averages include only Runs 2 and 3 due to high sampling train leak rate during Run 1.
* Averages include all three runs except for parameters identified by d.
Grains/L)SCI:, pounds/hour and pounds/ton are calculated from average Total Simple Weights.
-------
TABI.F. 2-15
SUMMARY OF MMONIUM NITRATE AMI) INSOLUBLE PARTICUIATE MEASURIMENTS
ON GASES ENTERING NUUTRALIZER 81 SCRUBBER
AT C F INDUSTRIES, INC.,
HARRISON, TENNESSEE
I
LO
3 ("10 .
|-E (DSCFM)b
HUN NUMBER
HATE
VOUME OF GAS SAMPLED (DSCF)
PERCENT M01STORE BY VOLUME
AVF.RAGE STACK TEMPERATURE
STACK VOIUMimUC FLOW RATE
PERCENT ISOKINEFIC
I'ROUUCI'ION RATE (TONS/HOUR)
INSOLUBLE PARTICIPATE
Total Sample Weight (Milligrams)
Crains/l)SCI:
Pounds/Hour
Pounds/Ton
AMMONIUM NITRATE PARTICULAR C
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
TOTAL ['ARTICULATE: INSOLUBLE
AND AMMONIUM NITRATE
Total Sample Weight (Milligrams)
Grains/IXSCF
Poiuids/llour
I'ounds/Ton
PI-RCENT PARTrCUIJ\TE CATOI *
RUN 1
06-19-79
0.329
99.53
269
27.85
92.74
11.3
129.51
6.075
1.450
0.12832
6344
297.6
71.04
6.2867
6474
303.7
72.50
6.4159
2.0
RUN 2
06-20-79
4.568
94.43
275
315.6
113.7
11.5
69.49
0.2348
0.6352
0.05523
6890
23.28
62.98
5.4765
6960
23.51
63.60
5.5304
1.0
RUN 3
06-20-79
4.200
95.24
270
260.7
126.6
11.4
53.03
0.1'.14 8
0.4353
0.03818
7474
27.46
61.36
5.3825
7527
27.66
61.81
5.4219
0.7
AVERAGI*
4.384
94.84
271
288.2
120.2
11.4
84.01
0.2957
0.7305
0.06408
6903
24.30
60.03
5.2658
6987
24.59
60.74
5.3281
1.2
' . Dry standard cubic feet e 68 F, 29.92 inches llg.
Dry standard cubic feet per minute.
Specific Ion Electrode Analysis method. This method measures nitrate (NO,-); ammonium nitrate (nig) = nitrate (ing) X 80/62.
• J
These averages include only Runs 2 and 3 clue to a high sampling train leak rate during Run 1.
* (Insoluble particulate/Total pnrticulate) X 100.
** Averages include all three runs except parameters identified by d.
-------
TABLE 2-If.
SUMMARY OF AMMONIUM NITRATE AND INSOI1JBU- PART1UILATF. NtEASUiaMWI'S
ON GASHS EXITING NEUTRAL1ZER 01 SCRUBBER
AT C F INDUSTRIES, INC.,
HARRISON, TI-NNESSEE
I
U)
UUN NUMBER
DATE
VOI1JME OF GAS SAMPLED (DSCF) a
PERCENT MOISTURE BY VOIJUMF,
AVERAGE STACK TEMPERATURE ( F) ,
SI'ACK VOLUMETRIC FI/W RATE (DSCFM)
PERCENT ISOK1NETIC
PRODUCTION RATH (1X)NS/HaiR)
INSOLUBLE PAIO'ICUUTE
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/I lour
Pounds/Ton
AM^IONIUM NITRATE ['ARTICULATE C
Total Sample Weiglit (Milligrams)
Grains/IXSCI-'
I'ounds/llour
Pounds/Ton
TOI'AL PART I PILATE: INSOIJJBLE
AND ANMON1UM NITRATE
Total Sample Weiglit (Milligrams)
Grains/USCF
Pounds/I lour
Pounds/Ton
PERCEMI1 PARTlCIIIAri: CATOI *
RUN 1
06-1P-79
6.582
94.23
213
378.3
1.10.1
11.3
75.88
0.1779
0.5987
0.05299
474
1.111
3.739
0.33088
549.9
1.289
4.388
0.38388
13.8
RUN 2
06-20-79
5.484
95.01
212
302.1
114.9
11.5
97.75
0.2751
0.7356
0.06397
387
1.089
2.912
0.25326
484.8
1.364
3.647
0.31715
20.2
RUN 3
06-20-79
5.814
94.85
210
326.3
112.8
11.4
99.39
0.2638
0.7015
0.06680
353
0.9370
2.704
0.23723
4S2..4
1,201
3.467
0.30416
22.0
AVERAGE
5.960
94.70
212
335.6
112.6
11.4
91.01
0.2357
0.7012
0.06151
405
1.049
3.121
0,27378
496.0
1.284
3..820
0.33507
18.3
' Dry standard cubic feet e 68 F, 29.92 inches llg.
Dry standard cubic feet per minute.
Specific Ion Electrode Analysis method. This method measures nitrate (NO,-); ammonium nitrate (mg) = nitrate (ing) X 80/62.
* (Insoluble particulate/Total Paniculate) X 100.
-------
TABLE 2-17
SUMMARY OF ANMONIUM NITRATE AND INSOLUBLE PARTICUIATE MEASUREMENTS
ON GASES EXITING NEUTRAL!ZER NO. 2 SCRUBBER AT
fTT INDUSTRIES, INC.,
HARRISON, TENNESSEE
I
LO
RUN NUMBER
DATE
APPROXIMATE 1SOKINETIC
VOUME OP GAS SAMPLED (DSCF)a
PERCENT MOISTURE BY VOIilME
AVERAGE STACK TEMPERATURE (°F)
PERCENT ISOKINETIC
INSOmBLE PARTICUIAVE
Total Sample Weight (Milligrams)
Grains/DSCF
Difference (Percent)*
ANMONIUM NITRATE PART1CULATE
Total Sample Weight (Milligrams)
Grains/DSCF
Difference (Percent)*
TOTAL PARTIQI1ATE: INSOLUBLE
AND ANMONIUM NITRATE
Total Sample Weight (Milligrams)
Grains/aSCF
Difference- (Percent)*
Run 4
06-21-79
2004
3.493
94.01
209
206.1
27.78
0.1227
-31.1
132.0
0.5832
-6.1
159.8
0.7060
-10.4
504
2.466
93.90
212
51.0
25.71
0.1609
98.9
0.6189
124.6
0.7797
Run 5
06-21-79
200%
3.405
94.19
211
212.9
66.60
0.3018
22.5
*
158.0
0.7161
-5.0
224.6
1.018
10.1
504
2.642
94.12
212
55.7
40.06
0.2340
116.5
0.6805
156.6
0.9147
Run 6
Averag
e
06-21-79
2004
2.792
95.09
210
200.8
27.60
0.1526
-16.7
194.0
1.072
25.4
221.6
1.225
lQi_?
504
2.508
94.50
211
48.4
28.94
0.1781
130.0
0.7997
158.9
0.9777
2004
3.230
94.43
210
2118.6
40.66
0.1943
_1.2
161.0
0.7692
9.0
202.0
0.9651
7.6
504
2.539
94.17
212
51.7
31.57
0.1919
115.1
0.6996
146.7
0.8916
a Dry standard cuhic feet P 68°l:. 29.P2 inches llg.
b Specific Ion Electrode Analysis method. This method measures nitrate (NOj-); ammonium nitrate (ing) = nitrate (nig) x 80/62.
* Relative difference between 2004 and 504 grain loadings; defined here as 100 X ((20114 gr/l)SCI:) - (50% gr/DSCF) }/(2004 gr/DSCF).
-------
Because of the high ammonia concentration in the neutralizer samples, the
ammonium nitrate values shown in Tables 2-14, 2-15, and 2-16 may be somewhat
higher than what actually exists. The interference effects of ammonia on the
ammonium nitrate analyses are discussed in Section 5.0.
The ammonia measurement data from the neutralizer No. 1 inlet and outlet
gas stream samples are shown in Tables 2-18 (inlet and outlet) 2-19 (inlet)
and 2-20 (outlet). The average ammonia removal efficiency was calculated to be
less than zero, indicating more ammonia leaving the scrubber than entering.
The implication is that ammonia is being stripped from the scrubber water.
However, since only the scrubber inlet water was sampled and analyzed, the
reason for this negative ammonia removal efficiency remains unclear.
The ammonia measurement data from the 200% and 50% isokinetic sampling at
neutralizer No. 2 outlet are shown in Tables 2-21 (200% data) and 2-22 (50%
data). As with the particulate data in Table 2-17, no definite conclusions on
the effects of the anisokinetic sampling can be drawn. •
The carbon dioxide content of the Neutralizer No. 1 and No. 2 samples was
evaluated by CFI using the Van Slyke analysis method. The results of these
analyses (corrected to 70°F and 29.92 inches Hg) are as follows:
Location Run
Neutralizer No. 1 Scrubber
1
2
3
Neutralizer No. 2 Scrubber Outlet
1
2
3
C02 Concentrations
(SCF/gallon)
Inlet
1,079
1.284
1.926
200%
0.411
0.770
0.899
Outlet
1.220
1.592
2.465
50%
0.462
0.642
0.899
-35-
-------
TABLE 2-18a (English)
SIINMARY OF MMONTA AND CALCULATUD AKNONKJM NITRATE MEASUREMENTS
ON GASOS ENTERING AND EXITING NEl/iRALIZER NO. 1 SCRUBBER AT
C F INWJSrRIKS, INC.,
HARRISON. TENNESSEE
RUN NUMBER
DATE
Run 2
VOUIME OF GAS SAMPLED (DSCF)3
PERCENT MOISTURE BY VOUJME
AVERAGE STACK TEMPERATURE ( F) .
STACK VOLUMETRIC FLOWRATE (DSCFM)
PERCENT ISOKINETIC
PRODUCTION RATE (TONS/I OUR)
AI*MONIAC
Total Sample Weight (Milligrams)
Grains/ DSCF
Pounds/I bur
Poiuids/Ton
Collection Efficiency (Percent)
ANHONUM NITRATE CALCULATED
FROM AMWNTJjcl
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/I bur
P
-------
TABLE 2-18b (Metric)
SUKMARY OF AMWNIA AND CAIOJIATED AMMONIUM NITRATE MEASUREMENTS
ON (ASKS ENTERING AND EXITING NEUTRALIZER NO. I SCRUBBER
AT C l: INDUSTRIES, INC.,
HARRISON, TENNESSEE
LO
~J
I
RUN NUMBER
DATE
LOCATION
VOLUME OP GAS SAMPLED (DNm3)a
PERCENT MOISTURE BY VOLUME
AVERAGE STACK TEMPERATURE ( C)
STACK VOLUMETRIC FLOWRATE (DNin3/min)
PERCENT ISOKINETIC
PRODUCTION RATE (Mg/llour)
AMMONIA c
Total Sample Weight (Milligrams)
Grams/DNin3
Kg/I lour
Kg/Mg
COLLECTION EFFICIENCY (Percent)
AMMON1UM NITRATE CALOJIATCD
" FROM-AM-tONTA"3
Total Sample Weight (Milligrams)
Grams/DNm5
Kg/Hour
Kg/Ms
COI.MiCriON EFFICIENCY (Percent)
RUN 1
06-19-79
INLET OUTLET
131322
14095
666.8
6S.05
<0
193656
1039
693.1
67.59
RUN 2
06-20-79
RUN 3
AVERAGE
06-20-79
INLET
OUrLlTT
INLET
OUTLl-T
0.5
249313
1927
1034
99.10
301360
1940
1028
98.58
<0
303671
2554
1131
109.4
<0
0.6
<0
459454
2791
IS'.IH
154.5
INLET
<0
228104
1837
899.5
86.95
OUTLET
.0093
99.53
132
0.7887
92.7
10.2
27906
2995
141. B
13.83
0.1864
94.23
101
10.71
110. 1
10.2
41152
220.8
147.3
14.4
0.1294
94.43
135
8.938
113.7
10.5
52979
409.6
219.6
21.05
0.1553
9S.01
100
8.555
114.9
10.5
64039
412.3
218.6
20.96
0.1189
95.24
132
7.383
126.6
10.4
64530
542.5
240.3
23.24
0.1647
94.85
99
9.241
112.8
10.4
97634
592.8
339.2
32.80
0.1242 e
94.84 e
133
8.162 e
120.2 c
10.4
48472
390.3
191.1
18.48
0.1688
94.70
100
9.502
112.6
10.4
67608
400.6
236.3
22.8(,
318155
1885
1112
107.5
Dry normal cubic meters @ 20°C, 760 mm Mg.
Dry normal cubic meters per minute.
S|>ecific 'on Electrode analysis method.
Ammonium nitrate (mg) = Ammonia (ing) X 80/17.
e These averages include Runs 2 and 3 only because of high sampling train leak rate during Run 1.
* Averages include all three runs except for parameters identified by e.
Grains/DSCF, Poiinds/llour and pounds/ton are calculated from average Total Sample Weights.
-------
TABU: 2-19
SUMMARY OF ANMONIA, CALCULATED AMMONIUM NITRATE
AND CALCULATED EXCESS Af>M.lNIA MEASUREMENT
ON GASES ENTERING 'HIE NEIITRA1.IZER NO. 1 SCRUBBER
F INDUSTRIES, INC.,
HARRISON, TliNNESSKE
I
U)
OO
RUN NUMBER
DATE
VOLIIMF. Ol: GAS SAMPLED (HSCF) a
STACK VOLUMETRIC FLOWRATE (DSCFM)
AVERAGE STACK TEMPERATURE CM
PROIXJCTION RATE (TONS/HOUR)
AMMONIA
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/I luur
Pounds/Ton
AMMONIUM NITRATE CALCULATED
FI«3M AMMONIA K "~~~
Total Sample Weight (Milligrams)
Crains/KSCF
I'ou n3s/l lour
Pounds/Ton
EXCESS AMMONIA f
Total Sample Weight (Milligrams)
Grains/IKCF
Pounds/Hour
Pounds/Ton
SIE C
27906
1309
312.5
27.65
RUN 1
06-19-79
0.329
27.85
269
11.3
NESSLER d
24705
1159
276.6
24.48
RUN 2
06-20-79
SIE
52979
179.0
484.2
42.10
4.568
315.6
275
11.5
NI-SSLIiR
46955
158
429
37.
.6
.1
31
RUN 3
AVERAGE
06-20-79
SIE
645
237
529
46.
30
.1
.8
47
4.200
260.7
270
11.4
NESSIJiR
59091
217.1
485.2
42.56
SIE
48472
170.6
421.4
36.96
*
4.384
288.2*
271
11.4
N1-SS1.ER
43584
511.9
396.8
34.81
131322
6160
1470
130.1
26558
1246
297.4
26.32
116259
5453
1302
115.2
23357
1096
261.5
23.14
249313
842.3
2279
198.2
51515
174.0
470.8
40.94
220965
746.5
2019
175.6
45491
153.7
415.6
153.7
303671
1116
2494
218.8
62942
231.3
516.8
45.33
278075
1022
2283
200.3
57503
211.3
472.1
41.41
228104
802.9
1983
173.9
47005
165.5
408.7
35.85
205100
722.0
1783
156.4
42117
148.3
3W..2
32.13
Dry standard cubic feet 0 68 F, 29.92 inches llg.
Dry standard cubic feet per minute.
Specific Ion Electrode Analysis method.
Nessler (with preliminary distillation) analysis method.
Ammonium nitrate (nig) = ammonia (nig) X 80/17.
Excess ammonia = {(Ammonium nitrate calculated from ammonia) - (Aiinminiioii nitrate calculated directly, from Table 2-15)1 X 17/80.
Includes runs 2 and 3 only.
-------
TAHLE 2-20
SUMWRY OP AMMJNIA, CALCULATEU AMMONIUM NITRATE
AND CALCULATEn EXCESS MH1N1A MEASUREMENTS
ON CASES EXITING NEUTRAL)ZER NO. 1 SCRUBBER
ATTTl-'. INDUSTRIES, INC.,
HARRISON, TENNESSEE
RUN NUMBER
DATE
VOLUME OF GAS SAMPLE11 (OSCP) a
STACK VOUJMIH'RIC FLOWRATE (DSCFM)
AVERAGE STACK TEMPERATURE
PRODUCTION RATE (TONS/HOUR)
AMMONIA
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/Hour
I'oinuls/Ton
ANMUNUM NITRATE CALCULATED
FROM AMMONIAC
Total Sample Weight (Milligrams)
Grains/DSCI;
Pounds/Hour
Pounds/Ton
EXCESS ANMON1A f
Total Sample Weight (Milligrams)
Grains/l>Sa:
Pounds/Hour
Poiu ids/Ton
RUN ]
1
06-19-79
6.S82
378.3
213
11.3
S1E C
41152
96.48
324.7
28.73
NESSLER d
36742
86.14
28'.). 9
25.66
RUN 2
06-20-79
5.484
302.1
212
11.5
S1E
64039
180.2
481.9
41.90
NESSLER
60790
171.1
457.4
39.77
RUN 3
AVERAGE
06-20-79
SIE
97634
259.1
747.9
65.61
5.814
326.3
210
11.4
NESSLER
97072
257.7
743.8
65.24
SIE
67608
175.1
520.9
45.69
5.960
335.6
212
11.4
NESSLEK
64868
171.6
497.1
43 .62
193656
454.0
1528
135.2
41051
96.25
323.9
28.67
172904
405.4
1 364
120.7
36641
85.91
289.1
25.58
301360
848.0
2267
197.1
63957
180.0
489.1
41.85
286070
805.0
2152
187.2
60708
170.8
456.8
39,72
459454
1220
3522
308.9
97559
259.0
747.6
65.59
456809
1213
3500
307.0
96997
257.5
743..3
65.19
31815S
823.8
2451
215.0
67522
174.8
529.0
45.63
305261
810.3
2341
205.4
64782
172.0
496.9
43.59
Dry standard cubic feet e 68 l;, 29.92 inches llg.
Dry standard cubic feet per minute.
Specific Ion Electrode analysis method.
Nessler (with preliminary distillation) analysis method.
Ammonium nitrate (nig) = ammonia (nig) X 80/17.,
Excess ammonia = ((Ammonium nitrate calculated from ammonia) - (Aimnoniinn nitrate calculated directly, from Table 2-16)) X 17/80.
-------
o
I
RUN NUMBER
DATE
VOLUME OF GAS SAMPLED (DSCF)a
AWMNIA
Total Sample Weight (Milligrams)
Grains/nSCF
AMMONIUM NITRATE CALCULATED
FROM
Total Sample Weight (Milligrams)
Crains/DSCF
EXCESS AMMONIA6
Total Sample Weight (Milligrams)
Grains/DSCF
TABLE 2-21
SUMMARY OF AMMONIA, CALCULATED AMMONIUM NITRATE AND
CALCULATED EXCESS AMMONIA MEASUREMENTS ON
CASES SAMPLED AT 2004 ISOKINET1C I-XITING
NEUTRALIZER NO. 2 SCRUBBER AT
C F INDUSIIUES, INC.,
HARRISON, TI-NNESSHE
Run 4
06-21-79
3.493
SIE1' Nessler
9455 9305
41.77 41.11
44494 43788
196.6 193.5
9427 9277
41.65 40.99
Run 5
06-21-79
3.405
Run 6
06-21-79
2.792
c SIE Nessler S1E Nessler
19552
88.61
92009
417.0
19518
88.46
17922 27857 22483
81.23 154.0 124.3
84339 131092 105802
382.2 724.6 584.8
17888 27816 22442
81.07 153.7 124.0
Average
3.230
SIE Nessler
18955 16570
90.56 79.17
89198 77976
426.2 372. S
18920 16536
90.39 79.00
;i Dry standard cubic feet e 68°F, 29.92 inches llg.
b Specific Ion Electrode Analysis method.
c Nessler (with preliminary distillation) analysis method.
d Ammonium nitrate (ing) = ammonia (mg) x 80/17.
c Excess ammonia = (Aiunonium nitrate calculated from ammonia) - (ammonium nitrate measured directly, from Table 2-17) x 17/80.
-------
TABU- 2-22
SUMMARY OF ANMONIA, CALCUI.ATED A»«NHM NITRATE
AND CAI.CUUV1ED EXCESS ANMON1A MEASUREMENTS
ON GASES SAMPLED AT 50% ISOKlNliTIC EXITING NF.UTRALIZER NO. 2 SCRUBBER
AT C FiNmSTKIES, [NT.,
HARRISON, TliNNESSEE
RUN NUMBER
OATH
VOI.UMK OP GAS SAMPLED (DSCF) !l
AMMONIA
Total Sample Weight (Milligrams)
Grains/DSCF
AMMONIUM NITRATE CALCULATED
I-ROM AMMONIAC
Total Sample Weight (Milligrams)
Grains/DSCF
I-XCI-SS MMONIAe
Total Sample Weight (Milligrams)
Graijis/DSCP
RUN 4
RIIN S
RUN 6
AVERAGE
06-21-79
SIP. ''
7145
44.71
33624
210.4
7124
44.58
2.466
NESSLER c
6729
42.11
31666
198.2
6708
41.98
06-21-79
S1E
13932
81.38
65562
383,0
13907
81.23
2.642
NESSLER
13223 '
77.24
62226
363.5
13198
77.09
06-21-79
SIE
21435
131.9
100871
620.7
21407
131.7
2.508
NP.SSLER
16868
103.8
79379
488.4
16840
103.6
SIE
14171
86.1
66686
405.3
14146
85.98
2.539
Nl-SSLI-R
12273
74.60
57757
351.0
12249
74.45
a Dry standard cucic feet 8 68°F, 29.92 inches llg.
h Specific Ion Electrode analysis method.
c Nesslcr (with preliminary distillation) analysis method.
d Ammonium nitrate (nig) = Ammonia (mg) X 80/17.
e P.xcess Ammonia = {(Ammonium nitrate calculated from Ammonia) - (Ammonium nitrate measured directly, from Table 2-17)) X 17/80.
-------
As described in Section 2.9, TRC directly evaluated the C0_ content of
the neutralizer No. 1 scrubber inle't gas stream during each test run using the
EPA orsat analyzer procedure. Since this scrubber system is essentially air
tight, these inlet COj concentrations were applied to both inlet and outlet
Neutralizer No. 1 sampling data in order to calculate gas stream molecular
weights.
Cyclonic flow was observed at the neutralizer scrubber outlets and
cyclonic flow angles were measured using the pitot-nulling technique described
in EPA Reference Method 1. During the actual sampling however flow angles
were not employed (probe tip was not rotated directly into the gas flow) . No
corrections have been made to the calculated neutralizer scrubber flow data,
so the volumetric and mass flowrates in these tables may be lower than the
flowrates that actually exist in the stacks. Average flow angles of 47 and 51
degrees were measured at the Neutralizer No. 1 and No. 2 scrubber outlets,
respectively. The flow angles measured at each traverse point are shown in
Appendix E. Details on current techniques of cyclonic flow measuring and data
handling are contained in Section 5.1 and Appendix E.
2.4 Evaporators
The ammonium nitrate and insoluable particulate data for the gas stream
leaving the Calandria alone, and for the combined gas streams from both the
Calandria and the air-swept falling-film (ASFF) evaporator, are shown in
Tables 2-23 and 2-24, respectively. The ammonia data for these gas streams
are shown in Tables 2-25 and 2-26, respectively.
-42-
-------
TABLE 2-23
SUMMKY OP AMMONIUM NITRATE AND INSOLUBLE PARTI CULATE MEASURB1ENTS
ON CASES EXITING '1103 CALAND1UA EVAPORATOR AT
C F INDUSTRIES, INC.,
HARRISON, TENNESSEE
u>
I
RON NUMBER Run 7
DATE 06-22-79
VOJ.UME OP GAS SAMPLED (DSCF)a 0.1561
PERCENT MOISTURE BY VOLUME 99.77
AVERAGE STACK T»1PERATURE ( F) . 289
STACK VOLUMETRIC FLOWRATE (DSCFM) 8.272
PERCENT ISOKINETIC 98.3
pRonucriON RATE (TONS/HOUR) 17.2
INSOLUBLE PARTICUI.ATE
Total Sample Weight (Milligrams) 46.31
Grains/DSCF 4.578
Pounds/! bur 0.3246
Pounds/Ton 0.01887
AMMONIUM NITRATE PARTIOJLATEC
Total Sample Weight (Milligrams) 541.0
Grains/DSCF 53.48
Pounds/I bur 3.792
Pounds/Ton 0.22047
TOTAL PARTIQII.ATE: INSOLUBIJE
AND AMMONIUM NITRATE
total Sample Weight (Milligrams) 587.3
Grains/DSCF 58.06
Pounds/ltaur 4.117
Pounds/Ton 0.23936
Run 8
06-22-79
0.1674
99.78
291
8.291
105.1
17.5
68.81
6.343
0.4508
0.02576
565.0
52.09
3.702
0.21154
633.8
58.43
4.152
0.23726
Run 9
06-22-79
0.2054
99.73
290
10.280
104.1
17.7
21.60
1.623
0.1430
0.00808
768.2
57.72
5.086
0.28734
789. f,
59.34
5.229
0.29542
0.1763
99.76
290
8.948
102.5
17.5
45.57
3.989
0.3059
0.01748
624.7
54.68
4.194
0.23966
670.3
58.67
4.500
0.25714
a Dry standard cubic feet @ 68 F, 29.92 inches l!g.
h Dry standard cubic feet per minute,
c Specific Ion Electrode Analysis method. This method measures nitrate (Nf)j-); ammonium nitrate (nig) = nitrate (mg) x 80/62,
-------
TABLE 2-24
SUMMARY OP AMMONIUM NITRATE AND INSOLUBLE PARTICULATE MEASURB1ENTS
ON COMBINED GASES EXITING BOTH THE CALANDIUA EVAPORATOR
ANI1 THE AIR-SWEPT FAI.tlNG- ¥ ILM EVAPORATOR AT
C F •INDUSTRIES, INC.,
HARRISON, TENNESSEE
RUN NUMBER
DATE
VOIiUME OF GAS SAMPLED (DSCF)a
PERCENT MOISTURE BY VOIJJME
AVERAGE STACK TIM>ERATURE ( F) .
STACK VOLUMETRIC F1XWRATE (DSCFM)
PERCENf ISOKINETIC
pRonucnoN RATE (IONS/HOUR)
Run 7
06-22-79
19.85
32.45
311
3196
113.2
20.3
Run 8
06-22-79
19.09
43.38
313
2728
127.5
21.0
Run 9
06-22-79
19.63
35.71
315
3213
111.4
21.0
19.52
37.18
313
3046
117.4
20.8
INSOUJBLE PARTICULATE
Total Sample Weight (Milligrams)
Graiiis/DSCF
Pounds/Hour
Poiuids/Ton
AMMONIUM NITRATE PART1CULATEC
Total Sample Weight (Milligrams)
Graiiis/DSCF
Pounds/Hour
Poiinils/Ton
TOT'AL PARTICULATE: INS01AJBLE
AND AWDNIUM NITRATE
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
44.78
0.0348
0.9533
0.04696
144.0
0.1120
3.068
0.15113
188.8
0.1468
4.021
0.19808
21.03
0.0170
0.3975
0.01893
148.0
0.1196
2.797
0.13319
169.0
0.1366
3.194
0.15210
12.80
0.0101
0.2771
0.01320
146.5
0.1152
3.173
0.15110
159.3
0.1252
3.448
0.16419
26.20
0.0207
O.S404
0.02598
146.2
0.1156
3.018
0.14510
172.4
0.1363
3.559
0.17111
a Dry standard cubic feet e 68 F, 29.92 inches llg.
b [try standard cubic feet per minute.
c Specific Ion Electrode Analysis method. This method measures nitrate (NOj-); ammonium nitrate (mg)
nitrate (mg) x 80/62.
-------
TABLE 2-25
SUNMARY OP AMMONIA, CALCUIATED AMMONUM NITRATE
AND CALCULATED EXCESS ANMONIA MEASUREMENTS
(IN CASKS EXITING TIIE CAIANDR1A EVAPORATOR
AT C P INDUSTRIES, INC.,
HARRISON, TENNESSEE
Ln
I
RUN NIMHRR
MATE .
VOLUME OF CAS SAMPLED (DSCF) a .
STACK VOLUMETRIC FLOWRATE (DSCFM)
PRODUCTION RATE (TONS/HOUR)
AMMONIA
Total Sample Weight (Milligrams)
Crains/DSCF
Pounds/Hour
Pounds/Ton
AMMONIUM NITRATE CALCULATED
FROM AMMONIA e
Total Sample Weight (Milligrams)
Crains/DSCF
Pounds/I lour
Pounds/Ton
EXCESS ANHONIA f
Tot.al""Saniple Weight (Milligrams)
Crains/DSCF
Pounds/Hour
Pounds/Ton
Run 7
06-22-79
Run 8
06-22-79
Run 9
06-22-79
SIEC
6672
659.6
46.77
2.719
0.1561
8.272
17.2
0
.1674
8.291
Nesslerd
5802
573.6
40.67
2.365
SIE
6181
569.8
40.49
2.314
17.5
Nessler
5841
538.5
38.27
2.187
SIE
8921
670.3
59.06
3.337
0.2054
10.28
17.7
Nessler
8278
621.9
54.80
3.096
SIE
7258
635.3
48.73
2.785
0.1763
8.948
17.5
Nessler
6640
581.2
44.58
2.547
31398
3104
220.0
12.79
6557
648.2
45.96
2.672
27304
2699
191.4
11.13
5687
562.2
39.86
2.317
29087
2681
190.5
10.89
6061
558.7
39.70
2.269
27487
2534
180.1
10.29
5721
527.4
37.48
2.142
41981
3154
277.9
15.70
8758
658.0
57.98
3.276
38955
2927
257.9
14.57
8115
609.7
53.72
3.035
34155
2990
229.3
13.10
7125
623.7
47.84
2.734
31249
2735
209.8
11.99
6508
569.7
43.69
2.497
Dry standard cubic feet @ 68 F, 29.92 inches llg.
Dry standard cubic feet per minute.
Specific Ion Electrode Analysis method.
Nessler (with preliminary distillation) analysis method.
Ammonium nitrate (mg) = Ammonia (mg) X 80/17.
Excess aninonia = ((Ammonium nitrate calculated from ammonia) - (Ammonium nitrate measured directly, from Table 2-23)) X 17/80.
-------
TABLE 2-26
SUMMARY OP AMMONIA, CALCUIATED AMMONIUM NITRATE AND
CALCUIArED EXCESS AMMONIA MEAStlRlMENTS ON COMBINED
GASl-S EXITING BOTH THE CAIJVNuRIA EVAPORATOR AND
THE AIR-SWEPF FALLING-1-1LM EVAPORATOR AT
C F INDUSTRIES, INC.,
HARRISON, TENNESSEE
RUN NUMBER
DATE
V01.UME OP GAS SAMPLED (DSCF)a .
STACK VOUMETRIC FLOWRATE (DSCFM)
pRomicnoN RATE (TONS/HOUR)
AKMONIA
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
AMMONIUM NITRATE CALCULATED
FROM ANMOfTTA5
Total Sample Weight (Milligrams)
Grains/DSCF
Pounds/llour
Pounds/Ton
EXCESS AMMONlAf
Total Sample Weight (Milligr;uns)
C*ains/l)SCF
Pounds/1 tour
Pounds/Ton
Run 7
06-22-79
19.85
3196
20.3
S1EC
39238
30.51
835.8
41.17
8307
6.458
176.9
8.714
Nessler
29092
22.62
619.7
30.53
6151
4.782
131.0
6.453
Run 8
06-22-79
19.09
2728
21.0
SIE
Nessler
8338
6.482
177.6
8.749
6182
4.806
131.7
6.488
6739
5.448
127.4
6.067
6185
5.000
116.9
5.567
10233
8.045
221.5
10.55
10203
8.021
220.8
10.51
8437
6.670
174.1
8.370
7523
5.948
155.2
7.462
31713
25.64
599.5
28.55
6708
5.423
126.8
6.038
29106
23.53
550.2
26.20
6154
4.975
116.3
5.538
Run 9
06-22-79
19.63
3212
21.0
SIE Nessler
10233
8.045
221.5
10.55
481S5
37.86
1042
49.62
10202
8.020
220.8
10.51
10203
8.021
220.8
10.51
48014
37.75
1039
49.48
10172
7.997
220.2
10.49
SIE
8437
6.670
174.1
8.370
39702
31.39
819.3
39.39
8406
6.646
173.5
8.341
19.52
3045
20.8
Nessler
7523
5.948
155.2
7.462
35404
27.99
730.5
35.12
7492
5.923
154.6
7.433
a Dry standard cubic feet @ 68 F, 29.92 inches llg.
b Dry standard cubic feet per minute.
c Specific Ion Electrode Aiuilysis method.
d Nessler (with preliminary distillation) analysis method.
e Ammonium nitrate (mg) = ammonia (nig) x 80/17.
f Excess ammonia = [(ammonium nitrate calculated from ammonia)
- (ammonium nitrate measured directly, from Table 2-24)] x 17/80
-------
Table 2-27 shows the results of subtracting the Calandria gas stream data
from the combined Calandria and ASFF gas stream data to yield calculated mass
flowrates for the ASFF alone. A possible explanation for the negative
ammonium nitrate mass flowrates shown in Table 2-27 is that the measured
ammonium nitrate concentrations and mass flowrates for the Calandria alone are
erroneous (too high) . This is consistent with fact that the SIE analysis
method for ammonium nitrate (AN) is subject to positive error if the
background ion concentration is high relative to the nitrate concentration.
The very high concentrations of ammonia compared to AN concentrations in the
Calandria gas stream could be sufficient to produce a positive interference in
the AN analysis. This interference is discussed further in Section 5.0.
2.5 Particle Size Test Data
Particulate size distribution tests were performed on the prill tower
scrubber and prill cooler scrubber inlet gas streams with a cascade impactor.
No size distribution information was obtained, however, because essentially
all of the particulate matter was caught in the pre-collector. The data for
these particle sizing test runs is shown in Appendix F.
2.6 Visible Emissions
The prill tower scrubber outlet plume was monitored by certified visible
emissions observers from TRC and CFI for approximately seven hours during the
May 1979 test period. The 6-minute average opacity of the bluish-white plume
ranged from 2 percent to 19 percent. The TRC data are shown graphically in
Figure 2-1 and are tabulated in Appendix H.
-47-
-------
TABLE 2-27
SUMMARY OP INSOLUBLE PART Kill API;, ANMDNIUM NITRATE PARTICULATE AND
ANNONIA CALCU1ATED* MASS FLOWRATES FROM
TUB AIR-SWEPT FALLING-FILM EVAPORATOR AT
CF INDUSTRIES, INC.,
HARRISON, TENNESSEE
WIN NUMBER
DATE
.STACK VOLUMETRIC FLOWRATE (DSCFM)a
INSOLUBLE PARl'IOILATE
Pounds/I tour
, AMMONIUM NITRATE PARTICULATE
o^ Pounds/Hour
TOTAL PARTICULATE
Pounds/Hour
MEASURED ANMONIA
Run 1 Run 2
06-22-79 06-22-79
3192 2720
0.629 <0
<0 <0
<0 <0
SIEb Nessler0 SIE Nessler
Run 3
06-22-79
3203
0.134
<0
<0
SIE Nessler
Average
3036
0.234
<0
<0
Pounds/Hour
130.83 91.03 86.91 78.63 162.44 166.00 125.37 110.62
a Dry standard cubic feet per minute § 68 F, 29.92 inches llg.
b Specific Ion Electrode Analysis method.
c Nessler (with preliminary distillation) analysis method.
* All data on this table were calculated as follows: ASPF (this table) = Combined (Tables 2-24 and 2-26) - Calandria (Tables 2-23 and 2-25).
-------
>-
t-
I—I
CJ
o
20
15
10
0
3 4
TIME (HOURS)
o
o
LD
o
5-7-79
Otn
CO i-l
o
o
LO
o
5-8-79
5-9-79-
o
o
-5-10-79-
FIGURE 2-1: OPACITY READINGS ON THE PRILL TOWER SCRUBBER OUTLET
AT CF INDUSTRIES, INC.,
HARRISON, TENNESSEE
0988-002
-------
The two prill cooler scrubber outlet plumes were observed simultaneously
for three hours during the May testing period by certified TRC and CFI
observers, and all observations were zero. The combined plumes from the two
neutralizer scrubber outlets were monitored for five hours during the June
test period by both TRC and CFI observers, and these observations were also
all zero. The TRC prill cooler scrubber and neutralizer scrubber data are
shown tabulated in Appendix H.
2.7 Scrubber Liquor Analysis Data
Half-liter samples of scrubber liquor from the prill tower scrubber
sump, the prill cooler scrubber system inlet and outlet, and the neutralizer
No. 1 scrubber inlet were taken approximately every 30 minutes during each
emission test run. The analysis data for these samples are shown in Tables
2-28, 2-29 and 2-30, respectively.
The solution temperature was measured immediately after each sample was
taken; the pH was measured when the sample had cooled to room temperature.
At the completion of each test run the individual samples obtained during
that run were combined into one composite sample and analyzed for ammonia,
ammonium nitrate, undissolved solids, and, in the case of one prill tower
scrubber sample, magnesium.
2.8 Scrubber Pressure Drop Measurements
Pressure drop measurements were made across the prill tower scrubber,
prill cooler scrubber and neutralizer No. 1 scrubber during the emission test
runs. These data are shown in Tables 2-31 (prill tower) , 2-32 (prill cooler
east), 2-33 (prill cooler west) and 2-34 (neutralizer number 1). The
following data show the pressure drop ranges observed at each location.
-50-
-------
TABU 2-28
SUM4ARY OP MEASUREMENTS ON THE PRILL TOWER SCRUBBER LIQUOR
AT C F INDUSTRIES INC.,
HARRISON, TENNESSEE
Date
5-8-79
5-9-79
Run Number Time
1 1120
1150
1223
1250
1320
Average
2 1520
1550
1620
1650
Average
3 0930
0955
1030
1100
1200
Average
pjl
7.30
7.25
7.25
7.20
7.05
7.21
7.30
7.20
7.30
7.30
7.28
6.50
6.50
6.50
6.50
6.50
6.50
Temp.
80
81
81
81
81
81
81
80
80
80
80
79
79
79
80
80
79
Measurements Made on Combined Sitniples (PPM)
Ammonia . Ammonium
SlEaMessier" Nitrate3 Magnesium0
llndissolved
Solids*
115000
97895
507000
311
18.2
117000 105250
535400
13.0
73000
69125
363800
6.0
a Specific Ion Electrode Analysis method.
b Nessler (with preliminary distillation) analysis method.
c Analyzed by atomic absorption.
* Milligrams per liter.
-------
TABLE 2-29
SUMMARY OF MEASURI.MENTS MADE ON PIULI. COOLER SCN1IWER LIQUOR
AT C F INDUSTRIES, INC., HARRISON, TENNESSEE
Hate
5-10-79
5-11-79
N3
I
5-11-79
Run No. Time
4 1208
1238
1308
1350
1430
Average
5 0900
0940
1020
1100
1130
Average
6 1410
1450
1530
1605
1630
Average
j)M
6.20
6.35
6.40
6.40
6.45
6.36
6.30
6.55
6.30
6.60
6.60
6.47
6.45
6.45
6.50
6.45
6.50
6.47
1NLIT
Measurements Made on Combined Samples (PPM)
Ammonia A™. ,„;,„,, n,,i;ccr.i.io,i
Temp.(°F) SIE''1 Nesslerh Nitrate" Solids*
84
86
86
86
86
86 4400 4800 2300 1.3
84
83
85
84 .
88
85 5000 4600 2480 2.0
86
86
86
86
86
86 6600 6000 3100 3.0
nil
6.25
6.40
6.35
6.35
6.50
6.37
6.40
6.40
6.40
6.50
6.55
6.45
6.50
6.40
6.40
6.40
6.45
6.43
Measurements Made
Ammonia
Temp.(°F) SIE Nessler
83
86
86
86
86
84 4400 4400
82
85
85
86
86
85 5000 4400
87
88
88
88
88
88 6700 6300
OUTLI-T
on Combined Samples (PPM)
Aiiuuoniiim Undissolved
Nitrate Solids*
2300 2.3
2450 3.2
3250 4.4
Specific Ion Electrode Analysis method.
Nessler (with preliminary distillation) analysis method.
* Milligrams per liter.
-------
TABU: 2-30
«
SUMMARY OP MEASUREMENTS MADE ON THE NEUTRAUZER NO. 1
SCRUBBER 1NU3T LIQUOR AT C I- INDUSTRIES, INC.,
HARRISON, THNNESSEE
OJ
I
Date Run Niunber Time
6-19-79
6-20-79
6-20-79
1 1545
1610
1650
Average
2 1040
1110
1150
Average
5 1525
1345
1405
Ml
8.60
8.80
8.80
8.73
8.80
8.80
8.80
8.80
8.90
8.85
8.90
Temp. °F
168
175
190
178
170
170
182
174
170
178
180
Measurements Made on Combined Samples (ppm)
Annnonia . Aiiinoniurn Undissolved
SIEa Messier Nitrate3 Solids*
Average 8.89
176
16120 12900 70950
19400 12010 76760
18900 14970 78690
6.9
1.9
1.6
a Specific Ion Electrode Analysis method.
b Nessler (with preliminary distillation) analysis method.
* Milligrams per liter.
-------
TABIJB 2-31
SlINMAKY OF PRESS! IRC DROP MI2ASI (RIM-NTS MAD1; ACROSS
PRILL. TOWER SCRUBBIiR AT C P INDUSTRIES, INC.,
HARRISON, TENNESSEE
Date
5-8-79
Pressure Drop
Pressure Drop Pressure Drop
Run Number Time - (inches MzO) Date Run Number Time (inches 1120)
1 1114
1129
1138
1144
1159
1202
1208
1223
1226
1238
1241
1247
1250
1259
1305
1314
1320
1329
1332
1335
Average
K-
10.6 5-8-79
10.4
10.4
10.4
10.6
10.4
10.4
10.6
10.6
10.7
10.7
10.6
10.6
10.7
10.7
10.7
10.7
10.6
10.6
10.6
10.6
2 1458
1504
1510
1513
1516
1522
1525
1528
1534
1537
1540 .
1543
1546
1549
1552
1558
1601
1604
1636
1639
1642
1645
1648
1651
1700
1706
1709
1718
1721
1724
1727
1733
1736
1739
1742
1745
Average
10.9
10.8
10.8
10.8
10.8
10.8
10.8
10.8
10.9
10.9
10.1)
10.9
10.9
10.9
10.8
10.8
10.8
10,9
10.9
10.9
10.9
10.9
10.9
10.8
10.9
10.9
10.9
10.8
10.8
10.9
10.9
10.9
10.9
10.9
10.9
10.9
10.9
Date Run Number Time
5-9-79 3 0908
0911
0914
0934
0937
0940
0943
0946
0949
0952
0955
0958
1001
1004
1007
1010
1013
1016
1019
1022
1025
1028
1042
1045
1048
1051
1054
1057
1100
1103
1132
1135
1138
1141
1144
1147
1150
1153
1156
1159
1202
1205
1208
(inches llyO)
10.8
10.8
11.0
10.8
10.8
10.8
10.8
10.8
10.0
10.9
10.9
10.9
10.9
10.9
10.9
10.9
10.9
10.9
10.8
10.6
10.6
10.6
10.6
10.7
10.7
10.6
10.6
10.6
10.4
10.4
10.2
10.2
10.5
10.5
10.5
10.5
10.5
10.5
10.5
10.5
10.5
10.5
10.5
Average
10.7
-------
TABLE 2-32
SUWARY OF PRESSURE DROP MEASURB1UNTS MADE ACROSS THE
PRILL COOLER HAST SCRUBBER AT C F INUUSTRIliS, INC.,
Ln
(_n
I
Date Run Number Time
5-10-79 4 1203
1206
1209
1212
1215
1218
1221
1224
1227
1230
1233
1236
1239
1242
1245
1248
1251
1254
1257
1300
1303
1306
1309
1330
1333
1336
1339
1342
1345
1348
1351-
1354
1357
1400
1403
1406
1409
1412
1415
1418
1421
1424
1427
1430
1433
Average
Pressure Drop
(inches 1^0)
3.0
3.0
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.7
3.7
3.7
3.7
3.6
3.6
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.6
3.6
3.6
3.6
HARRISON, TENN
Date Run Number Time
5-11-79 5 0906
0909
0912
0915
0918
0921
0924
0927.
0930
0933
0936
0939
0942
0945
0948
0951
0954
0957
1000
1003
1006
1009
1041
1044
1047
1050
1053
1056
1059
1102
1105
1108
1111
1114
1117
1120
1123
1126
1129
1131
1134
1137
1140
1143
1146
3.7
Average
Pressure Drop
(inches 11?0)
3.5
3.5
3.5
3.5
3.6
3.6
3.6
3.6
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.6
3.6
3.7
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.6
3.6
3.6
3.7
Date liun Number
5-11-79 6
Time
1406
1409
1412
1415
1418
1421
1424
1427
1430
1433
1436
1439
1442
1445
1448
1451
1454
1457
1500
1503
1506
1509
1521
1524
1527
1530
1533
1536
1539
1542
1545
1548
1551
1554
1557
1600
1603
1606
1609
1612
1615
1618
1621
Average
Pressure Drop
(inches 1120)
3.5
3.6
3.6
3.5
3.6
3.6
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.6
3.6
3.6
3.6
3.6
3.4
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.8
3.7
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
-------
TABLE 2-33
SIWIARY OP PRESSURE DROP MEASUREMENTS MADE ACROSS
THE PRILL COOLER WEST SCRUBBER AT
Date
5-10-79
Pressure Drop
Run Number Time (inches 1120)
4 1200
1215
1230
1245
1300
1315
1327
1330
1345
1400
1415
1430
4.4
4.5
4.5
4.5
4.5
4.5
4.5
4.5
4.5
4.5
4.5
4.5
Average
I
Ul
CTi
4.5
C F INDIJSHUES, INC.
HARRISON, TENNESSEE
»
Pressure
Date
5-11-79
Run Number Time
5 0815
O'JOO
0915
0930
0945
10(10
1(115
1030
1045
1100
1115
1J30
1146
Average
(inches
4.4
4.4
4.3
4.3
4.3
4.3
4.3
4.3
4.3
4.3
4.2
4.2
4.2
4.3
Drop
1120)
Pressure Drop
Date Run Number
5-11-79 6
,
Time
1403
1415
1430
1445
1500
1515
1530
1545
1600
1615
(inches
4.2
4.3
4.2
4.2
4.2
4.2
4.2
4.2
4.2
4.2
1120)
Average
4.2
-------
TABLE 2-34
SUN-MARY OF PRESSURE DROP MEASUREMENTS
MADE ACROSS THE NEUTRALIZER NO. 1 SCRUBBER
AT CF LNDUSTRIES, INC., HARRISON, TENNESSEE
Date
Run Number
Time
Pressure Drop
Inches I
Inches Hg
6-19-79
1558
1616
1632
1640
1650
1700
Average
52.n
50.0
49
49
48
48
49.7
3.8
3.7
3.6
3.6
3.6
3.6
3.7
6-20-79
6-20-79
2
3
1034
1333
1339
1344
1359
1409
Average
64.5
56.0
57.0
57.0
58.
58.
,0
.0
57.2
4.7
4.1
4.2
4.2
4.3
4.3
4.2
-57-
-------
Location Pressure Drop Range
Prill tower scrubber 10.2 - 11.0 inches H20
Prill cooler scrubber (east) 3.0 - 3.8 inches H20
Prill cooler scrubber (west) 4.2 - 4.4 inches H20
/
Neutralizer No. 1 3.6-4.7 inches Hg
2.9 Integrated Gaseous Bag Samples
One single-point gaseous bag sample was taken directly from the
neutralizer No. 1 scrubber inlet gas stream during each of the three
neutralizer tests runs. Each sample was analyzed for C0_ an<3 Q within
one hour of collection using the EPA Reference Method 3 Orsat analyzer
procedure. The data obtained from these analyses are as follows:
Location Run Percent C02 Percent 02
Neutralizer No. 1 Scrubber Inlet
1
2
3
80.5
80.0
77.0
4.5
4.0
4.5
2.10 Ambient Air Measurements
Ambient air temperature/ relative humidity and barometric pressure were
recorded periodically during each emissions test run at the prill tower
scrubber, prill cooler scrubber, neutralizers and evaporators. These data are
shown in Tables 2-35, 2-36 and 2-37, respectively.
2.11 Product Samples
Solid product samples were taken by TRC personnel during the prill tower
scrubber and prill cooler scrubber emissions tests. These samples were
-58-
-------
TABLE 2-35
SllNMARY OF AMBIENT AIR MEASUREMENTS MADE AT
'HIE PRILL TOWER AT C F 1NDUSMUES, INC.,
HARRISON, TENNESSEE
Date Riui Nuiiber Tiine
5-8-79
Ul
vo
I
1030
1045
1100
1115
1130
1145
1200
1215
1230
1245
1300
1315
1330
1345
1400
Average
1415
1430
1445
1500
1515
1530
1545
1600
Ambient
73
74
76
77
78
78
79
78
78
80
80
80
80
80
80
78
80
79
79
77
77
76
76
76
Relative
Humidity %
69
67
62
59
60
60
64
60
60
64
54
54
54
54
54
60
54
57
57
59
59
62
62
62
Barometric
Pressure
Indies llg
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
Date
5-8-79
Run Number
2
Time
1615
1630
1645
1700
1715
1730
Ambient
Temp. °F
76
76
77
77
76
76
Relative
Humidity t
62
62
63
59
62
62
Barometric
Pressure
Inches llg
29.3
29.3
29.3
29.3
29.3
29.3
Average
5-9-79
77
0915
0930
0945
1000
1015
1030
1045
1100
1115
1130
1145
1200
1215
1230
1245
73
74
75
75
76
76
78
78
78
78
79
80
82
81
81
Average
78
60
73
74
70
70
70
74
63
63
63
63
60
61
58
57.5
57.5
65
29.3
29.3
29.3
29.3
29.3
29.3
29.
29.
29.
29.
29.
29.
29.
29.
29.
29.3
29.3
-------
TABLE 2-36
SUMMARY OF AMBIENT AIR MEASUREMENTS MADE AT
THE PRILL COOLER AT C F INDUSTRIES, INC.,
HARRISON, TENNESSEE
Hate
5-10-79
Run Number Tine
4 1200
1215
1230
1245
1300
1315
1330
1345
1400
1415
1430
1445
1500
Ambient
Temp. °F
92
92
92
93
93
93
93
95
95
97
97
97
97
Relative
Humidity %
48
48
48
48.5
48.5
48.5
48.5
41.5
41.5
37.5
39.5
39.5
39.5
Barometric
Pressure
Inches llg
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
5-11-79
O
Average
0900
0915
0930
0945
1000
1015
1030
95
85
85
87
88
88
88
88
45
56.
56.
53.
51
51
51
51
29.3
29,
29,
29,
29,
29,
29,
Date
5-11-79
Run Number Time
5 1045
1100
1115
1130
1145
Average
6 1400
1415
1430
1445
1500
1515
1530
1545
1600
1615
Average
Ambient
Temp. °F
89
90
91
92
93
89
97
98
97
97
98
99
100
99
99
99
98
Relative
Humidity %
48.5
47
47.5
45
42.5
50
39.5
38
39.5
39.5
38
35.5
35
34.5
34.5
36. S
37
Barometric
Pressure
Inches llg
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
29.3
-------
TABLE 2-37
SUMMARY OF .AMBIENT AIR MEASUREMENTS MADE AT
THE NEUTRALIZERS AiND EVAPORATORS AT
C F INDUSTRIES, !>£.,
HARRISON, TENNESSEE
Run Number Time
1 1633
1645
1654
Average
6-20-79
6-22-79
Average
1324
1333
1345
1357
Average
1036
1046
1051
Average
1322
1337
Average
1514
1524
1529
Average
Ambient
Temp. °F
94
98
95
96
1033
1039
1045
1105
1114
1120
85
88
88
83
37
87
86
89
89
90
87
89
84
81
81
82
85
91
88
96
90
90
92
Relative
Humidity %
34.5
34.0
34.0
34
54.5
51.0
51.0
76.0
57.0
53.5
57
51.5
51.5
47.0
57.0
58
62
69
69
67
53
46
49
48
41
44
44
Barometric
Pressure
Inches Hg
29.6
29.6
29.6
29.6
29.67
29.67
29.67
29.67
29.67
29.67
29.67
29.67
29.67
29.67
29.67
29.67
-61-
-------
analyzed at the CFI plant for bulk density and sieve size within two hours of
collection time. The time and location of the sampling, and the results of
these analyses are shown in Tables 2-38 and 2-39.
Solid product samples were also taken by CFI personnel and were chemically
analyzed by CFI. The results of these analyses are considered confidential by
CFI and are not presented in this report.
Samples of the liquid ammonium nitrate (AN) solutions and feed melts were
taken by CFI personnel periodically during all the emissions test runs.
Sampled were the 85% AN solution from neutralizer No. 1 to the surge tank, the
85% AN solution from the surge tank to the Calandria, the 94% AN solution from
the Calandria to the ASFF evaporator and the 99% AN feed melt from the ASFF
evaporator to the prill tower. Chemical analyses were performed by CFI on the
samples for pH, temperature, ammonia and ammonium nitrate. These analyses
results are also considered confidential by CFI and are not presented in this
report.
-62-
-------
TABU: 2-38
SUMMARY OP SUM: ANALYSIS AND HULK DI-NSITY MliASURI-MHNTS
ON 'nil: SOLID PROIXICT SAMPLED HI-r-OKI- LMIT-RING Till; PRILL COOUiR
AT 0 F INDUSTRIES, INC., HARRISON, TENNESSEE
Run Number
Hate
Time
Mass
(Grains)
1 Total Sample To Sieves 150. SI
ty>
U)
S.ieve #6 0.12
Sieve «8 20.61
Sieve #10 39.93
Sieve S12 57.73
Sieve #1.4 30.43
Sieve #16 9-07
Itottoin Pan 1.62
Total Mass on Sieves ami Pan 159.51
]
5-8-79
1250
t Cumulative
Total 5 Total Miss
Mass Mass (Grams)
201.38
O.I 100 0.58
12.9 99.9 30.12
25.0 87.0 55.74
36.2 62.0 74.65
19.1 25.8 30.32
5.,7 6.7 8.13
J..O 1.0 1.84
201,38
2
5-8-79
1525
4 Cumulative
Total % Total Mass
Mass Mass (Grains)
203.73
0.3 100 1.14
15.0 99.8 48.34
27.7 84.8 65.61
37.1 57.1 52.52
15.1 20.0 31.96
4..0 4.9 3.02
0.9 0.9 1..10
203.69
3
5-9-79
1000
S Cumulative
Total 1 Total
Mass Mass
0.56 100
23.7 99.44
32.2 75.74
25.8 43.54
15.7 17.74
1.48 2.04
0.54 0.56
Ikilk Density (Grams per 250 ml) 258.25
254.76
260.84
-------
TABLE 2-39
SUNMARY OP SIEVE ANALYSIS AND BULK DENSITY MEASUREMENTS
ON THE SOLID PRODUCT LEAVING THE PRILL COOLER
(BEPORE SCREENING) AT C F INDUSTRIES, INC.,
HARRISON, TENNESSEE
cr.
RUN NUMBER
DATE
TIME
TOTAL SAMPLE TO
SIEVES
SIEVE NO. 6
SIEVE NO. 8
SIEVE NO. 10
SIEVE NO. 12
SIEVE NO. 14
SIEVE NO. 16
BOTTOM PAN
TOTAL MASS ON
SIEVES AND PAN
BULK DENSITY
(grams per 250 ml)
5-10-79
1225
1
5-10-79
1225
2
5-11-79
0935
2
5-11-79
0937
3
5-11-79
1430
3
S-ll-79
1430
Cmnula-
% tive
Mass Total % Total
(grams) Mass Mass
201.76
0.96 0.5 100
42.48 21.0 99.5
60.25 29.9 78.5
57.62 28.6 48.6
32.22 16.0 20.0
7.21 3.6 4.1
1.02 0.5 0.4
20 1 . 76
257.94
Cuimila-
% tive
Mass Total \ Total
(grams) Miss Mass
201.37
1.20 0.6 100
48.42 24.0 99.4
60.93 30.2 75.4
57.05 28.2 45.2
28.12 13.9 17.0
S.33 2.6 3.1
0.85 0.4 0.4
201.90
2 SO. 10
Cimuila-
% tive
Mass Total \ Total
(grains) Mass Mass
202.66
1.19 0.6 100
42.99 21.2 99.4
65.63 32.3 78.2
65.38 32.2 45.9
19.94 9.82 13.7
7.29 3.6 3.9
0.54 0.3 0.3
202.96
258.47 .
Cum.il a -
1 tive
Mass Total 1 Total
(grams) Mass Mass
202.57
1.50 0.7 100
54.26 26.7 99.3
62.29 30.7 72.6
54.84 27.0 41.9
22.32 11.0 14.9
6.14 3.0 3.9
1.76 0.9 0.9
203.11
248.25
Qimula-
% tive
Mass Total \ Total
(grains) Mass Mass
203.50
0.55 0.3 100
26.59 13.0 99.7
49.92 24.5 86.7
77.68 38.1 62.2
38.25 18.8 24.1
9.33 4.6 5.3
1.47 0.7 0.7
203.79
258.51
Cumuia-
% tive
toss Total \ Total
(grams) Mass Mass
200.79
0.84 0.4 100
33.49 16.6 99.6
53.21 26.4 83.0
69.55 34.6 56.6
34.44 17.1 22.0
7.46 3.7 4.9
2.29 1.1 1.1
201.28
248.8
-------
3.0 PROCESS DESCRIPTION AND OPERATION
Emission measurements were made at the CF Industries, Inc., Chattanooga
Nitrogen Complex facility in Harrison, Tennessee during May and June 1979 in
order to obtain data necessary for the development of a new source performance
standard for the ammonium nitrate (AN) manufacturing industry. This plant is
considered to employ process and emission control technology representative of
high density AN prilling, rotary drum cooling, and modern AN solution
production and concentration processes.
Figure 3-1 presents a flow diagram of the entire AN production process,
and Figure 3-2 shows more detail of the AN solution production and
concentration process. The emissions tests were designed to characterize and
quantify uncontrolled emissions from the solids production processes (Prill
Tower and Prill Cooler: May 8 - 11) and the solution production processes
(Neutralizers and Evaporators: June 19 - 22) , and to determine emission
control equipment efficiency. During the emissions tests, process parameters
pertinent to the operation of the various production streams were monitored in
order to determine if the process was operating at representative steady-state
conditions. Emission test locations and process product sampling locations
are indicated by T and S, respectively, in Figures 3-1 and 3-2.
3,1 Process Equipment
Nitric acid at a concentration of approximately 58% by weight and
ammonia-rich off-gas from the 120 ton per day (108.9 x 103 kg/hr) once
through urea plant are fed to two parallel neutralizers. Additional ammonia,
when needed, can be supplied from ammonia vaporizers. Ammonia-rich urea plant
off-gas is preferred since this gas has no other use in the facility and would
-65-
-------
TO ATMOSPHERE
CYCLONIC SEPARATORS
r
VENTURI
SCRUBBERS
SCRUBBER LIQUOR MAKE-UP TO VENTURIS
TO ATMOSPHERE
VALVED
VENT TO
ATMOSPHERE
RUPTURE DISC VENT
TO ATMOSPHERE
___!__
-i/TL
WEAK LIQUOR ^
EYAPORATI
*~ 1 ">
». L _ _ I i. _ _ —.
i BUHERFLY VALVE |
} OPEN 99^91 AH t ,250.000 J/HR_AIRJ
AIR FLO
I FANS |ATR~FLCfl"
>200 HPf CONTROL
MPERS
JL EACHJLj)AMI
SOUTHJ | NOR1
|NORTH
t
t-J$
- ->f±3
SCRUBBER LIQUOR
RECYCLE *• 35X AN
I
ADDITIVE
PRODUCTION
STEAM ^
C
COK
n
ALANORIA 1
CENTRATOR
BUELL SEPARATORS
AP • 10" W.C.
EACH PAIR
_COOLING AIR IN
^ J 25.000 SCFM
HEATED SWEEP
AIR
AIR-SWEPT
FALLING-FILM
EVAPORATOR
\ 90 TON / Xffi TON./
XBULK/ xAGGiNy
X«,y ^*IN/
BIN
OFFSIZE RECYCLE AS LIQUID
LEGEND
—— AMMONIUM NITRATE
GAS STREAMS
OTHER PROCESS STREAMS
FIGURE 3-1: HIGH DENSITY AMMONIUM NITRATE PRODUCTION AT
CF INDUSTRIES, INC., HARRISON, TENNESSEE
0988-003
-------
VENTURI -\
SCRUBBER N. .
SCRUBBER
LIQUOR *
OUT
(
1 * f
/^UREA^X NEL
VOFF - GASy nt
1 '
WEAK
LIQUOR
rvAnflPATOR
r~i
1 ADDITH
1 PRODUCT
1 , t
j) SCRUBBER © X^
T LIQUOR T {
(^\ IN
t\^\.J W
l4» ^
A X|\
m i I
•—/ _ ..^TV x
* f f •r^-*i
\ \ \ H
ITRALIZER NEUTRALIZE
(S2) A VENT
Y , JATMOSPI
85% AN
^ SURGE TANK
^)85% AN
^Y^
CALANDRIA
CONCENTRATOR
/E
ION °T|:AM *
<
CONDLNSAIL
ADDITIVE
1
1
1
,- VENTURI
/ SCRUBBER
SCRUBBER
^ LIQUOR
OUT
L ••
R (JW;T) (^NOT) ^.
TO V
« ^" |
,*
96% AN
t
/ <&
| TO ATMOSPHERE
1
KOCH
VALVE
TRAY
SCRUBBER •«- ,
t 1
Y
I
I
STEAM 1
^ 1
i
t
1
I
' i
CONDENSATE 1
1
^ TO PRILL 1
R-SWEPT-^ qn.y flN - TOWFR i
FALLING-FILM "+% AN 10WER 1
EVAPORATOR 1
_l
FIGURE 3-2: AMMONIUM NITRATE SOLUTION PRODUCTION AND CONCENTRATION LINE,
AT CF INDUSTRIES,INC., HARRISON, TENNESSEE
0988-004
-------
otherwise be wasted. The plant considered their neutralizers to be of the
atmospheric type because they operate at an internal pressure of about 5
psig. The neutralizer pH is generally between 6.3 and 7.0.
The 85% AN solution produced in the neutralizers flows into a common surge
tank. This surge tank also received recycled AN solution from the weak-liquor
evaporator. (The weak-liquor evaporator is a Calandria and receives recycled
scrubber liquors and redissolved off-size product rejected by the screening
operation.)
The AN solution leaving the 85% AN surge tank is passed through a shell
and tube steam-heated Calandria for the first stage of concentration to a
nominal 96% AN concentration. The solution is then sent to the 96% AN surge
tank.
From the 96% AN surge tank, the AN solution is sent through an air-swept
falling-film evaporator for second stage concentration to a nominal 99.4 to
99.9% by weight AN concentration.
Magnesium nitrate additive is injected into the 96% AN solution
immediately before the second stage of concentration at a rate of 0.5% by
weight as MgO or 1.85% by weight as Mg(N03)2< This additive serves three
purposes: it increases the crystalline transition temperature of the solid
final product from 89°F (32°C) to 120°F (49°C) ; it acts as a dessicant
to draw water into the final product prills, thus reducing caking; and it
allows prilling to be conducted at a lower temperature by reducing the molten
AN salting-out temperature.
The 99+ percent melt is pumped through jacketed pipe to the top of the
25-foot diameter aluminum Prill Tower. Either steam or weak condensate can be
pumped through the jacket, depending upon whether heating or cooling is
-68-
-------
required. The AN droplets fall downward countercurrent to an induced air flow
in the Prill Tower. The prills are collected at the bottom of the Tower on a
belt conveyor. The solid prill product is then conveyed to a rotary drum
cooler.
The rotary drum cooler reduces the AN prill temperature while removing
nominal amounts of residual moisture from the prills. This is accomplished by
a stream of refrigerated air flowing countercurrent to the direction of the
prill movement inside the cooler.
After the cooler, a vibrating screen sizes the prills. Over and
under-size prills are redissolved and recycled to the weak liquor concentrator.
The cooled, correctly sized prills leave the screen and are belt-conveyed
to either a 90-ton (81.6 x 10 kg) capacity bulk bin from which railcars or
trucks can be loaded or a 25-ton (22.7 x 10 kg) capacity bulk bin used to
supply the bagging operation.
3.2 Emission Control Equipment
Each neutralizer has been retrofitted with Monsanto "Brinks" H-V mist
eliminators to lessen the carry-over of raw materials and product.
Venturi-cyclonic separator scrubbers have also been recently installed on each
of the neutralizers. The 5 psig {3.4 x 10 Pa) internal operating pressure
of the neutralizers provides enough force to operate the venturi scrubber at a
pressure drop of approximately 55 inches (140 cm) vertical water column.
Cyclonic separators immediately follow the Venturis.
Along with the Prill Tower emissions, the first-stage Calandria
Concentrator, the second-stage Air-Swept Falling-Film Evaporator, the
weak-liquor concentrator, and the additive reactor vents are normally ducted
-69-
-------
to a Koch valve tray scrubber. For these emission tests, however, these
latter four process units were vented directly to the atmosphere so that only
the Prill Tower emissions were applied to the Koch scrubber.
Four ducts collect the total air flow through the Prill Tower and carry it
down the side of the Tower from where it is ducted over to the Koch valve tray
scrubber. Contaminated air from the Prill Tower enters the bottom of the
scrubber from two sides and must bubble up through two "valve" trays which are
each flooded with 4 inches (10 cm) of scrubbing liquor. The valve trays
operate in a similar manner to the bubble cap distillation principle.
The scrubbing liquor is maintained at 30 to 35 percent AN and is adjusted
to a pH of between 6.7 and 7.6 by the addition of nitric acid. This plant has
found that AN is not effectively scrubbed from the gas stream at a pH below 6
and ammonia is not scrubbed effectively above 7.8. The addition of nitric
acid to the scrubber liquor enhances ammonia removal from the gas stream by
promoting the formation of ammonium nitrate in the scrubber. Scrubber liquor
is recycled to the weak-liquor concentrator for AN recovery.
Two fans, one 500 horsepower (3.73 x 10 watts) and one 600 horsepower
(4.47 x 10 watts), operate in parallel and exhaust to a common stack.
These fans induce the air flow through both the Prill Tower and the Koch
scrubber and their associated ducting. Dampers in the ducts after the fans
provide air flow rate control.
The rotary drum cooler exhaust air stream is divided into two separate
streams. These air streams each enter a spray chamber. The air exiting each
of the spray chambers is again divided into two streams (four streams total).
Each stream tangentially enters a Buell cyclonic separator. Each of the
-70-
-------
cyclonic separators as well as the spray chambers are irrigated with a weak
ammonium nitrate solution. This scrubber solution as well as the Koch
scrubber solution is recycled to the weak-liquor concentrator for AN
recovery. Two fans induce the air flow through separate pairs of Buell
units. The two fans in parallel also induce the chilled air flow through the
cooler. The fans each exhaust through a separate stack.
3.3 Production Rate Monitoring
During emissions testing of Neutralizer No. 1 and its associated venturi-
cyclonic separator unit, the nitric acid feed rate to the neutralizer was
monitored and recorded. Since no other flow measuring device was available,
the on-site nitric acid plant total production was piped directly to the two
parallel neutralizers and the production rate was recorded. The nitric acid
surge tank and its pump were bypassed so that the nitric acid production rates
could be utilized as a measure of acid fed to the Neutralizer. By setting
both neutralizer internal pressures equal to one another, equal production
rates for each neutralizer were assured. This equalization of internal
pressures was checked before each emission test. Total production rates for
the neutralizers were calculated as 100% AN stoichiometrically from the
equation:
NH3 + HNO3 * NH4N03
and are as follows:
-71-
-------
Average Neutralizer No. 1
Production Rates
During Emissions Tests
PRODUCTION RATE
TEST
Scrubber
Scrubber
Scrubber
Inlet
Inlet
Inlet
and
and
and
Outlet
Outlet
Outlet
Test
Test
Test
No.
No.
No.
1
2
3
(Ton/Hr)
11
11
11
.26
.54
.43
(Mg/Hr)
10
10
10
,21
47
37
During emissions testing of the two-stage concentrators, direct reading
flow meters were utilized. The 85% AN solution flow rate to the first-stage
Calandria Concentrator and the 99% AN solution flow rate from the second-stage
Air-Swept Falling-Film Concentrator were monitored and recorded. Actual
production rates were calculated as 100% AN and are as follows:
Average Concentrator
Production Rates
During Emissions Tests
PRODUCTION RATE
TEST (Ton/Hr) (Mg/Hr)
Uncontrolled Calandria Test No. 1
Uncontrolled Calandria Test No. 2
Uncontrolled Calandria Test No. 3
Uncontrolled Air-Swept Falling-Film
Test No. 1
Uncontrolled Air-Swept Falling-Film
Test No. 2
Uncontrolled Air-Swept Falling-Film
Test No. 3
17.18
17.51
17.66
20.30
20.99
20.99
16.14
15.89
16.02
18.42
19.04
19.04
Ammonia (NH^) is injected into the high density evaporator and the head
house at the top of the Prill Tower. This is done to inhibit the
dissociation (fuming) of AN melt and reportedly cuts down on fine particulate
formation. Testing of the Prill Tower scrubber was conducted both with and
without ammonia injection. The ammonia injection status during each test was
as follows:
-72-
-------
Ammonia Injection Status
During Each Test
TYPE OF TEST
Prill Tower Emissions
Prill Tower Particle Size
Cooler Emissions
Cooler Particle Size
TEST 1
on
off
off
off
TEST 2
on
on
off
off
TEST 3
off
on
on
on
The feed rate of concentrated ammonium nitrate melt to the Prill Tower as
measured by a volumetric flow meter was monitored and recorded. Actual
production rates are determined from this feed rate and a conversion equation
given by the plant. Since all of the prills leaving the Prill Tower go
directly to the cooler and no other product rate measuring devices are
present, the AN melt feed rate to the Prill Tower was used in calculating
production rates for the cooler. Average Prill Tower production rates during
testing of the Prill Tower and Prill Cooler scrubbers are as follows:
Average
Prill Tower Production Rates
During
Prill Tower Scrubber and Prill Cooler Scrubber
Testing
TEST
Scrubber Inlet and Outlet Test No. 1
Scrubber Inlet and Outlet Test No. 2
Scrubber Inlet and Outlet Test No. 3
Scrubber Inlet Particle Size Test No.
Scrubber Inlet Particle Size Test No.
Scrubber Inlet Particle Size Test No.
PRILL TOWER
TESTING
(Tons/Hr) (Mg/Hr)
21.0 19.1
21.0 19.1
21.3 19.3
1 21.0 19.1
2 21.0 19.1
3 21.0 19.1
PRILL COOLER
TESTING
(Tons/Hr) (Mg/Hr)
21.0 19.1
21.0 19.1
20.7 18.9
21.0 19.9
21.0 19.1
21.7 18.7
-73-
-------
Appendix M contains the actual production rate calculations for all
emissions tests.
3.4 Production and Control Equipment Monitoring
In addition to production rate determinations mentioned above, other
parameters were also monitored. During emission testing of Neutralizer No. 1,
the pH and temperature of both neutralizers, the 85% AN flow rate to the
Calandria, the nitric acid tank level and feed pressure, and the 85% AN tank
level were monitored and recorded.
During testing of the concentrators, the temperature and pressure of the
steam to the Calandria and the temperature of the steam to the Air-Swept
Falling-Film Evaporator were monitored and recorded.
Averages and standard deviations of all the above parameters monitored
during the emissions tests have been calculated and are presented in Table 3-1.
During testing of the prill tower and its scrubber emissions, the
temperature of the steam to the high density evaporator, the AN melt spray
temperatures, the pressures of the two scrubber pumps, the north and south
scrubber fan amperes, and the scrubber liquor pH were monitored and recorded.
During testing of the cooler and its scrubbers, the AN melt feed rate to
the Prill Tower, the temperature of the steam to the high density evaporator,
AN melt spray temperatures, cooler air inlet temperature, four scrubber pumps
pressures, and scrubber liquor tank level were monitored and recorded.
Averages and standard deviations of all the above parameters monitored
during the emissions tests have been calculated and are presented in Table 3-2
for Prill Tower tests, and Table 3-3 for cooler tests.
Standard deviations of parameters are not .presented for a test where the
number of parameter readings was three or less, unless the standard deviation
is zero. All recorded parameter values are presented in Appendix M.
-74-
-------
TABLE 3-1
AVERAGE VALUES OF NEUTRALIZER AND EVAPORATOR OPERATING PARAMETERS DURING EMISSIONS TESTING
No. 1 Neutralizer pH
No. 2 Neutralizer pH
No. 1 Nuetralizer Temp (r)
(°C)
No. 2 Neutralizer Temp (°F)
<°C)
85% AN Flow to Evap. (gpm)
Nitric Acid Feed Press (psi)
(Pa x 10')
Nitric Acid to Tank Level
85% AN Tank Level
99% AN Flow from Evap. (gpm)
(1pm)
Steam Temp to ASFF» (°F)
(°C)
Steam Temp to Calandria (°F)
<°C)
Stemp Press to Calandria (psi)
(Pa x 105)
Neutralizer Number 1 Emissions Tests
Test i
Avg.
6.54
7.67
288.7
142.6
289.1
142.8
59
223.3
62.7
0.32
61
-
Std.
Dev.
0.162
0.197
0.950
0.527
1.46
0.811
0.00
0.00
5.09
0.35
0.00
-
Test 2
Avg.
6.70
7.64
297.4
147.4
296.8
147.1
70.0
264.9
19.2
1.32
49
61
Std.
Dev.
0.212
0.055
0.894
0.496
0.836
0.464
0.00
0.00
0.273
0.018
0.00
8.51
Test 3
AVR.
6.94
8.0
296.0
146.7
295.6
146.4
70
264.9
19.5
1.34
49
66.6
Std.
Dev.
0.114
0.071
0.071
0.039
0.548
0.304
0.00
0.00
0.00
0.00
0.00
3.13
Concentrator Emissions Tests
Test 1
AVR.
61.0
230.9
59.0
223.3
341.2
171.7
333.2
167.3
121.3
8.35
Std.
Dev.
0.00
0.00
0.00
0.00
0.447
0.248
1.643
0.912
0.447
0.031
Te
AVR.
60.0
227.1
61.0
230.9
340.5
171.4
337.0
169.4
123.0
8.48
U 2
Std.
Dev.
0.00
0.00
0.00
0.00
0.577
0.32
0.00
0.00
1.154
0.079
Test 3
AVR.
60.5
229.0
61.0
230.9
340.3
171.3
341.0
171.7
128
8.83
Std.
Dev.
0.00
0.00
0.00
0.00
1.155
0.641
0.00
0.00
0.00
0.00
Ul
I
•Air-Swept Falling-Film Evaporator
-------
TABLE 3-2
AVERAGE VALUES OF PRILL TOWER OPERATING PARAMETERS DURING PRILL TOWER EMISSIONS TESTING
99% AN Melt to Tower (gpm)
(Ipm)
Steam Temp, to H.D. Evap. (°F)
(°C)
Spray Temp. East (°F)
<°C)
Spray Temp. West (°F)
<°C)
No. 1 Scrubber Pump Pressure (psig)
(Pa x I05)
No. 2 Scrubber Pump Pressure (psig)
(Pa x I05)
South Fan Amps (Amps)
North Fan Amps (Amps)
Scrubber Liquor pH
Particulate Concentration
Scrubber Inlet and Outlet Tests
Test 1
Avg.
59.9
226.7
340
171.1
3*3
172.7
3*3
172.7
17.5
1.21
17.5
1.20
70
85
-
Std.
Dev.
0.133
0.503
0.267
0.148
0.474
0.263
0.474
0.263
0.00
0.00
0.00
0.00
0.00
0.00
-
Test 2
Avg.
60
227.1
339.7
170.9
343
172.7
343
172.7
18
1.24
18
1.24
70
85
Std.
Dev.
0.00
0.00
0.492
0.273
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Test 3
Avg.
60.9
230.5
339.7
170.9
341.6
172.0
341.6
172.0
17
1.17
17
1.17
70
85
6.83
Std.
Dev.
0.363
1.37
0.725
0.403
0.497
0.276
0.497
0.276
0.00
0.00
0.00
0.00
0.00
0.00
-
Particle Size Tests
Test 1
AVR.
60
227.1
340
171.1
341
171.7
341
171.7
17
1.17
17
1.17
70
85
6.85
Std.
Dev.
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
-
Test 2
Avg.
60
227.1
339
170.6
343
172.7
343
172.7
17
1.17
17
1. 17
70
85
7.6
Std.
Dev.
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Test 3
Avg.
60
227.1
339.7
170.9
342.3
172.4
342.3
172.4
17
1.17
17
1.17
70
85
7.6
Std.
Dev.
0.00
0.00
-
-
-
0.00
0.00
0.00
0.00
0.00
0.00
0.00
-------
TABLE 3-3
AVERAGE VALUES OF PRILL TOWER AND PRILL COOLER OPERATING PARAMETERS DURING COOLER EMISSIONS TESTING
99% AN Melt to Tower (gpm) gal/min
(1 pm)lit/min
Steam Temp, to H.D. Evap. (°F)
<°C)
Spray Temp. East (°F)
(°C)
Spray Temp. West (°F)
(°C)
Cooler Air Temp. In (°F)
(°C)
Scrubber Flow 1 (gpm)
(1 pm)
Scrubber Flow 2 (gpn~>)
(1 pm)
Scrubber Flow 3 (gpm)
(1 pm)
Scrubber Flow 4 (gpm)
(Ipm)
Scrubber Solution
Tank Level (inches)
(cm)
('articulate Concentration
Scrubber Inlet and Outlets
Test 1
AVR.
60
227.1
339.5
170.8
3*3.1
168.0
331.1
168.0
13.7
6.5
6.2
23.5
6.0
22.7
6.0
22.7
1.2
15.9
25
63.5
Std.
Dev.
0.00
0.00
0.687
0.381
1.12
0.622
1.12
0.622
0.52
0.288
0.26
0.981
0.00
0.00
0.00
0.00
1.2
1.51
0.0*
0.00
Test 2
Avg.
59.1
224.8
311.0
171.6
312.9
172.7
312.9
172.7
36.1
2.27
6.0
22.7
5.0
18.9
6.0
22.7
1.8
18.2
25
63.5
Std.
Dev.
0.51
1.93
2.33
1.29
0.99
0.55
0.99
0.55
2.03
1.12
0.00
0.00
0.00
0.00
0.00
0.00
0.75
2.83
0.00
0.00
Test 3
AVR.
59.1
221.8
311.2
171.7
316.2
171.5
316.2
171.5
12.5
5.83
6.0
22.7
5.5
20.8
6.0
22.7
1.8
18.2
25
63.5
Std.
Dev.
0.50
1.89
1.16
0.64
1.33
0.739
1.33
0.739
2.25
1.25
0.00
0.00
0.00
0.00
0.00
0.00
0.75
2.86
0.00
0.00
Particle Size Tests
Test 1
AVR.
60
227.1
341.3
171.8
175.5
348
175.5
44
6.66
6.0
22.7
6.0
22.7
6.0
22.7
1.5
17.0
25
63.5
Std.
Dev.
0.00
0.00
_
o.eo
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
-
0.00
0.00
Test 2
AVR.
60
227.1
310
171.1
310
172.2
314
173.3
34
1.11
6.0
18.9
5.0
18.9
6.0
22.7
4.5
17.0
25
63.5
Std.
Dev.
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
.
-
-
0.00
0.00
22.7
0.00
0.00
Test 3
AVR.
59
223.3
342
172.2
344
173.3
344
173.3
40
4.44
6.5
22.7
5.5
20.8
6.0
22.7
6.0
25
63.5
Std.
Dev.
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
-
-
-
-
-
0.00
0.00
-------
3.5 General Plant Operation
Neutralizer and Concentrator Operation
Overall, the solution production and concentration line operated smoothly
as the above data indicates. However, during the neutralizer testing,
constant monitoring and adjusting of the neutralizer pH was necessary.
The pH of both neutralizers never really "lined out", but plant personnel
did not feel this would affect either the emissions or the product.
Normal operation of the neutralizers includes a nitric acid surge tank and
pump; perhaps the removal of this surge tank and pump increased the lag
time of the pH controller and caused more fluctuations than normal. (For
these emissions tests, this tank and pump were bypassed, thus allowing the
nitric acid plant instrumentation to be used for neutralizer production
rate determinations.)
A decreased production demand led to a substantially reduced Air-Swept
Falling-Film Evaporator production rate between the first and second tests
of this unit. (Since no warehouse exists, the product must be shipped
very shortly after it is produced.) The unit's production rate had been
increased before the first two tests. After the second test, it was
decided not to turn down the rate until the testing was completed because
of the amount of manpower to accomplish this.
Prill Tower Scrubber and Cooler Operation
Overall, the entire AN solids production line operated very smoothly, as
Tables 3-2 and 3-3 indicate. However, during the first test of the Prill
Tower scrubber, the opacity of the scrubber stack seemed to noticeably
increase. The only explanation of this is that fumes from the neutralizer
overhead vents were sucked into the Prill Tower air inlet. One of the two
neutralizer overhead vents looked dirtier than the other until the liquor
flow rate to its venturi scrubber was increased.
Problems with the CO2 compressor in the 120 ton/day (108.8 x 103
kg/day) once-through urea plant caused that plant to shut down.
Therefore, ammonia feed to the neutralizers had to be supplied from the
ammonia vaporizers instead of the normal, ammonia-rich, urea off-gas.
This problem occurred before the third test of the Prill Tower scrubber
and was corrected before the test started.
-78-
-------
4.0 LOCATION OF SAMPLING POINTS
This section presents descriptions of the sampling locations used during
the emissions testing program conducted at the CF Industries, Inc., Harrison,
Tennessee, ammonium nitrate plant during May and June 1979. During the week
of May 7 - 11, 1979, the Prill Tower scrubber and Prill Cooler scrubber were
evaluated. During the week of June 18 - 22, 1979, the neutralizer scrubbers
and the evaporator emissions were evaluated. Figure 4-1 presents a simplified
overhead view of the ammonium nitrate production facilities.
4.1 Prill Tower
4.1.1 Scrubber Inlet - Ammonium Nitrate Sampling
The scrubber inlet sampling site was located in a 117-3/4 inch I.D.
horizontal fiberglass duct. A schematic of the sampling site, including the
traverse point sampling locations and duct dimensions, is shown in Figure
4-2. Two 3-1/2 inch pipe-flange sampling ports positioned 90° apart were
located 14 feet 1 inch (1.4 duct diameters) upstream of a short radius
right-angle bend. The nearest upstream disturbance was a contraction 40 feet
(4.1 duct diameters) from the ports. Since this sampling site did not meet
the "eight and two" criteria for distance from flow disturbances, eighteen
sampling points were chosen for each axis traverse, for a total of 36 sampling
points as specified in EPA Reference Method 1. Shown also in Figure 4-2 is a
cross-sectioned view of the duct at the sampling location and the exact
distance of each sampling point from the outside flange edge.
4.1.2 Scrubber Outlet - Ammonium Nitrate Sampling
The gases exiting the scrubber unit pass through two fans which direct the
-79-
-------
RAILROAD
i
00
O
I
BAGGING,
LOADING,
AND
STORAGF
AREAS
MO .7
V A
p^
(NO.I
v >
v^^x
PRILL
COOLER
PRILL
TOWER
NEUTRALIZERS
CONTROL
ROOM
O
O
CALANDRIA
EVAPORATOR
AIR-SWEPT FALLING-FILM
EVAPORATOR
O
PRILL TOWER
SCRUBBER
I I I I | I I I I
PRILL TOWER
SCRUBBER STACK
I I I I I I
RAILROAD
NOT TO SCALE
FIGURE 4-1: GENERAL LAYOUT OF AMMONIUM NITRATE PROCESS FACILITIES
AT CF INDUSTRIES, INC., HARRISON, TENNESSEE
0988-005
-------
TO SCRUBBER
TRAVERSE POINT
NUMBER
i
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
TRAVERSE POINT
LOCATION FROM
OUTSIDE OF
NIPPLE (INCHES)
5-1/8
8-5/8
12-3/8
16-3/8
20-3/4
25-5/8
31-1/4
38-3/8
48-1/2
76-1/4
86-3/8
93-1/2
99-1/8
104
108-3/8
112-3/8
116-1/8
119-5/8
TO SCRUBBER
INLET SAMPLING
PORTS
OVERHEAD VIEW
VERTICAL
FROM
PRILL
TOWER
\
121-1/4"
HORIZONTAL | ...ttt.tt + . .,IMM»
FIGURE 4-2: PRILL TOWER SCRUBBER INLET SAMPLING LOCATION
AT CF INDUSTRIES, INC., HARRISON, TENNESSEE
0988-006-001
-------
gases vertically through a fiberglass stack to the atmosphere. The scrubber
outlet sampling site was located in a 119-1/2 inch vertical fiberglass duct.
The stack was fitted with two 4-inch pipe-flange sample ports positioned 90°
apart. The two ports were located 5 feet 9 inches (0.6 diameters) upstream
from the top of the stack, and about 5 feet (0.5 diameters) downstream from a
baffle inside the stack. EPA Method 1 was again followed to yield 24 sampling
points for each axis traverse and a total of 48 sampling points in the stack.
Figure 4-3 shows a schematic of this sampling site including a cross-sectioned
view of the duct and the exact distance of each point from the outside flange
edge.
4.1.3 Particle Sizing Tests at Scrubber Inlet
Particle sizing tests were performed in the Prill Tower scrubber inlet gas
stream using a Sierra cascade impactor positioned in the duct through the test
ports used for the ammonium nitrate sampling tests. The impactor nozzle was
positioned at the geometric center of the duct for each impactor run.
4.1.4 Scrubber Pressure Drop Measurements
The gas pressure drop across the prill scrubber was measured with a water
manometer connected to taps in the scrubber inlet duct and the scrubber outlet
duct (upstream of the fans).
4.1.5 Scrubber Liquor Sampling
Scrubber liquor samples were taken from the scrubber sump downstream from
the circulating pump. Figure 4-4 shows the location of this sampling point.
-82-
-------
TRAVERSE POINT
NUMBER
1
?.
3
4
• , 5
6
7
8
9
10
11
I?
13
14
15
16
17
in
19
20
21
?.?.
23
24
TRAVERSE POINT
LOCATION FROM
OUTSIDE OF
NIPPLE (INCHES)
5-1/4
7-7/8
10-5/8
13-1/2
16-1/2
19-3/4
23-1/4
27-1/8
31-1/2
36-1/2
42-1/2
51-1/2
76
84-7/8
91
96
100-1/4
104-1/4
107-3/4
111
114
116-7/8
119-5/8
122-1/8
OVERHEAD VIEW OF
PRILL TOWER SCRUBBER
FROM PRILL TOWER
SOUTH
SCRUBBER
OUTLET
PORTS
BAFFLE
FIGURE 4-3:
NOT TO SCALE GROUND
PRILL TOWER SCRUBBER OUTLET SAMPLING LOCATION
AT CF INDUSTRIES,INC.,HARRISON, TENNESSEE
0988-007-001
-------
^.
w
1 V—i
VALVE W
TRAYS T
£V—J
BUELL ^^
SEPARATORS
« * v
SYSTEM
Tfc •&•
)
*,
«r
/"
( PU
V.
V
PRILL TOWER KOC
VALVE TRAY SCRUBB
m
*
s
MP )
_X
n rn rTI
j V Y
SPRAY
CHAMBERS
NO.l
NO.2
J
FIGURE 4-4: SCRUBBER LIQUOR SAMPLING LOCATIONS
AT CF INDUSTRIES, INC.,
HARRISON, TENNESSEE
-84-
NEUTRALIZER VENTURI
SCRUBBERS
jfSSAMPLING LOCATIONS
0988-008
-------
4.2 Prill Cooler
4.2.1 Scrubber Inlet - Ammonium Nitrate Sampling
The Prill Cooler inlet sampling site was located in a 30-inch I.D.
horizontal section of a stainless steel duct. Two 3-inch pipe-flange sampling
ports positioned 90° apart were located 21 inches downstream of a long
radius bend. The nearest downstream disturbance was a short radius right
angle bend 13 inches from the ports. Following the EPA Reference Method 1, 24
sampling points were located on each of the two traverse axis, to yield a
total of 48 sampling points. Figure 4-5 shows a schematic of the sampling
site including a cross-section of the duct and the exact location of each
sampling point.
4.2.2 Scrubber Outlets -. Ammonium Nitrate Sampling
The two Prill Cooler scrubber system outlet stacks (identified as East and
West) are identical in size. The sampling site in each was a 36-inch I.D.
vertical duct. Two 3-inch pipe flange sampling ports positioned 90° apart
were located 9 feet (3.0 duct diameters) downstream from an interior fan. The
nearest downstream disturbance was the top of the stack more than 6.0 feet
(2.0 duct diameters) from the ports. This sampling location required a total
of 48 sampling points, 24 on each traverse axis. The extreme points on each
traverse (points II, 24, 25 and 48) were within 1/2 inch of the stack wall.
Due to an oversignt by the field test leaders these points were dropped from
sampling, instead of being moved to and sampled at 1" from the stack wall as
called for in EPA Reference Method #1. Figure 4-6 shows a schematic of this
sampling location.
-85-
-------
TO SPRAY
OVERHEAD VIEW CHAMBERS
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22 .
23
24
TRAVERSE POINT
LOCATION FROM
OUTSIDE OF
NIPPLE (INCHES)
4
4
4-1/2
5-1/3
6-1/8
7
7-2/3
8-2/3
9-3/4
11-1/8
12-2/3
14-3/4
21
23-1/4
24-2/3
26
27-1/8
28-1/8
29
29-2/3
30-1/2
31-1/3
32
32
^^^^^^^^^
INLET SAMPLING — ^___ A
PORTS ^xT~T~l
/ O C=J> C=O \ ) TO SPRAY
/ Y CHAMBERS
-------
00
^J
I
-^"^
^^^
f~\
U.
A
ft
S T~ A fcl^V
FROM BUELL\ C=£> ( ™R ^
SEPARATORS/) V )
ROOF
^^^
\
>6'
- — | \
1^ >
~"^— PRILL
COOLER
OUTLET
PORTS
9'
i
t
SOUTH/WEST
f\ S .aX*"*^ '
90°-
// 1
EAST/SOUTH
1
;I-»X. t
\
|j •* l
I liiiilni li 1 • II Illlllllll • 1
F ;
t
39"
£11
""• i|i mill iv ^r^ •" i » ••!•¥ ¥r« i ^ u
' > I in
\ '.
N. :
WEST OUTLET/EAST OUTLET ^^
f
Ls .
^"^
u
, ,
'
f
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1 T
15
16
17
18
19
20
21
22
23
24
TRAVERSE POINT
LOCATION FROM
OUTSIDE OF
NIPPLE (INCHES)
4
4
4-1/4
5-3/16
6-1/8
7-3/16
8-1/4
9-1/2
10-7/8
12-7/16
14-3/8
17-1/8
24-7/8
27-5/8
29-5/8
31-3/8
32-1/2
33-3/4
34-7/8
35-7/8
36-3/4
37-7/8
38
38
FIGURE 4-6: PRILL COOLER OUTLET SAMPLING LOCATION (WEST
AND EAST) AT CF INDUSTRIES. INC.,
HARRISON, TENNESSEE
0988-010-001
-------
4.2.3 Particle Sizing Tests at Scrubber Inlet
Particle sizing tests were performed in the Prill Cooler scrubber system
common inlet gas stream using a Sierra cascade impactor positioned in the duct
through the test ports used for the ammonium nitrate sampling. The impactor
nozzle was positioned at the geometric center of the duct for each impactor
run.
4.2.4 Scrubber Pressure Drop Measurements
The pressure drops across the Prill Cooler scrubber system were measured
from the common gas stream inlet to the two outlet ducts, using two
manometers. The inlet pressure tap was a stainless steel tube inserted
through one of the ammonium nitrate sampling ports into the middle of the
duct. The outlet taps were located adjacent to each fan inlet.
4.2.5 Scrubber Liquor Sampling
Scrubber liquor samples were taken from the common inlet liquor line
(feeding both spray chambers) and from the common outlet liquor line returning
from all four Buell separators. Figure 4-4 shows the location of these
sampling points.
4.3 Neutralizers
4.3.1 Scrubber Inlet
The Neutralizer No. 1 venturi scrubber inlet sampling site was located in
a 20-inch I.D. vertical section of stainless steel duct. Because of physical
limitations at this location, only the southwest port with an extension was
used. This port was located seven feet (4.2 duct diameters) from the nearest
upstream flow disturbance (the neutralizer itself) and 22
-88-
-------
inches (1.1 duct diameters) from the nearest downstream flow disturbance (a
short radius right angle bend). On the one traverse axis, twelve sampling
points were chosen, in accordance with EPA Reference Method 1. Figure 4-7
shows a schematic of this sampling location. A special sampling probe
assembly was used to seal the port against the relatively high gas stream
pressure.
The inlet on Neutralizer No. 2 venturi scrubber was not tested.
4.3.2 Scrubber Outlets
Both neutralizer scrubber outlets were tested, and both outlet stacks are
identical. Each 19-1/2 inch I.D. vertical stack was fitted with two 3-1/2 inch
pipe-flange sampling ports positioned 90° apart. The ports were located
66-1/2 inches (3.4 duct diameters) downstream from a contraction, and 55
inches (2.8 duct diameters) upstream from the top of the stack.
In Neutralizer No. 1 scrubber outlet, only the back half of each traverse
axis could be used because of the physical limitations imposed by an in-stack
orifice. On each axis 7 sampling points were chosen, for a total of 14
sampling points. Figure 4-8 shows a schematic of the Neutralizer Number 1
scrubber outlet sampling location.
One sampling point on each axis (one inch from the duct center) was used
at the Neutralizer No. 2 scrubber outlet. Two probes were operated
simultaneously: one probe sampling at 50% isokinetic and the other probe at
200% isokinetic. Figure 4-9 shows a schematic of this sampling location.
4.3.3 Scrubber Pressure Drop Measurements
The pressure drop across the Neutralizer No. 1 scrubber was measured with
a manometer connected to taps in the scrubber inlet and outlet ducts.
-89-
-------
TO VENTURI
o
I
1
r 10"
t '
7
i
1
t
S
ft
FLOW
NEUTRALIZER
TRAVERSE POINT
NUMBER
1
2
3
4
5
6-
7
8
9
10
11
12
TRAVERSE POINT
LOCATION FROM
OUTSIDE OF
NIPPLE (INCHES)
34-1/8
35-1/16
36-3/16
36-2/8
38-3/4
40-7/8
46-5/8
48-3/4
50-1/4
51-3/8
52-7/16
53-3/8
SAMPLING
PORT
EXTENSION
FIGURE 4-7: NEUTRALIZER NO. 1 SCRUBBER INLET SAMPLING
LOCATION AT CF INDUSTRIES, INC.,
HARRISON, TENNESSEE
0988-011
-------
VO
M
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
TRAVERSE POINT
LOCATION FROM
OUTSIDE OF
NIPPLE (INCHES)
4-1/16
4-1/8
5"
5-7/8
7"
8-5/16
10-2/8
15-1/2
17-3/8
18-11/16
19-13/16
20-11/16
21-1/2
21-9/16
*ONLY POINTS 8 THROUGH 14 WERE USED
DURING TEST RUNS.
o
ft
FLOW
t
4'-7"
T
J
5 '-6V'
1
NORTHWEST
NORTHEAST
FIGURE 4-8: NEUTRALIZER NO. 1 SCRUBBER OUTLET SAMPLING
LOCATION AT CF INDUSTRIES, INC.,
HARRISON, TENNESSEE
0988-012-001
-------
VO
ro
o
n-
FLOW
4'-7'
22-5/8"
5'-6V
SOUTHEAST
SOUTHWEST
SAMPLING POINTS ONE
INCH FROM CENTROID
FIGURE 4-9: NEUTRALIZER NO. 2 SCRUBBER OUTLET SAMPLING
LOCATION AT CF INDUSTRIES, INC.,
HARRISON, TENNESSEE
0988-013-001
-------
The inlet tap consisted of a stainless steel tube inserted through the special
probe assembly into the center of the duct. The special probe assembly was
inserted through the inlet sampling port. The outlet tap was a stainless
steel tube inserted through the outlet sampling port into the center of the
duct.
4.3.4 Scrubber Liquor Sampling
Scrubber liquor samples were taken from the Neutralizer No. 1 scrubber
liquor inlet, downstream of the circulating pump discharge. The sampling
location is shown in Figure 4-4.
4.4 Evaporators
4.4.1 Calandria Concentrator Outlet
The Calandria concentrator outlet sampling site was located in a 20-inch
I.D. vertical stainless steel duct connecting the Calandria to the gaseous
effluent duct from the Air-Swept Falling-Film Evaporator. Because of the
extremely high moisture content in this duct, sampling was limited, with the
use of an in-stack orifice, to one port and only one sampling point at the
center of the duct. Figure 4-10 shows a schematic of this sampling location.
The distances of this location from upstream and downstream flow disturbances
were not determined because only one point was sampled.
4.4.2 Calandria and Air-Swept Falling-Film Evaporator Combined Outlet
The sampling site was located in a 19-5/8-inch I.D. vertical stainless
steel duct, venting gaseous emissions from both the Calandria concentrator and
the ASFF separator. Two 2-7/8-inch pipe-flange sampling ports positioned 90°
-93-
-------
FLOW
CALANDRIA
i
VO
SAMPLING
PORT
VENT
TO PRIL
TOWER
SCRUBBER
AIR
SWEPT/FALLING-
FILM
EVAPORATOR
VALVE
ONE SAMPLING POINT
AT CENTER OF DUCT
FIGURE 4-10:
CALANDRIA EVAPORATOR SAMPLING LOCATION
AT C F INDUSTRIES. INC.,
HARRISON, TENNESSEE
0988-014-001
-------
apart were located 45-1/2-inches (2.3 duct diameters) downstream from the
horizontal run of duct normally venting to the Koch scrubber, and 148-inches
(7.5 duct diameters) upstream from the top of the stack.
Only the back half of each traverse axis could be used because of the
physical limitations imposed by the in-stack orifice. Eight sampling points
were chosen on each axis, for a total of 16 sampling points. Figure 4-11
shows a schematic of this sampling location.
4.5 Visible Emissions Observation Locations
The Prill Tower scrubber outlet stack plume was observed from the top of a
holding tank 60 feet above the ground and 350 feet to the east of the stack.
A large black warehouse and silo was used as a background. This observation
position is shown in Figure 4-12.
The Prill Cooler scrubber outlet plumes were observed from a walkway 40
feet above the ground and 150 feet northeast of the stacks. The Prill Tower
was used as background. This observation position is shown in Figure 4-13.
The combined plume from the two neutralizer scrubber stacks was observed
from three different locations:
LOCATION
HEIGHT ABOVE GROUND
DISTANCE AND DIRECTION
FROM
NEUTRALIZER STACKS
A
B
C
0 feet
8 feet
0 feet
300 feet SSW
75 feet NE
150 feet W
The stack heights are 30 feet above ground level. Blue sky was used as a
background from locations A and B; blue sky and/or the Prill Tower were used
as a background from location C. Figure 4-14 shows these observer locations.
-95-
-------
VENT
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
7
8
TRAVERSE POINT
LOCATION FROM
OUTSIDE OF
NIPPLE (INCHES)
15-3/16
16-13/16
18-3/16
19-3/16
20
20-13/16
21-1/2
21-1/2
O
12'-4"
3
3'-9.5
FROM CALANDRIA
AND ASFF
EVAPORATORS -
CLOSED
VALVE
TO PRILL
TOWER
SCRUBBER
SOUTHWEST
NORTHWEST
FIGURE 4-11:
COMBINED CALANDRIA AND AIR-SWEPT FALLING-FILM EVAPORATOR
SAMPLING LOCATION AT CF INDUSTRIES, INC.,'
HARRISON, TENNESSEE
0988-015-001
-------
INDUSTRIAL
SILO
WAREHOUSE
PRILL TOWER
SCRUBBER
O PRILL TOWER
OBSERVERS POSITION
HOLDING
TANK
HOLDING
TANK
301
HEIGHT OF OBSERVATION POINT - 60'
DISTANCE TO DISCHARGE POINT - 350'
FIGURE 4-12:
PRILL TOWER SCRUBBER VISIBLE EMISSIONS OBSERVATION
LOCATION AT CF INDUSTRIES, INC.,
HARRISON, TENNESSEE
0988-016
-97-
-------
PRILL
TOWER
o
N
O STACK WEST
N
O STACK EAST
\
\
CO
RAILCAR
HANGER
AND
LOADING
\
TRUCK
LOADING
WALKWAY
OBSERVERS POSITION
HEIGHT OF OBSERVATION POINT - 40'
DISTANCE TO DISCHARGE POINT - 150'
FIGURE 4-13: PRILL COOLER SCRUBBER VISIBLE EMISSIONS OBSERVATION
LOCATION AT CF INDUSTRIES, INC.,
HARRISON, TENNESSEE
0988-017-001
-------
OUTLET
STACK
OVERFLOW
TANK
HOLDING
TANK
302.
; POSITION
C
POWER POLE
POSITION A
PLANT
ROAD
PRILL
COOLING
TOWER
POSITION B
VENTURI
SCRUBBER
POWERHOUSE
BUILDING
OVERHEAD
TRANSMISSION LINES
NOT TO SCALE
FIGURE 4-14:
NEUTRALIZER SCRUBBER VISIBLE EMISSIONS OBSERVATION
LOCATIONS AT CF INDUSTRIES, INC.,
HARRISON, TENNESSEE
-99-
0988-018-001
-------
All visible emissions observer locations conformed to the EPA Reference
Method 9 guidelines.
4.6 Product Sampling
Intermediate and final product samples were taken throughout the testing
program directly from their associated processes. Sampled material included
ammonium nitrate solution from the neutralizers and evaporators and solid
prills from the Prill Tower and the Prill Cooler.
4.7 Ambient Air Measurements
Ambient temperature and relative humidity measurements were taken
periodically during each emission test run in the immediate vicinity of the
process unit being tested. Barometric pressure at each sampling location was
measured with an aneroid barometer calibrated against a mercury barometer
maintained by CFI.
During the Prill Tower emissions tests, temperature and relative humidity
^
measurements were taken at the base of the Prill Tower. Measurements during
the Prill Cooler testing were taken inside the cooler operation building.
During the Calandria and ASFF evaporator testing, measurements were taken on
the ground next to these process units.
-100-
-------
5.0 SAMPLING AND ANALYSIS METHODS
This section presents general descriptions of sampling and analysis
procedures employed during the emissions testing program conducted at the CF
Industries, Inc., ammonium nitrate manufacturing facility in Harrison,
Tennessee, during the weeks of May 7-11, 1979, and June 18-22, 1979. Details
of sampling and analysis procedures are contained in the Appendices.
5.1 EPA Reference Methods Used in This Program
The following EPA Reference Methods were used during this emission testing
program. These methods are taken from "Standards of Performance for New
Stationary Sources, Appendix A," Federal Register, Volume 42, No. 160,
Thrusday, August 18, 1977, pp 41755 ff.
o Method 1 - Sample and Velocity Traverses for Stationary Sources
This method specifies the number and location of sampling points
within a duct, taking into account duct size and shape and local flow
disturbances. In addition, this method discusses the pitot-nulling
technique used to establish the degree of cyclonic flow in a duct.
o Method 2 - Determination of Stack Gas Velocity and Volumetric Flowrate
This method specifies the measurement of gas velocity and flowrate
using a pitot tube, manometer and temperature sensor. The physical
dimensions of the pitot tube and its spatial relationship to the
temperature sensor and any sample probe are also specified.
o Method 3 - Gas Analysis for C02, 02, Excess Air and Dry Molecular
Weight
This method describes the extraction of a grab or integrated gas
sample from a stack and the analysis of that sample for C02 and
02 with an Orsat analyzer.
o Method 4 - Determination of Moisture Content in Stack Gases
This method describes the extraction of a gas sample from a stack and
the removal and measurement of the moisture in that sample by
condensation impingers. The assembly and operation of the required
sampling train is specified.
-101-
-------
o Method 5 - Determination of Particulate Emissions from Stationary
Sources
This method specifies the isokinetic sampling of particulate matter
from a gas stream utilizing techniques introduced in the above four
methods. Sample collection and recovery, sampling train cleaning and
calibration and gas stream flowrate calculation procedures are
specified.
o Method 9 - Visual Determination of the Opacity of Emissions from
Stationary Sources
This method describes how trained observers are to determine the
opacity of emissions. The duration and frequency of observations,
orientation of the observer with respect to the source, sun and
background, methods of data recording and calculation, and
qualifications of observers are specified.
Presently, the methods of cyclonic flow measurement and interpretation are
largely in their formative stages. As noted in Section 2.3, cyclonic flow was
observed and measured in the neutralizer scrubber outlet stacks. The
pitot-nulling technique described in EPA Reference Method 1 was followed in
determining the magnitude of one component of the flow angle. In this
instance the actual sampling was performed without any adjustment for the flow
angles. In situations where cyclonic flow angles are taken into account, the
alignment approach (*•' is generally used, as follows:
1. During particulate or velocity traverses, the probe top is rotated
according to the measured flow angle at each traverse point so that
the probe tip faces directly into the gas flow;
2. The sampling time at each traverse point is weighted according to the
magnitude of the flow angle at that point;
3. The cosine of the flow angle is applied(2) to the velocity
equations used to calculate flowrate.
(1) "Evaluation of Particulate Sampling Methods for Cyclonic Flow," Westlin,
P.R., et al., OAQPS, ESED, EMB, TSS, August 2, 1979. See Appendix E.
(2) Source Sampling Reference Method, prepared by Entropy Environmental-
ists, Inc., for USEPA, November 1977. See Appendix E.
-102-
-------
5.2 Ammonium Nitrate Sampling and Analysis
5.2.1 Sampling Methods
5.2.1.1 Prill Tower Scrubber and Prill Tower Cooler Scrubber
Ammonium nitrate in the Prill Tower scrubber and Prill Cooler scrubber
inlet and outlet gas streams was sampled at points identified in accordance
with the relationship of the sampling ports to upstream and downstream
disturbances. The velocity of the duct gas was measured with S-type pitot
tubes that were constructed, calibrated and used in accordance with EPA
Method 2. Two traverse axes were utilized at each sampling location, and
points along the complete length of each axis were sampled. Inlet and outlet
sampling tests were run concurrently.
The sampling train used is shown in Figure 5-1, and is a modification of
the standard EPA Reference Method 5 sampling train. The sampling train
consists of a nozzle; probe, teflon line, six impingers, vaccum pump, dry gas
meter, and an orifice flow meter. The nozzle is stainless steel and is of a
buttonhook shape. It was connected to a 5/8" stainless steel glass lined
probe. Following the probe, the gas stream passed through a 3/8" I.D. Teflon
line into an ice bath/impinger system.
The first two impingers each contained 100 ml of deionized distilled
water. Between the second and third impinger a glass fiber filter was
positioned. This filter did not have to be tared bacause it was eventually
added to the water contents of the first two impingers. The next two
impingers were filled with IN H2so4 (100 ml of each). The fifth impinger
remained empty while the sixth was filled with 200 grams of indicating silca
gel to remove any remaining moisture.
Leaving the last impinger, the sample gas stream flowed through flexible
tubing, a vacuum gauge, needle valve, pump, and dry gas meter. A calibrated
-103-
-------
STACK WALL —
THERMOMETER
n}/M
o
.p-
LEGEND
1 - NOZZLE 7
2 - PROBE 8
3 - TEFLON LINE 9
4 - ICE BATH 10
5 - FLEXIBLE LINE 11
6 - VACUUM GAGE 12
NEEDLE VALVE
PUMP
DRY GAS METER
ORIFICE
PITOT TUBE & INCLINED MANOMETER
POTENTIOMETER
FIGURE 5-1: MODIFIED EPA PARTICULATE SAMPLING TRAIN
AUGUST 18,1977, FEDERAL REGISTER
0988-019-f
-------
orifice and inclined manometer completed the sampling train. The stack
velocity pressure was measured with a pitot tube and inclined manometer.
Stack temperature was monitored by a thermocouple attached to the probe and
connected to a potentiometer. A nomograph was used to determine the orifice
pressure drop required for any measured pitot velocity pressure and stack
temperature in order to maintain isokinetic sampling conditions.
Test data recorded included test time, sampling duration at each traverse
point, pitot pressure, stack temperature, meter volume, meter inlet-outlet
temperature, and orifice pressure drop.
5.2.1.2 Neutralizer Scrubbers
The sampling train used at the Neutralizer scrubbers was similar to that
used at the Prill Tower scrubber and Prill Cooler scrubber except that an
in-stack orifice and eight impingers were used, and the glass fiber filter
was positioned between the fourth and fifth impingers. The in-stack orifice
was necessary because of the high moisture contents of the Neutralizer
scrubber gas streams. With an in-stack orifice, the sampling rate can be
measured at actual stack conditions prior to any moisture condensation.
The train configuration consisted of an in-stack orifice and nozzle
assembly connected to a metal probe which was attached to eight impingers by
a teflon line. The first three impingers were filled with deionized,
distilled water (100 mis in each). The fourth impinger was empty. Between
the fourth and fifth impingers, the glass fiber filter was positioned. The
filter was not tared since it was eventually added to the water contents of
the first four impingers. The fifth, sixth, and seventh impingers contained
ION H2S04 solution (150 mis in each). The eighth impinger was filled
with 200 grams of silica gel. The rest of the train was the same as that
shown in Figure 5-1, but without the final orifice.
-105-
-------
The inlet and outlet tests were run independently of each other. At the
Neutralizer No. 1 scrubber inlet, access existed to only one sampling port.
The relatively high pressure within the inlet duct (4 inches Hg) required the
use of a special probe assembly and shut-off valve that would seal the port
when inserted into the duct. A two-foot external extension was added to the
i,nlet sampling port to facilitate use of this probe assembly.
Before each test run, the probe with in-stack orifice was inserted, into
the gas stream for about 15 minutes. This ensured that the orifice would be
at stack temperature when sampling began. Orifice gas temperature was
measured with an in-stream thermocouple located six inches from the orifice
assembly. A typical in-stack orifice assembly is shown in Figure 5-2.
Some problems were experienced at the Neutralizer No. 1 scrubber inlet
because of the high moisture content of the gas stream. As a result,
complete sampling tests were performed only on Neutralizer No. 1 scrubber.
Capillary tubing (0.1175 inch I.D.) connected the in-stack orifice pressure
taps to regular pressure lines within the sealed probe housing. These
capillary tubes frequently filled with water, thus interferring with
monitoring of the sampling rate. Because of the high pressure in the gas
stream, the plugged lines could not be easily blown out, so the following
procedure was followed. An average orifice pressure drop was calculated to
represent the average velocity pressure across the duct. This pressure drop
was then set and left unchanged.
The outlet testing site on the Neutralizer No. 1 scrubber had two ports
positioned 90 degrees apart. The static pressure was less than one inch of
water at the outlet, therefore the valve and seal assembly used at the inlet
was not needed. The outlet testing site had the same condensation problem
occur with the in-stack orifice system. Since these outlet ports were not
-106-
-------
TO SAMPLING TRAIN
ADAPTORS
MANOMETER
TAPS
TIP
FIGURE 5-2: TYPICAL IN-STACK ORIFICE AND NOZZLE ASSEMBLY
0988-020
-------
under pressure, the orifice pressure lines could be blown out with compressed
air after each traverse point. Then the proper orifice pressure drop could
be set at each traverse point to maintain isokinetic sampling. An excessive
amount of water was collected in the impingers and they had to be emptied
during port changes.
A special set of tests were performed on the Neutralizer No. 2 scrubber
outlet, with two ports 90 degrees apart. Simultaneous sampling with two
sampling trains (identical to those used on the No. 1 scrubber) was performed
at one point on each traverse axis near the duct center. One train was
operated at a sampling rate of approximately 200 percent isokinetic, and the
other train was operated at approximately 50 percent isokinetic. The purpose
of these special tests was to provide additional information for sampling
neutralizer emissions.
5.2.1.3 Evaporators
The sampling trains at the Calandria vent and combined vent (Calandria
and Air-Swept Falling-Film Evaporator) were identical to those used at the
Neutralizer scrubbers.
Because of the small size of the Calandria vent and the extremely high
moisture content of the gas stream, only one point (duct center) on one
traverse axis was sampled. The extremely low dry gas flowrate through the
sampling train resulted in an unusually high vacuum being drawn in the
train. Extra care was required to minimize sampling train leaks and to make
sure that the initial dead volume of gas in the train (normally
insignificant) was discounted on the data sheets.
The test runs on the combined evaporator emissions were performed at two
ports spaced 90 degrees apart. The much lower moisture content of this gas
stream made sampling at several points along each traverse axis practical.
-108-
-------
5.2.2 Sample Recovery and Preparation
o Prill Tower Scrubber and Prill Cooler Scrubber Samples
At the completion of each test run, the train was leak checked. Then the
nozzle, probe, flexible teflon line, first two impingers, and their
connecting glassware were rinsed three times with deionized, distilled
water. Samples were put in glass containers with teflon-lined caps as
follows:
Container #1 - contents of the nozzle, probe, flexible teflon line, first
two impingers, filter holder, their connecting glassware,
and the deionized distilled water wash of these articles
along with the glass fiber filter.
Container 12 - contents of the third, fourth, and fifth impingers, their
connecting glassware, and their IN H2S04 solution
rinse.
Container #3 - silica gel from the sixth impinger.
The content of the first container was filtered using a tared Buchner
funnel filter and a vacuum filtration setup in order to remove all traces of
undissolved material. The funnel filter was then stored in a labelled petri
dish and returned to the TRC chemical laboratory. The filtrate was divided
into two equal portions with concentrated H2S04 being added to one
portion until its pH was six or less. To the second portion, 1 ml of 1M
boric acid was added per 100 mis of sample.
o Neutralizer Scrubber and Evaporator Samples
A procedure similar to that described for the Prill Tower scrubber and
Prill Cooler scrubber samples was followed. The contents of the sample
containers were:
Container II - contents of the first 4 impingers, the filter and the
distilled water wash of the nozzle, probe, teflon line,
filter holder, and their connecting glassware.
-109-
-------
Container #2 - contents of impingers 5, 6 and 7 and the ION H2SC>4
rinse of these impingers and their connecting glassware.
Container #3 - silica gal from impinger 8.
The water contents of Container No. 1 were filtered using a tared glass
fiber filter and a vacuum filtration setup to remove all traces of
undissolved material. This filtration was done with a vacuum flask, vacuum
pump, and Buchner funnel. The filter was stored in a sealed petri dish and
returned to the TRC chemical laboratory. Then the filter from the sampling
train was added to the filtrate and allowed to dissolve out.
The filtrate was then divided into two portions: concentrated H_SO.
was added to one portion until its pH was less than or equal to six; to the
second portion 1 ml of 1M boric acid solution was added per 100 mis of sample.
5.2.3 Sample Analysis
o Prill Tower Scrubber and Prill Cooler Scrubber Samples
Only the boric acid treated portion of the water impinger samples was
analyzed for ammonium nitrate (AN). The analysis was performed in the CFI
laboratory within 48 hours of sampling, using the specific ion electrode
(SIE) method.
An Orion Model 92-07 nitrate electrode was used to specifically measure
the nitrate (NO^) ion concentration in the sample. The amount of ammonium
nitrate in the sample was computed by assuming that nitrate was the limiting
species. Therefore, any dissociated nitrate ions detected in the sample
solution originated as ammonium nitrate. The acidified portion of the water
impinger samples and the acid impinger samples were not analyzed for AN
because high concentrations of other ions interfere with the analysis.
No difficulties were encountered with the ammonium nitrate analyses of
the Prill Tower scrubber and Prill Cooler scrubber samples.
-110-
-------
o Neutralize! Scrubber and Evaporator Samples
Only the boric acid treated portion of the water impinger samples were
analyzed for ammonium nitrate. The analyses were performed in exactly the
same manner as described for the Prill Tower scrubber and Prill Cooler
scrubber samples.
The interferring effects of high background ion concentrations were
apparently observed in the Calandria samples, as discussed in Section 2.4.
The Calandria gas stream contained a relatively high concentration of ammonia
which/ in aqueous solution as ammonium ion, may have positively interferred
with the indicated ammonium nitrate (AN) concentrations. The result was
calculated negative AN mass flowrates from the ASFF evaporator.
While this ammonia interference may explain the calculated negative ASFF
ammonium nitrate mass flowrates, it also could have affected the neutralizer
AN values. The ratios of ammonia concentration to AN concentration were as
large or larger in the neutralizer samples as in the Calandria samples.
Consequently, the neutralizer AN values presented in Section 2.0 may be
somewhat greater than what actually exist. This interference was
demonstrated in the analysis of audit samples (Appendix Q) . The analysis of
one audit sample, with an ammonia-to-nitrate concentration ratio of about 19,
indicated a nitrate concentration 17% higher than the actual nitrate
concentration.
It appears that the only sure way to circumvent such situations would be
to remove or neutralize the interferring species. Because the degree of
interference depends on the relative strength of the interferring ion
concentration compared to nitrate ion concentrations, dilution of samples
will not relieve the problem.
-Ill-
-------
5.3 Ammonia Sampling and Analysis
5.3.1 Sampling, Sample Recovery and Sample Preservation
The same samples collected, recovered and preserved as described in
Sections 5.2.1 and 5.2.2 were analyzed for ammonia as well as ammonia nitrate.
5.3.2 Sample Analysis
o Prill Tower Scrubber and Prill Cooler Scrubber
All acid impinger samples (Container 12) and the acidified portion of all
water impinger samples were analyzed for ammonia by the specific ion
electrode analysis method at the CF1 laboratory within 48 hours of sampling.
In addition, a portion of each of these outlet samples was brought to the TRC
chemical laboratory and analyzed for ammonia by the Nessler method with
preliminary distillation. ' These Nessler analyses were done within 10
days of sampling.
An Orion Model 95-10 ammonia electrode was used for the SIE analysis.
This method is extremely specific for ammonia and is not subject to the
interferences that affect SIE ammonium nitrate analysis. To each sample was
added enough 10M NaOH to bring the sample pH to 11 or greater, in accordance
with the electrode manufacturer's procedures.
The Nessler analysis method is a colorimetric method subject to turbity
interference from a variety of species. Delays in sample analysis may result
in some species, like urea, breaking down or converting to ammonia and
yielding falsely high ammonia concentrations. Alternatively, delays in
sample analysis may allow dissolved ammonia to diffuse out of solution,
yielding reduced ammonia concentrations.
(i)Standard Methods of Water and Wastewater Analysis, 14th Edition, 1975,
pp 412 ff.
-112-
-------
A comparison of the SIE and Nessler data for the Prill Tower scrubber and
Prill Cooler scrubber, as well as the Neutralizers and Evaporators, shows
that some ammonia diffusion may have occured. Table 5-1 shows the average
ammonia sample weight measured at each sampling location (averaged over the
three test runs performed at each location). Over all tests at all
locations, the ammonia weight indicated by the Nessler Method was 89% that
indicated by the SIE Method. The Nessler analyses were performed within 10
days of the SIE analyses.
o Neutralizer Scrubber and Evaporator Samples
These samples were analyzed in exactly the same was as described for the
Prill Tower scrubber and Prill Cooler scrubber samples. All ammonia analyses
were performed by both the SIE and Nessler methods.
The Neutralizer No. 1 (inlet and outlet) and Neutralizer No. 2 scrubber
samples were also analyzed for C02 by CFI. This analysis was performed on
the water impinger samples (Container #1) within 3 days of sampling using the
Van Slyke method.
5.4 Magnesium Sampling and Analysis
5.4.1 Sampling, Sample Recovery and Sample Preparation
The same Prill Tower scrubber samples collected, recovered and prepared
as described in Sections 5.2.1 and 5.2.2 were analyzed for magnesium as well
as ammonium nitrate and ammonia. The one exception to the above sample
preparation procedure was that a portion of the sample from the water
impingers (Container #1) was set aside untreated (no boric acid solution or
HSO. added) for magnesium analysis.
-113-
-------
TABLE 5-1
COMPARISON OF ANMONIA ANALYSIS RESULTS FROM EMISSIONS TESTS
AT C F INDUSTRIES, INC.,
HARRISON, TENNESSEE
Sampling Location
Prill Tower Scrubber Outlet
Prill Cooler Scrubber Outlet East
Prill Cooler Scrubber Outlet West
Neutralizer No. 1 Scrubber Inlet
Neutralizer No. 1 Scrubber Outlet
Neutralizer No. 2 Scrubber Outlet
200% Isokinetic
50% Isokinetic
Calandria
Combined Calandria § ASFF
Average Sample Weight*(mg)
SIE*
572
27
37
48472
67608
18955
14171
7258
8437
Nessler0
513
23
33
43584
64868
16570
12273
6640
7523
Percent Ratio
(Nessler/SIEJx 100
90
85
89
90
96
87
87
91
89
Average 89
* Averaged of three test runs
a Specific Ion Electrode Analysis Method
b Nessler (with preliminary distillation) Analysis Method
-114-
-------
5.4.2 Sample Analysis
The untreated portion of the water impinger sample and a portion of the
acid impinger sample were brought to TRC and analyzed for total magnesium by
atomic absorption (AA). An aliquot of sample was digested with a small
amount of nitric acid in order to dissociate any bound magnesium. A small
amount of this solution then was aspirated into the AA. These analyses were
performed in the TRC laboratory within 10 days of sample collection.
5.5 Insoluble Particulate
The water impinger samples (collected as described in Section 5.2.1) were
analyzed for insoluble particulate (undissolved solids) as follows. The
contents of Container fl were suction-filtered using a previously desiccated,
tared glass fiber filter, Buchner funnel and vacuum system, as described in
Section 5.2.2. The filter was then placed in a petri dish and brought to
TRC. In the TRC laboratory, the filters were desiccated and weighed to a
constant weight. This analysis took place within 10 days of sample
collection.
5.6 Particle Size Distribution Tests
Particle sizing tests were conducted at the Prill Tower scrubber and
Prill Cooler scrubber inlet sampling locations using a Sierra Model 226
multi-stage cascade impactor with a cyclone preseparator. Prior to testing
the impactor was leak tested and the probe was placed in the gas stream for
twenty minutes to allow it to reach equilibrium temperature in order to
prevent condensation. Each test was thirty minutes in duration and was
performed under isokinetic sampling conditions at a predetermined average gas
velocity. The impactor was operated in its in-stack mode in accordance with
the manufacturer's procedures.
-115-
-------
The impactor was loaded before each test cun with pre-weighed glass fiber
collection substrates. Upon completion of a test run, the substrates were
removed in a secluded, clean area and placed in petri dishes. The cyclone
preseparator contents were brushed into a tared sample jar and sealed. These
samples were brought to TRC and were weighed on an analytical balance to 0.1
mg in a constant humidity environment.
No meaningful data were obtained from the particle size distribution
tests in the Prill Tower Scrubber inlet and Prill Cooler scrubber inlet
because either too little particulate matter was collected or too much
particulate matter was collected in the cyclone preseparator. The reasons
for these erratic results could not be determined.
5.7 Integrated Gaseous Bag Sampling
An integrated gaseous bag sample from the Neutralizer No. 1 scrubber
inlet was drawn directly from the gas stream during each of the ammonium
nitrate particulate test runs. The sampling system consisted of a stainless
steel tube, a flexible teflon line, three impingers in series (each
containing concentrated sulfuric acid to absorb water) and a sample bag. The
duct gas pressure was sufficient to fill the sample bag without a pump. This
pressure also required that the stainless steel sampling tube be inserted
into the duct through the special probe assembly designed to seal the
sampling port.
The very low dry gas flow through the Calandria vent made it impractical
to obtain an adequate sample of dry gas. For this reason, no samples were
drawn at this location.
The bag samples were analyzed at the CF1 laboratory within one hour of
sample collection. The samples were analyzed for CO and 0- using an EPA
Method 3 Orsat analyzer.
-116-
-------
5.8 Visible Emissions
Visible emissions observations were made on the Prill Tower scrubber
outlet plume, the two Prill Cooler scrubber outlet plumes, and the combined
plumes from the two Neutralizer scrubber outlets. Opacity readings were made
simultaneously by certified TRC and CFI observers from locations chosen to
conform to the requirements of EPA Reference Method 9.
The Prill Tower scrubber plume was monitored every fifteen seconds over a
total observation period of about seven hours. Since the sky was overcast
during most of this time, the blue-white plume was observed against a black
industrial silo and warehouse.
The two Prill Cooler scrubber plumes (east and west) were monitored
simulataneously at seven second intervals each, over a total observation
period of about three hours. The Prill Tower was used as a background and no
visible emissions were observed from the two stacks.
The two Neutralizer scrubber plumes mingled and were observed as one
plume. The plume was monitored every fifteen seconds over a total
observation period of about five hours. Three different observation
locations were used, depending on the wind direction and lighting
conditions. Blue sky or the Prill Tower were used as a background, and no
visible emissions were observed.
5.9 Scrubber Pressure Drop Measurements
Pressure drop measurements across the Prill Tower scrubber, Prill Cooler
scrubber and Neutralizer No. 1 scrubber were made with vertical U-tube water
manometers connected to pressure taps at the scrubber inlets and outlets.
Pressure drops were recorded every three to fifteen minutes during the Prill
Tower scrubber and Prill Cooler scrubber test runs, and every six to thirty
minutes during each of the neutralizer scrubber test runs.
-117-
-------
5.10 Scrubber Liquor Sampling and Analysis
Half-liter aliquots of scrubber liquor were collected approximately every
30 minutes during the emission test runs at the Prill Tower scrubber/ the
Prill Cooler scrubber and the Neutralizer No. 1 scrubber. Scrubber liquor
temperature was recorded at the time of collection, and the pH was measured
in the CFI laboratory once the sample had reached room temperature.
The aliquots were then combined to form a single composite sample for
each emission test run. The composite samples were suction-filtered through
a tared glass fiber filter. The filtrate was then divided into two equal
portions, and concentrated sulfuric acid was added to one portion to bring
the pH to 6.0 or less. The second portion remained untreated.
The untreated portion was analyzed for nitrate by the specific ion
electrode analysis method and (for the Prill Tower scrubber samples) for
magnesium by atomic absorption. The acidified portion was analyzed for
ammonia by both the specific ion electrode (SIE) and Nessler analysis
methods. All these analyses were performed as described in Sections 5.2, 5.3
and 5.4. The Nessler ammonia concentrations averaged 88 percent of the SIE
ammonia concentrations, presumably for the same reason noted in Section 5.3.2.
The filter was desiccated and then weighed to a constant weight in order
to determine the undissolved solids content of the scrubber liquor.
5.11 Ambient Air Measurements
Ambient air temperature, relative humidity and barometric pressure
measurements were made approximately every fifteen minutes during each
emission test run. Measurements were made in the immediate vicinity of the
process operation being tested. Relative humidity was determined from wet
-118-
-------
bulb and dry bulb temperature measurements made with a Bendix psychron.
Barometric pressure measurements were made with an aneroid barometer
calibrated against a mercury barometer maintained at the CFI plant.
5.12 Process Sample Collection and Analysis
TRC personnel took samples of the solid ammonium nitrate product from the
Prill Tower and Prill Cooler during the emission test runs at these process
units. Bulk density and sieve analyses were performed on these samples at
the CFI plant within two hours of sample collection.
The bulk density was determined using a tared graduated cylinder and a
platform balance. The sample was passed through a riffle and then poured
into the graduated cylinder until it overflowed. The sample was then leveled
with the top of the cylinder, and the cylinder and contents were weighed.
The particle size of the product was estimated by means of a sieve
analysis. A small amount (about 250 grams) of sample was weighted to the
nearest 0.01 gram. This sample was then poured into the top sieve and then
shaken through the stack of sieves. After shaking, each sieve was weighed to
determine the amount of material retained by it.
Samples of the ammonium nitrate process solution were taken by CFI
.personnel from various loactions in the process. Chemical analyses were
performed on these samples by CFI who requested that the analysis results
remain confidential.
-119-
------- |