United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 79-NHF-11
July 1980
Air
Ammonium Nitrate
Emission Test Report
Swift Chemical Company
Beaumont, Texas
-------
MEASUREMENT OF EMISSIONS FROM A MODERN AMMONIUM NITRATE
MANUFACTURING PLANT, SWIFT CHEMICAL COMPANY,
BEAUMONT, TEXAS
by
Mark D. Hansen
Bruce C. DaRos
Robert C. Stultz
VOLUME I
FINAL REPORT
July 23, 1980
EPA Contract No. 68-02-2814, Work Assignment No. 18
MRI Project No. 4468-L(18)
For
Environmental Protection Agency
Emission Measurement Branch
Emission Standards and Engineering Division
MD-13
Research Triangle Park, North Carolina 27711
Attn: Mr. J. E. McCarley
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PREFACE
The work reported herein was conducted by personnel from Midwest Research
Institute (MRI), the GCA/Technology Division (GCA), Swift Chemical Company,
Beaumont, Texas, and the U.S. Environmental Protection Agency (EPA).
The scope of work issued under EPA Contract No. 68-02-2814, Work Assign-
ment No. 18, was under the supervision of MRI Project Manager, Mr. Douglas
E. Fiscus. Mr. Bruce C. DaRos of MRI served as Field Task Leader. Mr. Mark
D. Hansen was responsible for summarizing the test and analytical data in
this report. Sample analysis performed at the Swift Chemical Company,
Beaumont, Texas, plant and at the MRI labs located in Kansas City, Missouri,
was under the direction of Dr. George Scheil.
Mr. Stephen A. Capone and Mr. Timothy L. Curtin of GCA were responsible
for monitoring the process operations during the testing program. GCA per-
sonnel were also responsible for writing the Process Description and Operation
Section (Section 3) along with Appendix M of this report.
Members of the Swift Chemical Company, Beaumont, Texas, whose assistance
and guidance contributed greatly to the success of the test program, include
Mr. Ron E. Ashcroft, Plant Manager, Mr. Dwain Adcock, Production Supervisor,
and Mr. Terry Sparkman, Chief Chemist.
Mr. Eric A. Noble, Office of Air Quality Planning and Standards, Indus-
trial Studies Branch, EPA, served as Test Process Engineer and was respon-
sible for coordinating the process operations monitoring.
Mr. Clyde E. Riley, Office of Air Quality Planning and Standards, Emis-
sion Measurement Branch, EPA, served as Technical Manager and was responsible
for coordinating the emission test program.
Approved for:
MIDWEST RESEARCH INSTITUTE
M. P. Schrag, Director
Environmental Systems Department
July 23, 1980
111
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CONTENTS
Figures
Tables
1. Introduction 1-1
Rotary drum cooler measurements .... 1-3
2. Summary of Test Results 2-1
Introduction 2-1
Granulator test data 2-1
Cooler test data. . . . 2-1
Particle size test data 2-1
3. Process Description and Operation 3-1
Preliminary introduction 3-1
Process equipment .... 3-1
Process operation ... 3-3
4. Location of Sampling Points 4-1
Introduction 4-1
Physical description of facilities. . . 4-1
Rotary drum cooler sampling locations 4-4
Brink impactor particle size distribution test
locations 4-13
Visible emission observation locations 4-13
Rotary drum granulator scrubber and rotary drum
cooler inlet-to-outlet differential pressure
drop measurement locations 4-15
Relative humidity and ambient temperature
measurement locations 4-15
Rotary drum granulator scrubber liquor collection
locations 4-15
Process sample collection locations 4-15
5. Sampling and Analytical Procedures 5-1
Introduction 5-1
Federal Register methods. . 5-1
Ammonium nitrate emissions 5-2
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CONTENTS (continued)
6. Appendices (Volume II - Appendices A through P)
Appendix A - Computer Test Results for Ammonium Nitrate, Ammonia,
and Insoluble Particulate A-l
A-l Summary of Test Results, Table 1-A-l A-2
A-2 Rotary Drum Granulator Scrubber Results A-4
A-2-1 Rotary Drum Granulator Scrubber Inlet Results-English
and Metric Units A-5
A-2-2 Rotary Drum Granulator Scrubber Outlet Results-English
and Metric Units A-24
A-3 Rotary Drum Cooler Uncontrolled Outlet Results A-39
A-3-1 Rotary Drum Cooler Uncontrolled Outlet Results-English
and Metric Units A-40
Appendix B - Sample Equations and Example Calculations B-l
B-l Modified EPA Method 5 Run No. 3, Rotary Drum Cooler
Uncontrolled Outlet B-2
B-2 Equations for Converting Nitrate and Ammonia Results to
Ammonium Nitrate B-7
B-3 Calculation to Determine Obstructed Area of the Inlet
Duct to the Rotary Drum Granulator Scrubber B-9
Appendix C - Modified EPA Method 5 Field Data C-l
C-l Rotary Drum Granulator Scrubber Tests C-2
C-l-1 Rotary Drum Granulator Scrubber Inlet Tests C-3
C-l-2 Rotary Drum Granulator Scrubber Outlet Tests C-62
C-2 Rotary Drum Cooler Tests C-121
C-2-1 Rotary Drum Cooler Uncontrolled Outlet Tests C-122
Appendix D - Brink Impactor Particle Size Distribution Test Data. . D-l
D-l Brink Impactor Particle Size Distribution Test Com-
puter Data Reduction Results D-2
D-l-1 Rotary Drum Granulator Scrubber Inlet D-3
D-l-2 Rotary Drum Cooler Uncontrolled Outlet. D-10
D-2 Brink Impactor Particle Size Distribution Field Data
Sheets D-17
D-2-1 Rotary Drum Granulator Scrubber Inlet D-18
D-2-2 Rotary Drum Cooler Uncontrolled Outlet. D-30
D-3 Brink Impactor Particle Size Distribution Test
Laboratory Weighing Data D-40
D-4 Associated Correspondance Prior to the Field Test Re-
garding Brink Impactor Particle Size Distribution
Testing D-73
VI
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CONTENTS (continued)
Appendix E - Visible Emissions Data E-l
E-l Visible Emissions Summary Data E-2
E-2 Visible Emissions Field Data E-8
E-2-1 Visible Emissions Field Data Sheets E-9
E-2-2 Visible Emissions Observation Locations, Figure l-E-2-2. . . . E-22
E-3 Copy of EPA Visible Emissions Certification Certificate. . . . E-2A
Appendix F - Relative Humidity, Ambient Temperature, and Inlet-to
Outlet Differential Pressure Data F-l
F-l Summaries of Field Data • . . F-2
F-2 Field Data Sheets F-8
F-2-1 Rotary Drum Granulator Scrubber Tests F-9
F-2-2 Rotary Drum Cooler Uncontrolled Outlet Tests F-14
Appendix G - Ammonium Nitrate and Ammonia Analysis Laboratory Data . . . G-l
G-l Summary of Laboratory Data, Table 1-G-l, Table 2-G-l,
Table 3-G-l . G-2
G-2 Laboratory Notebook Data for Selective Ion Electrode (SIE)
Analysis G-9
G-3 Laboratory Notebook Data for Direct Nessler Analysis . . . . . G-32
G-4 Laboratory Weighing Data, Table l-G-4 G-50
Appendix H - Project Participants H-l
Appendix I - Sampling Logs 1-1
1-1 Field Sampling Task Logs . 1-2
1-1-1 Modified EPA Method 5 Tests 1-3
1-1-2 Brink Impactor Particle Size Distribution Tests 1-17
1-1-3 Scrubber Liquor Grab Samples 1-24
1-1-4 Inlet and Outlet Rotary Drum Cooler Product Grab Samples . . . 1-35
1-1-5 Unscreened Rotary Drum Granulator Product Grab Samples .... 1-42
1-2 Field Sample Identification Log 1-49
Appendix J - Sampling Train Calibration Data ... J-l
J-l Sample Orifice Calibration J-2
J-2 Nozzle Measurements J-9
J-3 Pitot Tube Calibration J-ll
Appendix K. - Audit Samples Analysis Results K-l
K-l Discussion and Summary Presentation of Audit Sample Results,
Table 1-K-l K-2
K-2 Summary of Laboratory Data, Table l-K-2 K-4
K-3 Copy of Laboratory Notebooks K-6
Vll
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CONTENTS (continued)
Appendix L - Process Sample Data L-l
L-l Summary of Laboratory Analysis of Process Samples L-2
L-l-1 Rotary Drum Granulator and Rotary Drum Cooler Product
Samples, Table 1-L-l-l L-3
L-l-2 Bulk Density Determination Data, Table l-L-1-2 . L-5
L-l-3 Sieve Analysis Data, Table l-L-1-3 L-7
L-l-4 Rotary Drum Granulator Scrubber Liquor Samples,
Table l-L-1-4 L-9
L-2 Bulk Density and Sieve Analysis Field Data Sheets L-ll
L-3 Bulk Density and Sieve Analysis Determination Procedures. . . L-23
L-4 Scrubber Liquor Sample Analysis Procedures. . . . ; L-25
Appendix M - Process Operations Data M-l
M-l Summary of Operating Parameter Values M-2
M-2 Notes Made at Swift Chemical Company Ammonium Nitrate
Manufacturing Plant M-6
Appendix N - Detailed Sampling and Analytical Procedures N-l
N-l Summary and Discussion of Sampling and Analytical
Procedures, Figure 1-N-l N-2
N-2 EPA Sampling and Analytical Methods ...-.' N-8
N-2-1 Ammonium Nitrate N-9
N-2-2 Ammonia N-20
Appendix 0 - Cleanup Evaluation Data 0-1
0-1 Discussion and Summary of Results - Clean Impinger Washes,
Table 1-0-1 0-2
0-2 Summary of Laboratory Data - Sample Blanks,
Table 1-0-2 0-5
0-3 Copy of Laboratory Notebook 0-8
Appendix P - Scope of Work P-l
P-l Copy of U.S. EPA Work Assignment P-2
P-2 Copy of Technical Directives and Associated Correspondence. . P-20
Vlll
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FIGURES
Number
2-1 Brink impactor particle size results: particulate
diameter versus percent weight less/greater than
stated size - rotary drum granulator at inlet to
scrubber, run Nos. 1 through 3 2-16
2-2 Brink impactor particle size results: differential
mass-loading (dM/d Log D) versus particulate
diameter - rotary drum granulator at inlet to
scrubber, run Nos. 1 through 3 2-17
2-3 Brink impactor particle size results: particulate
diameter versus percent weight less/greater
than stated size - rotary drum cooler outlet,
run Nos. 1 through 3 2-21
2-4 Brink impactor particle size results: differential
mass-loading (dM/d Log D) versus particulate
diameter - rotary drum cooler outlet, run
Nos. 1 through 3 2-22
2-5 Summary of EPA Method 9 visible emissions from the
rotary drum granulator scrubber outlet stack,
March 7 and 8, 1979 2-24
2-6 Summary of rotary drum granulator scrubber inlet-to-
outlet pressure drop measurements during emissions
testing, March 7 and 8, 1979 2-27
2-7 Summary of rotary drum cooler pressure drop measure-
ments during emissions testing, March 8 and 9,
1979. 2-29
2-8 Summary of relative humidity measurements during emis-
sions testing of the rotary drum granulator
scrubber, March 7 and 8, 1979 2-31
IX
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FIGURES (continued)
Number Page
2-9 Summary of relative humidity measurements during emis-
sions testing of the rotary drum cooler, March 8
and 9, 1979 2-33
3-1 Flow diagram of the rotary drum granulator and rotary
drum cooler 3-2
4-1 Overview of the Swift Chemical Company's Beaumont,
Texas, ammonium nitrate manufacturing facility . . . 4-2
4-2 Schematic of sampling port locations used to sample
the inlet of the rotary drum granulator wet
scrubber 4-3
4-3 Sampling point locations at the rotary drum granu-
lator scrubber inlet duct 4-5
4-4 Schematic of sampling port locations used to sample
the rotary drum granulator scrubber exhaust
stack 4-7
4-5 Sampling point locations on the exhaust stack of the
rotary drum granulator scrubber 4-8
4-6 Schematic of sampling port locations used to sample
the outlet duct of the rotary drum cooler 4-10
4-7 Sampling point locations used to sample the outlet
duct of the rotary drum cooler 4-11
4-8 Schematic plan indicating relative positions of plant
equipment and visible emission observer positions. . 4-14
5-1 Schematic of modified EPA reference Method 5 sam-
pling train 5-3
5-2 Schematic of Brink impactor sampling train 5-8
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TABLES
Number
1-1 Summary Log for Sampling of the Rotary Drum Granulator
Scrubber Inlet and Outlet, March 5, 1979 (Day 1). . . . 1-4
1-2 Summary Log for Sampling of the Rotary Drum Granulator
Inlet and Outlet, March 6, 1979 (Day 2) 1-5
1-3 Summary Log for Sampling of the Rotary Drum Granulator
Scrubber Inlet and Outlet, March 7, 1979 (Day 3). ... 1-6
1-4 Summary Log for Sampling of the Rotary Drum Granulator
Scrubber Inlet and Outlet; and the Rotary Drum
Cooler Outlet, March 8, 1979 (Day 4) 1-8
1-5 Summary Log for Sampling of the Rotary Drum Cooler
Outlet, March 9, 1979 (Day 5) 1-10
2-1 Rotary Drum Granulator Scrubber Efficiency-Particulate
and Ammonium Nitrate Concentration (NO., Selective
Ion Electrode Analysis) and Emission Data Summary
in English Units 2-2
2-2 Rotary Drum Granulator Scrubber Efficiency-Particulate
and Ammonium Nitrate Concentration (NO,, Selective
Ion Electrode Analysis) and Emission Data Summary
in Metric Units 2-3
2-3 Summary of Emission Test Results for Nitrate and Ammonia
Reported as Ammonium Nitrate Utilizing an NO., Se-
lective Ion Electrode and Direct Nessler Analysis-
Rotary Drum Granulator Scrubber Inlet 2-4
2-4 Summary of Emission Test Results for Nitrate and Ammonia
Reported as Ammonium Nitrate Utilizing an N0~ Se-
lective Ion Electrode and Direct Nessler Analysis-
Rotary Drum Granulator Scrubber Outlet 2-5
XI
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TABLES (continued)
Number Page
2-5 Ammonia Concentration Determined by Direct Nessler
Analysis for the Rotary Drum Granulator Scrubber
Inlet and Outlet - English Units 2-6
2-6 Ammonia Concentration Determined by Direct Nessler
Analysis for the Rotary Drum Granulator Inlet
and Outlet - Metric Units 2-7
2-7 Summary of Ammonia and Ammonium Nitrate Emissions Cal-
culated from Collected Ammonia for the Rotary Drum
Granulator Scrubber Inlet 2-8
2-8 Summary of Ammonia and Ammonium Nitrate Emissions Cal-
culated from Collected Ammonia for the Rotary Drum
Granulator Scrubber Outlet 2-9
2-9 Summary of Emission Test Results-Particulate and Am-
monium Nitrate Concentration (NO., Selective Ion
Electrode Analysis) for the Outlet of the Rotary
Drum Cooler in English and Metric Units 2-10
2-10 Summary of Emission Test Results at the Outlet of the
Rotary Drum Cooler for Nitrate and Ammonium Nitrate
Utilizing an N0~ Selective Ion Electrode and
Direct Nessler Analysis ......... 2-11
2-11 Summary of Ammonia and Ammonium Nitrate Emissions Cal-
culated from Collected Ammonia for the Outlet of
the Rotary Drum Cooler 2-12
2-12 Brink Impactor Sampling Parameters and Results - Rotary
Drum Granulator Scrubber Inlet, Run No. 1-IS 2-13
2-13 Brink Impactor Sampling Parameters and Results - Rotary
Drum Granulator Scrubber Inlet, Run No. 2-IS. ...... 2-14
2-14 Brink Impactor Sampling Parameters - Rotary Drum Gran-
ulator Scrubber Inlet, Run No. 3-IS 2-15
2-15 Brink Impactor Sampling Parameters and Results - Rotary
Drum Cooler Outlet, Run No. 1-CO 2-18
2-16 Brink Impactor Sampling Parameters and Results -
Rotary Drum Cooler Outlet, Run No. 2-CO 2-19
xii
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TABLES (continued)
Number ' Page
2-17 Brink Impactor Sampling Parameters and Results - Rotary
Drum Cooler Outlet, Run No. 3-CO 2-20
2-18 Six Minute Arithmetic Average Opacity Readings from the
Rotary Drum Granulator Scrubber Outlet Stack, March
7 and 8, 1979 2-23
2-19 Rotary Drum Granulator Scrubber Inlet-to-Outlet Pressure
Drop Measurements During Emissions Testing, March
7 and 8, 1979 2-26
2-20 Rotary Drum Cooler Pressure Drop Measurements During
Emissions Testing, March 8 and 9, 1979 2-28
2-21 Ambient Temperature and Relative Humidity Measurements
During Emissions Testing of the Rotary Drum Granulator
Scrubber, March 7 and 8, 1979 2-30
2-22 Ambient Temperature and Relative Humidity Measurements
During Emissions Testing of the Rotary Drum Cooler,
March 8 and 9, 1979 2-32
2-23 Summary of Chemical Analysis Data on the Scrubber Liquor
Entering and Exiting the Rotary Drum Granulator Scrub-
ber During Emissions Testing, March 7 and 8, 1979 .... 2-34
2-24 Summary of pH and Temperature Measurements on Individual
Samples of Scrubber Liquor Entering and Exiting the
Rotary Drum Granulator Scrubber During Emissions
Testing, March 7 and 8, 1979 2-35
2-25 Summary of Chemical Analysis Results for Process Product
Samples Collected from the Rotary Drum Granulator
and Rotary Drum Cooler, March 6 to 9, 1979 2-36
2-26 Summary of Sieve Analysis and Bulk Density Determinations
of the Unscreened Product Samples Collected During
Emissions Testing of the Rotary Drum Granulator
Scrubber, March 7 and 8, 1979 2-37
Xlll
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TABLES (continued)
Number Page
2-27 Summary of Sieve Analysis and Bulk Density Determinations
of the Screened Product Samples Collected at the Inlet
to and Outlet of the Rotary Drum Cooler During Emis-
sions Testing of the Rotary Drum Cooler, March 8
and 9, 1979 2-38
3-1 Average Rotary Drum Granulator Product Rates During
Granulator Emissions Testing 3-4
3-2 Average Rotary Drum Granulator Product Rates During
Emissions Testing of the Rotary Drum Cooler 3-5
3-3 Relative Average Values of Operating Parameters During
Testing 3-7
4-1 Rotary Drum Granulator Scrubber Inlet Sampling Point
Locations 4-6
4-2 Rotary Drum Granulator Scrubber Outlet Sampling Point
Locations 4-9
4-3 Rotary Drum Cooler Outlet Sampling Point Locations 4-12
xiv
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SECTION 1
INTRODUCTION
Section III 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. To assembly this background in-
formation, EPA utilizes emission data obtained from controlled sources in
the particular industry under consideration.
EPA's Office of Air Quality Planning and Standards (OAQPS) selected
the Swift Chemical Company ammonium nitrate manufacturing plant at Beaumont,
Texas, as a site for an emission test program. The test program was de-
signed to provide a portion of the emission data base required for SPNSS
for the process associated with the production of ammonium nitrate. The
Swift Chemical Company ammonium nitrate manufacturing plant at Beaumont,
Texas, produces granulated ammonium nitrate for fertilizer use. The am-
monium nitrate is made by a C and I Girdler Rotary Drum Granulator which
operates continuously, 24-hr a day and 7 days a week as production demands.
The plant represents the latest installation (1977) of a rotary drum
granulator installed by C and I Girdler using a Joy "Type D" Turbulaire
Scrubber in conjunction with a rotary drum cooler.
The rotary drum granulator exhaust is ducted through the scrubber., fan,
and is discharged from a stack. Flow.through the granulator to the constant
flow scrubber is controlled with a dilution damper which varies the ratio
of dilution air to exhaust gas.
Emissions sampling was conducted on the rotary drum granulator unit
while its ammonium nitrate production rate was approximately 400 tons/day.
Emission sampling was also conducted on the uncontrolled emissions venting
from the cooler operation.
EPA engaged MRI to measure ammonium nitrate and ammonia concentrations
and mass flow rates, particle size distributions, and plume opacities. Re-
sults of measurements contained in this report were performed during times
of normal operation of the production process as described in Section 3,
"Process Description and Operation."
During the testing program several of the test runs were discontinuous
due to the excessive particulate loading at the rotary drum granulator scrub-
ber inlet and the rotary drum cooler uncontrolled outlet sampling locations.
1-1
-------
These interruptions, which also delayed the concurrent rotary drum granu-
lator outlet sampling (concurrent with scrubber inlet sampling only), oc-
curred throughout the test program..
These test interruptions were the result of processing problems within
the plant. Test Nos. 1 and 2 (simultaneous inlet and outlet sampling) at
the rotary drum granulator scrubber on March 5 and 6, 1979, were most af-
fected by plant processing problems. Test No. 1 on March 5, 1979, was not
completed. Test No. 2 on March 6, 1979, was completed but due to plant proc-
essing problems was not considered representative. In concurrence with the
EPA Technical Manager, Test Nos. 1 and 2 at the rotary drum granulator scrub-
ber were not considered valid tests. Subsequent tests, Tests 3, 4, and 5
at the rotary drum granulator scrubber were representative tests at this
location. No other tests during the testing program were invalidated due
to plant processing problems.
Section 2 of this report presents the summary of test results for all
tests; except for Test Nos. 1 and 2 at the rotary drum granulator scrubber
which were considered not representative. All of the samples and data col-
lected during Test Nos. 1 and 2 at the rotary drum granulator scrubber were
analyzed in the same manner as other test samples and data. Since data from
these tests were not considered representative due to plant processing prob-
lems, it was omitted from Section 2 "Summary of Test Results," of this report.
However, all of the analytical analyses, field data sheets, computer data
reduction, and summary information pertaining to these two tests are pre-
sented in their appropirate appendices of Section 6.
The measurement program was conducted during the week of March 5 through
March 9, 1979, and consisted of the following:
Rotary Drum Granulator Scrubber Measurements
1. Ammonium Nitrate and Ammonia in Gas Stream
Three isokinetic test runs of concurrent inlet and outlet tests were
performed. The tests were conducted in accordance with the prescribed EPA
methods for ammonium nitrate and ammonia, and provided velocity, moisture,
ammonia, and ammonium nitrate particulate mass flow rate data.
2. Particle Size Distributions in Gas Streams
Three test runs were conducted at the inlet to the rotary drum granu-
lator scrubber. The tests were performed using the procedures provided by
the cascade impactor manufacturer.
3. Visible Emissions from Granulator Scrubber Stack
Approximately 9.5 hr of visible emissions observations were recorded
on the scrubber stack discharge. t Observations were performed in accordance
with EPA Method 9 guidelines.
1-2
-------
4. Gas Pressure Drop Across Scrubber
Pressure drop measurements were recorded approximately every 15 min
during the testing periods.
5. Ambient Air Temperature and Relative Humidity
Wet and dry bulb ambient air temperatures were recorded at frequent
intervals during the test days.
6. Scrubber Liquid Sampling
Samples of inlet and outlet scrubber liquor were collected during the
ammonium nitrate testing. The pH and temperature of each sample were re-
corded. The samples were composited into three inlet and three outlet sam-
ples which were analyzed for ammonium nitrate and ammonia.
7. Ammonium Nitrate and Ammonia Analyses of Product
A single grab sample of the ammonium nitrate melt was collected and
analyzed for ammonium nitrate and ammonia. In addition, grab samples of
the unscreened and screened granulator product had sieve, bulk density, and
temperature determinations performed on them. These samples were then com-
posited for ammonium nitrate and ammonia determination.
Rotary Drum Cooler Measurements
1. Ammonium Nitrate and Ammonia in the Gas Stream
Three isokinetic test runs were performed on the uncontrolled emis-
sions according to procedures prescribed in EPA methods for velocity, am-
monium nitrate and ammonia, moisture, and ammonium nitrate particulate mass
flow rates.
2. Particle Size Distributions in Gas Streams
Three test runs were conducted on the uncontrolled emissions of the
rotary drum cooler. The tests were performed using the procedures provided
by the cascade impactor manufacturer.
MRI personnel were responsible for collecting and measuring the above
emission parameters. Concurrently, GCA was responsible for monitoring and
recording necessary process parameters. A copy of MRI's Work Assignment
and Technical Directives is included in Appendix P.
The sequence of events performed during this sampling program is shown
in Tables 1-1 through 1-5 (Summary Log for Sampling Matrix).
The following sections of this report cover the summary of results (Sec-
tion 2), process description and operation (Section 3), location of sampling
points (Section 4), and sampling and analytical procedures (Section 5).
Appendices A-P (Section 6) are presented in Volume II of this report. The
appendices present copies of all field and laboratory data sheets, computer
reduction of test data, detailed sampling and laboratory analytical proce-
dures, and results of laboratory analyses.
1-3
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TABLE 1-1. SUMMARY LOG FOR SAMPLING OF THE ROTARY DRUM GRANULATOR SCRUBBER
INLET AND OUTLET, MARCH 5, 1979 (DAY 1)
Production
rate Scrubt
Time (tons/hr) Met
Visible Inlet Outlet
er inlet Scrubber outlet emissions scrubber liquor scrubber liquor Bulk density
hod 5 Method 5 Method 9 pH Temp. (°F) pH Temp. (°F) and sieve analysis
1529 HAa Start
1530
1534
1535
1536
1600
1607
1609
1630
1635
1636
1643
1647
1654
Stop 7.15 135 5.20 99
Begin t
Stop te
est 1-IS Begin test 1-OS
7.20 139 5.21 99
7.26 139 5.28 99 Grab sample-
unscreened granu-
. lator product
Stop test 1-OS
Start
Stop
st 1-IS
a Data not available.
b Only one-half of Test No. 1 completed due to process problems within plant. Test No. 1 and sample were voided.
c Sample lost.
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TABLE 1-2. SUMMARY LOG FOR SAMPLING OF THE ROTARY DRUM GRANULATOR SCRUBBER
INLET AND OUTLET, MARCH 6, 1979 (DAY 2)
Heteorologtc.il
data Inlet
Production Visible
rate Scrubber inlet Scrubber outlet emissions
Time (tons/hr). Method 5 Method 5 Method 9
0900 NAa
0904
0912
0915
09)6
0930
0910
0944
0945
1000
1004
1009
1015
1028
1030
1044
1045
1100
1102
1104
1106
1115
1130
1145
1200
1204
1209
1215
1219
Start
Stop
Start
Begin test 2-IS
Begin test 2-OS
Stop
Start
Stop, change ports
Stop, change ports
Stop
Resume test 2-IS Resume test 2-OS
Start
Test 2-OS completed
Test 2-IS completed
Stop
Am-
bient
temp .
(°F)
54.2
55.6
56.2
57.2
57.9
59.0
59.6
60.7
61.2
62.2
63.0
64.0
64.2
64.6
scrubber
Relative liquor
humidity Temp.
CO pH (°F)
NAa 6.60 129
55
55
55
51 6.50 130
52
48 6.65 136
44
44
41 6.85 130
42
38
38 7.0.5 134
35
Outlet
scrubber
liquor Scrubber
Temp. pressure drop
pit (°F) (in. II 0) Process sample
7
7
5.20 100 7
7
5.23 100 7
7
5.55 100 8
8
9
5.55 100 9
8
8
5.50 100 8
8
1
3
2
3
2
1
4
6
0
1
9 Grab sample -
AH melt to
graniilator
8
8
8
a Data not available.
b Test No. 2 is not considered representative because of plant process-problems.
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TABLE 1-3. SUMMARY LOG FOR SAMPLING OF THE ROTARY DRUM GRANULATOR SCRUBBER
INLET AND OUTLET, MARCH 7, 1979 (DAY 3)
Meteorological
data Inlet
Production Scrubber Scru
rate Inlet out
Time (tons/hr) Method 5 Heth
Brink particle An-
>ber Visible size distribution btent
let emissions granulator scrub- temp.
od 5 Method 9 her inlet (°F)
0915 14.49 59.0
1000
1015
1030
1031
1045
1100
1115
1119
1130
1138
1139
1145
1153
1200
1215
1230
1234 .
1238
1245
62.6
63.6
Begin test 64.3
3-OS
Begin test
3-IS
Stop,
change ports
64.1
65.8
66.4
Stop, 66.7
change ports
Resume test
3-OS
Resume test
3-IS
Test 3-IS
completed
67.9
68.1
68.2
70.0
Test 3-OS
completed
71.5
1300 14 49
1330 16.22 Begin test 1-IS
1340 16.22 Test 1-IS completed
1345
1445 77.4
scrubber li-
Relative quor
humidity Temp.
(%) pH (°F)
57
46
43
43 6.65 136
44
40
40 6.70 120
37
34 6.60 121
34
38
33 6.52 123
31
6.51 122
26
Outlet
scrubber li- Scrubber
quor pressure
Temp. drop
pH (°F) (in. H20)
10.7
10.3
5.99 92 10.1
9.9
5.80 94 9.9
10.2
6.18 94 9.4
9.4
5.74 94 9.5
9.2
6.55 94 8.8
8.6
9.2
9.7
Rulk density and
sieve analysts
Grab sample -
unscreened gran-
ulator product
(continued)
-------
TABLE 1-3. (concluded)
Meteorological
data Inlet
Brink particle Am-
Production Scrubber Scrubber Visible size distribution bient
rate inlet outlet emissions granulator scrub- temp.
Time (tons/hr) Method 5 Method 5 Method 9 her inlet (°F)
1500 17.45 Begin test 77.4
4-IS
1501 Begin test
4 OS
1515
1530
1545
1548 Stop,
change ports
1600
77.2
76.8
76.8
77.0
1601 Stop,
change ports
1605 Resume test
4-OS
1610 Resume test
4-IS
1615
1630
1640
1643
1644
1645
1700
76.7
75.8
Start
Stop
Start
75.4
75.0
1705 Test 4-OS
completed
1707 Test 4-IS
completed
1715
1733 17.45 Stop
1745
1755 Begin test 2-IS
1807 Test 2-IS completed
scrubber
Relative - liquor
humidity Temp.
(I) pH (°F)
26 6.59 121
23
23 6.55 124
23
26 6.57 127
23
25
27 6.55 128
27
6.60 125
Outlet
scrubber Scrubber
liquor pressure
Temp. drop Bulk density and
PH (°F) (in. H20) sieve analysis
5.23 98 10.4
9.9
10.5
5.00 98 10.5
10.4 Grab sample -
unscreened gran-
ulator product
5.11 99 10.2
10.4
5.30 99 10.4
10.0
5.29 99
-------
TABLE 1-4. SUMMARY LOG FOR SAMPLING OF THE ROTARY DRUM GRANULATOR SCRUBBER INLET AND
OUTLET; AND THE ROTARY DRUM COOLER OUTLET, MARCH 8, 1979 (DAY 4)
Production Rotary drum granulator Rotary drum Visible
rate Scrubber inlet Scrubber outlet cooler outlet emissions
Tine (ton/hr) Method 5 Method 5 Method 5 Method 9
0900 start
09H 20.54 Begin test 5-05S 'stop
0914
0915
0919 Begin test 5-IS
0920 !
0930 :
0943
0945
0949
0952
1000
1007
1011
1015
1023
M 1028
1 1030
CO 103l
1033
1045
1100
1103
1108
1115
1116
Stop, change ports
start
stop
start
- stop
start
stop
start
Stop, change ports
Resume test 5-OS
Resume test 5-IS
Test 5-IS completed
stop
start
stop
start
1123 20.54 Test 5-OS completed stop
1124 start
1125 stop
1126 start
1130
1149 stop
1150 start
1306 stop
1335 start
1400 20.5 stop
1403 20.5 start
1405 20.85 Begin test 1-ORDC 1
1410 | 1
Meteorological data Inlet Outlet
Ambient
Brink particle size temp.
distribution (°F)
55.9
56.3
59.0
59.9
61.0
61.8
62.5
62.8
62.8
63.6
64.3
Begin scrubber inlet 74.0
test 3-IS
1
1
Test 3-IS at scrubber
Relative Scrubber liquor Scrubber liquor Scrubber Bulk density
humidity Temp. Temp. pressure drop and sieve
(1) pH (°F) pH (°F) (in. H,0) analysis
55
55 7.35 140 6.00 99 13.3
47 13.7
39 7.30 143 5.95 100 13.2
40 12.5
36 7.10 140 12.5
37 5.80 100 12.3
Grab sample-unscreened graou-
lator product
37 12.6
37 6.99 144 5.76 100 12.9
34 7.10 150 12.6
34 5.71 100
12.6
29
11.8
inlet completed
continued
-------
TABLE 1-4. (concluded)
Meteorological data Inlet Outlet
Production Rotary drum granulator Rotary drum Visible " Ambient
rate Scrubber inlet Scrubber outlet cooler outlet emissions Brink particle size temp.
Time (ton/hr) Method 5 Method 5 Method 5 Method 9 distribution (°F)
1415
1425
1429
1430
1445
1452
1500
1512 20
15H
1530
1705
1719
74.7
!
Stop, change
ports
_
Resume test 1-
ORDC
75.2
75.8
| stop 75.8
85 Test 1-ORDC
completed
76.2
Begin cooler oulet
test 1-CO
Test 1-CO at cooler
outlet completed
Relative Scrubber liquor Scrubber liquor
humidity Temp. Temp.
(%) pH (°F) pH (°F)
30
30
28
28
28
Scrubber
pressure drop
(in. H20)
12.3
11.9
12.5
12.5
12.4
12.6
Bulk density
and sieve
analysis
product
Grab sample-screened granulator
product (cooler inlet product')
-------
TABLE 1-5. SUMMARY LOG FOR SAMPLING OF THE ROTARY DRUM COOLER
OUTLET, MARCH 9, 1979 (DAY 5)
Meteorological Data
Production Rotary drum Brink particle Ambient
rate cooler outlet size distribution temp.
Time (tons/hr) Method 5 cooler outlet (°F)
0834 18.9 Begin test 2-CO
0845
0848
1 69.4
Test 2-CO completed
0930 18.9 72.2
0945 20.83 Begin test 2-ORDC 72.2
1000
1009
1010
1014
1015
1030
1038
| 73.1
Stop, change ports
Resume test 2-ORDC 73.4
I
1 73.8
Test 2-ORDC completed
1045 20.83 74.1
1058 22.24 Begin test 3-CO
1100
1112
1 ».S
Test 3-CO completed
1515 22.24 77.0
1516 20.85 Begin test 3-ORDC
1530
1540
1545
1546
1600
1608
| 77.2
Stop, change ports
Resume test 3-ORDC 77.3
|
| 77.5
Test 3-ORDC completed
Relative
humidity
(X)
85
69
69
73
73
69
69
62
56
56
56
53
Scrubber
pressure drop
(in. H20)
5.0
4.8
4.8
4.8
4.9
4.8
4.8
4.8
4.5
4.5
4.6
4.5
Bulk density and
sieve analysis
Grab sample-cooler
outlet product
Grab sample-screened
granulator
Product (cooler
inlet product)
Grab sample-cooler
outlet product
Grab sample-screened
granulator product
(cooler inlet prod
uct).
1615
20.85
77.5
53
4.5
-------
The analysis results of the quality assurance audit samples supplied by EPA
are presented in Appendix K. Appendix 0 contains the results of the clean-
up evaluations performed on the sample collectors used during the test pro-
gram. Detailed description of methods and procedures, field and laboratory
data, and calculations are presented in various appendices, as noted in the
Table of Contents.
1-11
-------
SECTION 2
SUMMARY OF TEST RESULTS
INTRODUCTION
In this section, the results of the testing program conducted at the
Swift Chemical Company in Beaumont, Texas, are presented in Tables 2-1 through
2-27. The results are discussed briefly in eight separate sections. De-
tailed discussions of the procedures used are presented in Section 5, "Sam-
pling and Analytical Procedures," and in related appendices.
Samples were collected at the inlet and outlet of the rotary drum gran-
ulator and on the uncontrolled emissions of the rotary drum cooler. Complete
descriptions of the process is provided in Section 3, "Process Description and
Operation." The sampling locations of the test are described in Section 4,
"Location of Sample Points."
GRANULATOR TEST DATA
The results of the rotary drum granulator test are given in Tables 2-1
through 2-8.
COOLER TEST DATA
The test results of the cooler have been summarized in Tables 2-9 through
2-11.
PARTICLE SIZE TEST DATA
The particle size test data for the granulator. have been summarized in
Tables 2-12 through 2-14. The results are shown graphically in Figures 2-1
and 2-2.
Data for the cooler has been summarized in Tables 2-15 through 2-17.
The results are presented graphically in Figures 2-3 and 2-4.
Visible Emissions Test Data
The visible emissions data from the outlet stack of the rotary drum
granulator scrubber during emissions testing are presented in Table 2-18.
The results are shown graphically in Figure 2-5.
2-1
-------
TABLE 2-1. ROTARY DRUM GRANULATOR SCRUBBER EFFICIENCY-PARTICULATE AND AMMONIUM
NITRATE CONCENTRATION (N0;j SELECTIVE ION ELECTRODE ANALYSIS) AND
EMISSION DATA SUMMARY IN ENGLISH UNITS
Run number
Location
Date
Volume of gas sampled - DSCFa
Percent moisture by volume
Average stack temperature - °F ,
Stack volumetric flow rate - DSCFM
Percent isokinetic
Production rate - tons/hr
Average percent opacity
Insoluble particulate
Filter catch and collection
water filtrate
mg
gr/DSCF
Ib/hr
Ib/ton
Collection efficiency, percent
Ammonium nitrate particulate
N03 selective ion electrode
analysis 'e
mg
gr/DSCF
Ib/hr
Ib/ton
Collection efficiency, percent
Total particulate
Insoluble and ammonium nitrate
mg
gr/DSCF
Ib/hr
Ib/ton
Collection efficiency, percent
Inlet
58.62
2.0
166
41,401
102.6
10.0
0.00263
0.93
0.064
50,555
13.311
4,723.6
325.8
50,565
13.314
4,724.5
325.9
Run 3
Outlet
3/7/79
82.44
2.9
100
38,521
98.1
14.5
f
11.0
0.00205
0.68
0.047
22.1
139.3
0.026
8.58
0.59
99.8
150.3
0.028
9.26
0.64
99.8
Run 4
Inlet
3/7/79
61.79
2.0
186
43,442
103.1
U-4
5*
7.2
0.00179
0.67
0.039
i
55,529
13.868
5,163.9
296.8
99.9
55,536
13.870
5,164.6
296.8
99.8
Outlet
87.00
3.7
109
40,887
97.5
21.5
0.00381
1.33
0.076
98.2
0.017
5.96
0.34
119.7
0.021
7.29
0.42
Inlet
68.96
2.0
180
49,120
101.7
8.7
Run 5
Outlet
3/8/79
97.75
7.9
115
43,969
101.9
20.5
15
25.9
0.00194 0.00408
0.82
0.040
56,772
12.725
5,357.
261.3
56,781
12.727
5,358.
261.3
1.54
0.075
i
129.1
0.020
6 7.54
0.37
99.8
155.0
0.024
4 9.08
0.45
99.8
Average
Inlet
63.12
2.0
177
44,654
102.5
17.5
h
8.6
0.00212
0.81
0.048
j
54,285
13.301
5,081.7
294.6
99.8
54,294
13.304
5,082.5
294.7
99.8
Outlet
89.06
4.8
108
41,126
99.2
19.5
0.00331
1.18
0.066
122.2
0.021
7.36
0.43
141.7
0.024
8.54
0.50
aDry standard cubic feet at 68°F, 29.92 in. Hg.
Dry standard cubic feet per minute at 68°F, 29.92 in. Hg.
Includes train filter, and impinger water filtrate.
t
N03 selective ion electrode analysis results (H20 fraction only) measured as nitrate and reported as ammonium nitrate. Analysis was
performed at the MRI lab in Kansas City, Missouri.
Water fraction results include a 1.45 mg blank correction.
Opacity measurements not recorded during test.
Average percent opacity observed represents only 25 min of test 4-OS.
h.
Average opacity not calculated due to insufficient observations during testing.
Negative number.
No average calculated due to negative numbers in Run Nos. 4 and 5.
2-2
-------
TABLE 2-2. ROTARY DRUM GRANULATOR SCRUBBER EFFICIENCY-PARTICULATE AND
AMMONIUM NITRATE CONCENTRATION (NO^ SELECTIVE ION
ELECTRODE ANALYSIS) AND EMISSION DATA SUMMARY IN
METRIC UNITS
Run number
Location
Date
Volume of gas sampled - DNM3a
Percent moisture by volume
Average stack temperature - °C ,
Stack volumetric flow rate - DNM3/M
Percent isokinetic
Production rate - Mg/hrc
Average percent opacity
Insoluble particulates
Inlet
1.66
2.0
74
1,172
102.6
Run 3
Outlet
3/7/79
2.33
2.9
38
1,091
98.1
13.15
h
Inlet
1.75
2.0
86
1,230
103.1
Run 4
Outlet
3/7/79
2.46
3.7
43
1,158
97.5
15.82
5*
Inlet
1.95
2.0
82
1,391
101.7
Run 5
Outlet
3/8/79
2.77
7.9
46
1,245
101.9
18.60
15
Average
Inlet
1.79
2.0
81
1,264
102.5
Outlet
2.52
4.8
42
1,165
99.2
15.86
j
Filter catch and collection
water filtrate
mg
g/normalized cu meter
kg/hr
kg/Mge
Collection efficiency, percent
analysis
mg
g/normalized cu meter
kg/hr
kg/Mg
Collection efficiency, percent
Total particulate
Insoluble and ammonium nitrate
mg
g/normalized cu meter
kg/hr
kg/Mg
Collection efficiency, percent
10.0
0.00601
0.423
0.032
21.8
50,555
30.46
2,141.9
162.9
99.8
50,565
30.47
2,142.3
162.9
99.8
11.0
0.00470
0.308
0.023
139.3
0.060
3.928
0.299
150.3
0.065
4.236
0.322
7.2
0.00411
0.303
0.019
k
55,529
31.73
2,341.7
148.0
99
55,536
31.73
2,342.0
148.0
99
21.5
0.00871
0.605
0.038
98.2
0.040
2.779
0.176
.9
119.7
0.049
3.384
0.214
.8
8.7
0.00445
0.371
0.020
k
56,772
29.11
2,429.5
130.6
99
56,781
29.11
2,429.9
130.6
99
25.9
0.00934
0.697
0.037
129.1
0.047
3.511
0.189
.8
155.0
0.056
4.208
0.226
.8
8.6
0.00486
0.366
0.024
1
54,285
30.43
2,304.4
147.2
99,
54,294
30.44
2,304.7
147.2
99,
19.5
0.00758
0.537
0.033
122.2
0.049
3.41
0.221
,8
141.7
0.057
3.943
0.254
,8
Dry normal cubic meters at 20°C, 760 mm Hg.
Dry normal cubic meters per minute at 20°C, 760 mm Hg.
Mg/hr = megagrams (103 kg) per hour.
Includes train filter, and impinger water filtrate.
kg/Mg = kilograms/megagram.
NO] selective ion electrode analysis results (H20 fraction only) measured as nitrate and reported as ammonium nitrate. Analysis was
performed at the MRI lab in Kansas City, Missouri.
Water fraction results include a 1.45 mg blank correction.
Opacity measurements not recorded during test.
Average percent opacity observed represents only 25 min of test 4-OS.
Average opacity not calculated due to insufficient observations during testing.
Negative number.
No average calculated due to negative numbers in Run Nos. 4 and 5.
2-3
-------
TABLE 2-3. SUMMARY OF EMISSION TEST RESULTS FOR NITRATE AND AMMONIA REPORTED AS
AMMONIUM NITRATE UTILIZING AN NO^ SELECTIVE ION ELECTRODE AND
DIRECT NESSLER ANALYSIS-ROTARY DRUM GRANULATOR SCRUBBER INLET
Run number Run 3-IS Run 4-IS
Date 3/7/79 3/7/79
Volume of gas sampled - DSCF 58.62 61.79
Percent moisture by volume 2.0 2.0
Average stack temperature - °F , 166 186
Stack volumetric flow rate - DSCFM 41,401 43,442
Percent isokinetic 102.6 ' 103.1
Production rate - tons/hr 14.5 17.4
Insoluble particulates
Filter catch and collection
water filtrate
mg 10.0 7.2
gr/DSCF 0.00263 0.00179
Ib/hr 0.93 0.67
Ib/ton 0.064 0.039
Ammonium nitrate particulate Measured by Measured by
Nitrate and ammonia SIEd,e ^f.g SI£ DN
reported as ammonium nitrate
mg 50,555 128,941 55,529 57,887
gr/DSCF 13.311 33.949 13.868 14.457
Ib/hr 4,723.6 12,047.3 5,163.9 5,383.2
Ib/ton 325.8 830.8 296.8 309.4
Total particulates
Insoluble and ammonium
nitrate
mg 50,565 128,951 55,536 57,894
gr/DSCF 13.314 33.952 13.870 14.459
Ib/hr 4,724.5 12,048.2 5,164.6 5,383.9
Ib/ton 325.9 830.9 296.8 309.4
Percent insoluble catch of 0.020 0.008 0.013 0.012
total catch
Run 5-IS Average
3/8/79
68.96 63.12
2.0 2.0
180 177
49,120 44,654
101.7 102.5
20.5 17.5
8.7 8.6
0.00194 0.00212
0.82 0.81
0.040 0.048
Measured by Measured by
SIE DN SIE DN
56,772 67,768 54,285 84,865
12.725 15.189 13.301 21.198
5,357.6 6,395.0 5,081.7 7,941.8
261.3 312.0 294.6 484.1
56,781 67,777 54,294 84,874
12.727 15.191 13.304 21.200
5,358.4 6,395.8 5,082.5 7,942.6
261.3 312.0 294.7 484.1
0.015 0.013 0.016 0.011
Dry standard cubic feet at 68°F, 29.92 in. Hg.
Dry standard cubic feet per minute at 68°F, 29.92 in. Hg.
Includes train filter, and impinger water filtrate.
N03 selective ion electrode analyses results (H20 fraction only) measured as nitrate and reported as ammonium nitrate. Analysis was
performed at the MRI lab in Kansas City, Missouri.
eWater fraction results include a 1.45 mg blank correction.
Direct Nessler analyses results (H20 fraction only) measured as ammonia and reported as ammonium nitrate. Analysis was performed
at the MRI lab in Kansas City, Missouri.
*Zero blank correction.
2-4
-------
TABLE 2-4. SUMMARY OF EMISSION TEST RESULTS FOR NITRATE AND AMMONIA REPORTED AS
AMMONIUM NITRATE UTILIZING AN NO;} SELECTIVE ION ELECTRODE AND
DIRECT NESSLER ANALYSIS-ROTARY DRUM GRANULATOR SCRUBBER OUTLET
Run number Run 3-OS
Date 3/7/79
Volume of gas sampled - DSCFa 82.44
Percent moisture by volume 2.9
Average stack temperature - "F . 100
Stack volumetric flow rate - DSCFM 38,521
Percent isokinetic 98.1
Production rate - tons/hr 14.5
Insoluble particulates
Filter catch and collection
water filtrate
mg 11.0
gr/DSCF 0.00205
Ib/hr 0.68
Ib/ton 0.047
Ammonium nitrate particulate Measured by
Nitrate and ammonia ,
reported as ammonium nitrate SIE >e DN '*
mg 139.3 164.5
gr/DSCF 0.026 0.031
Ib/hr 8.58 10.24
Ib/ton 0.59 0.71
Total particulates
Insoluble and ammonium
. nitrate
mg 150.3 175.5
gr/DSCF 0.028 0.033
Ib/hr 9.26 10.92
Ib/ton 0.64 0.76
Percent insoluble catch of
total catch 7.3 6.3
Run 4-OS Run 5-OS Average
3/7/79 3/8/79
87.00 97.75 89.06
3.7 7.9 • 4.8
109 115 . 108
40,887 43,969 41,126
97.5 101.9 99.2
17.4 20.5 17.5
21.5 25.9 19.5
0.00381 0.00408 0.00331
1.33 1.54 1.18
0.076 0.075 0.066
Measured by Measured by Measured by
SIE DN SIE DN SIE DN
98.2 105.3 129.1 341.5 122.2 203.8
0.017 0.019 0.020 0.054 0.021 0.035
5.96 6.66 7.54 20.35 7.36 12.42
0.34 0.38 0.37 0.99 0.43 0.69
119.7 126.8 155.0 367.4 141.7 223.2
0.021 0.023 0.024 0.058 0.024 0.038
7.29 7.99 9.08 21.89 8.54 13.60
0.42 0.46 0.45 1.07 0.50 0.76
18.0 17.0 16.7 7.0 14.0 10.1
Dry standard cubic feet at 68°F, 29.92 in. Hg.
Dry standard cubic feet per minute at 68°F, 29.92 in. Hg.
Includes train filter, and impinger water filtrate.
N03 selective electrode analyses results (H20 fraction only) measured as nitrate and reported as ammonium nitrate. Analysis was
performed at the MRI lab in Kansas City, Missouri.
eWater fraction results include a 1.45 rag blank correction.
Direct Nessler analyses results (H20 fraction only) measured as ammonia and reported as ammonium nitrate. Analysis was performed
at the MRI lab in Kansas City, Missouri.
*Zero blank correction.
2-5
-------
to
TABLE 2-5. AMMONIA CONCENTRATION DETERMINED BY DIRECT NESSLER ANALYSIS FOR THE
ROTARY DRUM GRANULATOR SCRUBBER INLET AND OUTLET - ENGLISH UNITS
Kun number
Location
Date
Volume of gas sampled - DSCFa
Percent moisture by volume
Average stack temperature - °F
Stack volumetric flow rate - DSCFM
Percent isokinetic
Production rate - tons/hr
Ammonia concentration and
mass flow rates
Direct Nessler analysis'"'"
m8
gr/DSCEe
gr/ACF*
Ib/lir
ll>/ton
Collection efficiency, percent
Run 3
Inlet
3/7/79
58.62
2.0
166
41,401
102.6
14.5
36.4008
9.584
7.927
3,401.0
234.6
99.9
Outlet
Kun
Inlet
4
Outlet
3/7/79
82.44
2.9
100
38,521
98.1
69.7
0.013
0.012
4.292
0.296
61.79
2.0
186
43,442
103.1
17.4
12,301
3.072
2.456
1,143.9
65.7
99.
87.00
3.7
109
40,887
97.5
29.0
0.005
0.004
1.752
0.101
8
Run
Inlet
5
Outlet
Average
Inlet
Outlet
3/8/79
68.96
2.0
180
49,120
101.7
20.
14,402
3.228
2.595
1,359.1
66.3
99
97.75
7.9
115
43,969
101.9
5
159.0
0.025
0.021
9.422
0.460
.2
63.12
2.0
177
44,654
102.5
17.
21.0348
5.295
4.326
1,968.0
122.2
99
89.06
4.8
108
41,126
99.2
5
85.9
0.014
0.012
5.155
0.286
.6
Dry standard cubic feet at 68°F, 29.92 in. Hg.
l'Diy standard cubic feet per minute at 68°F, 29.92 in. Hg.
Direct Nessler analysis results include both the water and acid fractions measured as ammonia.
The analyses were performed at the MR1 lab in Kansas City, Missouri.
d.
Zero blank correction.
gr/DSCF = grains per dry standard cubic foot.
gr/ACF - grains per actual cubic foot.
8lnlet Run No. 3 acid fraction results are inconsistently high with other test results.
There may have been sample carryover in the impinger.
-------
TABLE 2-6. AMMONIA CONCENTRATION DETERMINED BY DIRECT NESSLER ANALYSIS FOR THE
ROTARY DRUM GRANULATOR INLET AND OUTLET - METRIC UNITS
Run number
' Locution
Date
Volume of gas sampled * DNM3
Percent moisture by volume
Average ^tack temperature - °C
Slack volumetric flow rale - DNMJ/M
Percent isokinet ic
Production rate - Mg/IirC
Ammonia concent rat ion and
mass f Low rates
Direct Messier analysis >e
? • . , f
g/norma lized cu m
g/actual cu tu
kg/hr
kg/Mg"
1
~*j Collection etticienoy, percent
Run 3
Inlet
3/7/79
1.66
2.0
74
1,172
102.6
13. 15
36,400*
21.93
18.14
1,542.1
117.3
99.9
Outlet
2.33
2.9
38
1 ,091
98. 1
69.7
0.030
0.028
1.964
0. 149
Run 4
Inlet
3/7/79
1.75
2.0
86
1 ,230
103.1
15.82
1 2 , 30 1
7.03
5.62
518.8
32.8
99.8
Outlet
Hun
Inlet
5
Outlet
Average
Inlet
Outlet
3/8/79
2.46
3.7
43
1, 158
97.5
29.0
0.012
0.011
0.834
0.053
1.95
2.0
82
1 ,391
10.1.7
18.
14,402
7.39
5.94
616.8
33.2
99.
2.77
7.9
46
1,245
101.9
60
159.0
0.057
0.048
4.258
0.229
2
1.79
2.0
81
1,264
102.5
15.
21.0341
12.12
9.90
892.6
61.1
99
2.52
4.8
42
1 , 165
99.2
,86
85.9
0.033
0.029
2.352
0.144
.6
Dry normal cubic meters at 20°C, 760 ami llg.
Dry normal cubic meters per minute jt 20°C, 760 mm Hg.
Hg/hr = Megagrains per hour (10* kg/hr).
t)i rect Messier analysis resul I s incl ude both thr water and acid fractions measured as ammonia.
The analyses were performed at thi: MR I lab in Kansas City, Missouri.
Zero blank correction.
g/norma 1 ized cubic meters = grams pur (dry) nonna 1 i zed cubic meters.
g/actnal cubic meters = gr;ims per actual cubic Dieters.
kg/Mg = kilograms per Megagiam.
Inlet Nun Nu. 3 a (.id f ract i on resnl ts are i neons i s tc-nl ly' high with other test resul ts.
There may have been sample carryover in the imp i ngt-r.
-------
TABLE 2-7. SUMMARY OF AMMONIA AND AMMONIUM NITRATE EMISSIONS CALCULATED FROM
COLLECTED AMMONIA FOR THE ROTARY DRUM GRANULATOR SCRUBBER INLET
to
i
00
Run number
Date
Volume of gas sampled - DSCFa
Stack volumetric rate - DSCFM
Production rate - tons/hr
Ammonia
(laboratory analysis as anunonia) *
ing
gr/DSCF
lb/hr
Ib/ton
Ammonium nitrate
Calculated from moles
r . u,e
of ammonia
mg
gr/DSCF
lb/hr
Ib/ton
Excess ammonia
Not combined with ,
aiiunoii i uni nitrate
ing
gr/USCF
lb/hr
Ib/ton
Run 3- IS
3/7/79
58.62
41,401
14.5
ON
36.4008
9.584
3,401.0
234.6
171,294
45.100
16,004.4
1,103.8
25.6I98
6.745
2,393.6
165.1
Run 4-IS
3/7/79
61.79
43,442
17.4
ON
12,301
3.072
1,143.9
65.7
57,887
14.457
5,383.2
309.4
493
0.123
45.8
2.63
Run 5- IS
3/8/79
68.96
49,120
20.5
DN
14,402
3.228
1,359.1
66.3
67,774
15.191
6,395.8
312.0
2,325
0.521
219.4
10.70
Average
63.12
44,654
17.5
DN
21,034s
5.295
1,968.0
122.2
98,985
24.916
9,261.1
575.1
9,479g
2.463
886.3
59.48
Dry standard cubic feet at 68°F, 29.92 in. llg.
Dry standard cubic feet per minute at 68°F, 29.92 in. Hg.
Direct Nessler analyses results include both the water and acid fractions measured as ammonia. The analyses
were performed at the MKI lab in Kansas City, Missouri.
Zero blank correction.
Direct Nessler analyses results include both the water and acid fractions. The ammonium nitrate data were
calculated from the mole fraction of the measured ammonia. The analyses were performed at the MRI lab
in Kansas City, Missouri.
S1E water fraction results include a 1.45 mg blank correction. Acid fraction
results had zero blank correction.
Inlet Run No. 3 acid fraction results are inconsistently high with other test
results. There may have been sample carryover in the impinger.
-------
TABLE 2-8. SUMMARY OF AMMONIA AND AMMONIUM NITRATE EMISSIONS CALCULATED
FROM COLLECTED AMMONIA FOR THE ROTARY DRUM GRANULATOR
SCRUBBER OUTLET
Run number
Date
Volume of gas sampled - DSCr'd
Slack volumetric flow rate - DSCKM '
Production rale - tons/lit
Afluuon i a ,
(laboratory analysis as ammonia) '
ing
gr/DSCK
Ib/hr
Ib/toii
Aiiunoiiiuiu nitrate
Calculated from fuotes
ot ammonia
nig
gr/DSCK
Ib/br
Ib/ton
Excess ammonia
Not combined with
anunonium nitrate
lug
gr/llSCF
Ib/br
Ib/ton
Kim 3-OS
3/7/79
82.44
38,521
14.5
DN
bt.l
0 . 0 1 3
4.292
0.206
328.0
0.062
20.5
1.41
40. 1
0.008
2.64
0. 18
Run 4-OS
3/7/79
87.00
40,887
17.4
DN
29.0
0.005
1.752
0.101
1 36 . 5
0.024
8.4
0.48
2.65
0.0005
0. 175
0.010
Run 5 -OS
3/8/79
97.75
43,969
20.5
DN
159.0
0.025
9.422
0.460
748.2
0.118
44.5
2.17
121.9
0.019
7.16
0.349
Average
89.06
41,126
17.5
DN
85.9
0.014
5.155
0.286
404.2
0.068
24.5
1.35
_
54.9
0.009
3.33
0.180
dOry standard cubic U>el at 68°F, 29.92 in. Hg.
*Dry slandaid cubic feel per minute at 68°F, 29.92 in. Hg.
cDireel Nessler analyses results include both the water and acid fractions measured as ammonia.
The anjlyses were performed at the MR I lab in Kansas City, Missouri.
Zero blank correction.
Di reel Nessler analyses resu1ts inc hnle both I be water and acid fractions. The ammonium nit rate
data were calculated from the mult: fraction of the measured ammonia. The lab analyses were
performed at the MKI lab in Kansas City, Missouri.
SIE water fraction results include a I.45 mg blank correction. Acid fraction results
bad zero blank correction.
-------
TABLE 2-9. SUMMARY OF EMISSION TEST RESULTS-PARTICULATE AND AMMONIUM
NITRATE CONCENTRATION (NO^ SELECTIVE ION ELECTRODE ANALYSIS)
FOR THE OUTLET OF THE ROTARY DRUM COOLER IN ENGLISH AND
METRIC UNITS
Units
Date
Volume of gas sampled
Percent moisture by volume
Average stack temperature
Stack volumetric flow rate
Percent isokinetic
Production rate
Insoluble particulate
English
A
DSCF
°F .
DSCFM
ton/hr
Metric
DNM38
°C
DNM3/M^
Mg/hr1
Run 1-ORDC
English
3/8/79
41.57
2.1
99
20,464
93.7
20.85
Metric
1.18
2.1
37
579
93.7
18.96
Run 2-ORDC
English
3/9/79
42.41
1.5
107
19,948
100.7
20.82
Metric
1.20
1.5
42
565
100.7
18.87
Run 3-ORDC
English
3/9/79
41.60
1.8
111
19,620
100.4
20.85
Metric
1.18
1.8
44
556
100.4
18.96
Average
English
41.86
1.8
106
20,011
98.3
20.84
Metric
1.19
1.8
41
567
98.3
18.93
Filter catch and collection
water filtrate*
Ammonium nitrate particulate
NOs selective ion electrode
Total particulate
Insoluble and ammonium
nitrate
gr/DSCFf
Ib/hr
Ib/ton
h r
analysis '
gr/DSCF
Ib/hr
Ib/ton
gr/DSCF
Ib/hr
Ib/ton
mg
g/NM3j
kg/hr.
kg/MgR
mg
g/NM3
kg/hr
kg/Mg
mg
g/NM3
kg/hr
kg/Mg
0.02590
4.547
0.218
1.903
333.8
16.0
1.929
338.3
16.2
69.9
0.05925
2.064
0.109
5,137.7
4.354
151.3
8.0
5,207.6
4.413
153.4
8.1
0.01565
2.680
0.129
1.735
296.7
14.3
1.751
299.4
14.4
43.1
0.03581
1.214
0.064
4,764.0
3.970
134.6
7.1
4,807.1
4.010
135.8
7.2
0.00574
0.965
0.046
1.826
307.1
14.7
1.832
308.1
14.7
15.5
0.01313
0.438
0.023
4,930.0
4.178
139.4
7.4
4,945.5
4.191
139.8
7.4
0.01576
2.731
0.131
1.821
312.5
15.0
1.837
315.3
15.1
42.8
0.03606
1.239
0.065
4,943.9
4.167
141.8
7.5
4,986.7
4.205
143.0
7.6
Includes train filter, and impinger water filtrate.
NO3 selective ion electrode analyses results (H20 fraction only) measured as nitrate and reported as ammonium nitrate. Analyses were performed
at the MRI lab in Kansas City, Missouri.
Water fraction results include a 1.45 mg blank correction.
Dry standard cubic feet at 68°F, 29.92 in. Hg.
eDry standard cubic feet per minute at 68°F, 29.92 in. Hg.
Grains per dry standard cubic foot.
8Dry normal cubic meters at 20°C, 760 mm Hg.
Dry normal cubic meters per minute at 20°C, 760 mm Hg.
1Megagrams (103 kg) per hour.
Grams per normalized (dry) cubic meters per minute.
k,,.
Kilograms per megagram (103 kg).
2-10
-------
TABLE 2-10. SUMMARY OF EMISSION TEST RESULTS AT THE OUTLET OF THE ROTARY DRUM
COOLER FOR NITRATE AND AMMONIUM NITRATE UTILIZING AN NO^
SELECTIVE ION ELECTRODE AND DIRECT NESSLER ANALYSIS
Run number
Date
Volume of gas sampled - DSCFa
Percent moisture by volume
Average stack temperature - °F
Stack volumetric flow rate - DSCFM
Percent isokinetic
Static pressure, in. H20
Production rate'- tons/hr
Insoluble part i cu i ate
• Filter catch and collection water
f i 1 tratec
mg
gr/DSCF
Ib/hr
Ib/ton
Ammonium nitrate particulate
Nitrate and ammonium reported
as ammonium nitrate
«'R
gr/DSCK
Ih/hr
1 h/t on
Tota 1 part i cu 1 ales
Insoluble and ammonium nitrate
mg
(•r/DSCK
Ili/hr
1 h/t on
Percent insoluble catch of
total catch
Run 1-ORDC
3/8/79
41.57
2.1
99
20,464
93.7
-2.6
20.85
69.9
0.02590
4.547
0.218
Measured by
SIEd'e DNf'g
5,137.7 4,469.8
1.903 1.656
333.8 290.5
16.0 13.9
5,207.6 4,539.7
1.929 1,682
338.3 295.0
16.2 14.1
1.342 1.540
Run 2-ORDC
3/9/79
42.41
1.5
107
19,948
100.7
-2.6
20.82
43.1
0.01565
2.680
0. 129
Measured by
S1E ON
4,764.0 3,591.6
1.735 1.308
296.7 223.6
14.3 10.7
4,807.1 3,634.7
1.751 1 . 324
299.4 226.3
14.4 10.8
0.897 1.186
Run 3-ORDC
3/9/79
41.60
1.8
111
19,620
100.4
-2.6
20.85
15.5
. 0.00574
0.965
0.046
Measured by
S1E DN
4,930.0 3,737.1
1.826 1.384
307.1 232.7
14.7 11.2
4,945.5 3,752.<>
1.832 1.3'JO
308.1 233.7
14.7 11.2
0.313 0.413
Average
41.86
1.8
106
20,011
98.3
-2.6
20.84
42.8
0.01576
2.731
0. 131
Measured by
SIK DN
4,943.9 3,932.8
1.821 1.449
312.5 248.9
15.0 11.9
4,')8b.7 3,975.7
1.837 1.465
315.3 251.7
15.1 12.0
0 . 85 1 1 . 046
Dry standard cubic feet at 68°F, 29.92 in. Hg.
*Mry standard cubic feet per minute at 6B°F, 29-92 in. Hg.
I IK" I udes tra i ri filter, and impinger water f i! trate.
NOjseIt-ctivc ion electrode analyses results (H20 fraction only) measured as nitrate and reported as ammonium nitrate.
Analyses were performed at the MRI lab in Kansas City, Missouri.
Water fract ion resnIts include a 1 .45 mg blank correction.
Direct Messier analyses results (H20 fraction only) measured as ammonia and reported as ammonium nitrate. Analyses were
performed at the MK1 lab in Kansas City, Missouri.
Zero blank correct ion.
2-11
-------
TABLE 2-11. SUMMARY OF AMMONIA AND AMMONIUM NITRATE EMISSIONS
CALCULATED FROM COLLECTED AMMONIA FOR THE
OUTLET OF THE ROTARY DRUM COOLER
.Run number
Date
Volume of gas sampled - DSCFa •
Stack volumetric flow rate - OSCFM
Production rate - tons/hr
Aiiunon i a
(laboratory analysis as ammonia)1"'
mg
gr/DSCF
Ib/hr
Ib/ton
Ammonium nitrate
Calculated from moles
ot ammonia '
mg
gr/DSCF
Ib/hr
Ib/ton
Excess ammonia
Not combined with
ammonium nitrate
ing
gr/USCF
Ib/hr
Ib/ton
Run l-OKDC
3/8/79
41.57
20,464
20.85
DN
954.1
0.353
61.9
3.0
4,489.9
1.663
291.7
14.0
f
f
f
f
Run 2-ORDC
3/9/79
42.41
19,948
20.82
DN
763.2
0.278
47.5
2.3
3,591.5
1.308
223.6
10.7
f
f
f
f
Run 3-ORDC
3/9/79
41.60
19,620
20.85
DN
796.6
0.295
49.6
2.4
3,748.7
1.388
233.4
11.2
f
f
t
(
Average
41.86
20,011
20.84
DN
838.0
0.309
53.0
2.6
3,943.4
1.453
249.6
12.0
f
f
f
f
Dry standard cubic feet at 68°F, 29.92 in. llg.
Dry standard cubic feet per minute at 68°F, 29.92 in. llg.
Direct Nessler analyses results include both the water and acid fractions measured as ammonia. The
analyses were performed at the MR1 lab in Kansas City, Missouri.
Zero blank correction.
Direct Nessler analyses results include uoth the water and acid fractions. The ammonium nitrate data were
calculated from the mole fraction of the measured ammonia. The analyses were performed at the MRI lab
in Kansas City, Missouri.
No data presented, negative difference.
-------
TABLE 2-12. BRINK IMPACTOR SAMPLING PARAMETERS AND RESULTS - ROTARY DRUM
GRANULATOR SCRUBBER INLET, RUN NO. 1-IS
jr, SIIMK'AUY
S3
I—'
oo
RUN NU'1HFU
PI IN DATE
SAMPLING POINT s i
PITOT F ACTOW
FILTER SET
V T . O)RWF (1 I (i:.| - .
SAMt-l ..I MR PA1>
«;AMPI i MI; i IMI-
RUN 1-IS
STAGE
CYCLONE
1
4
FH.TF4
TA4E
. 4 1 6 n o o
,4?jMon
.431300
.4? 70 OD
.344700
.?«>2^00
1-IS
^;;
T ICI.F OF MSI T Y
1.00 i.i/CC PAS COMPOSITION
F 4 uEfi F PERCENT C02
IFT CnFM STACK <^AS TF'*PE«ATllWf.
-fl.no'i AV. MFTF» TFI-IPE°ATII'VE
in HAPOMFTPfC PUFSSUI'F
,\'i"^
-------
TABLE 2-13. BRINK IMPACTOR SAMPLING PARAMETERS AND RESULTS - ROTARY DRUM
GRANULATOR SCRUBBER INLET, RUN NO. 2-IS
I
(—*
*-
PARTtClF S17IM'? SUMMARY
IMPACTOR
"UN NIJMHFR ?-IS
RUN OATF. 03-0 /-79
SAMPLING POINT S*'TFT CHFM
PITOT FACTOR -0.000
FILTER SFT ?F O»OH
SAMPLING TIME IP. 00 MJM NO/2LE !1T«''ETFR
H M/
0 LOGO
(OR/
SCF)
.054
.010
.013
.012
.005
GFOM
MEAN
DIAM
(MIC)
4.69
2.42
1.54
.93
.53
FILTFk
.?'S0400' .000?00
.76f.700 GRAMS Cf
.03 100.00
= R.430 GR/SCF
-------
KJ
I
TABLE 2-14. BRINK IMPACTOR SAMPLING PARAMETERS - ROTARY DRUM GRANULATOR
SCRUBBER INLET, RUN NO. 3-IS
P/VHTIHF
SHMMAUV
"UN NUMHFU
HUM OATF
3-IS
03 - n >. - 7 '.
SAMPLING POINT SWIFT CHpM
PITOT FACTOW -o.ooo
FILTF" SF.r 30
wT. OuHPFCTION -.
SAMPLING MATt
SAMPLING TJMe
SAMPL IMG
KI'N 3- IS
STAGF
'CVCLONF
1
3
FIL1F*
VOLUMh
TAPt
.47/300
.493400
.480700
. '* f> S 7 0 0
. ?K \ ^n i)
5 A"HI
i c.i f ni-Msi TV
f:MT TFMPFPATIJ°F.
STACK r,A<= TF^PfPATUPF
AV. MFTFP TFMPF94TU°E
,oon*ni) GSAMS STATIC PUFSSDWH
.ll^<* ACFM IMPACTO° DPFSSU°F DPOP
1 .1"? S(
- KHINK IMPiCTOR PC"
MASS n i
,.i r TH
FIMAL NFT(AOJ>
1 .733-ino i ,si??n6
.477 100 . 004f,00
.404300 .noosoo
.463400
.4H1300
.470100
.
-------
N>
ON
99.991 99.9
10.
99 98
Weight % Greater than Stated Size
90 50 10
'7 -
O Run 1 -IS
A Run 2 - IS
a Run 3-IS
6.01
O.i
1
98 99
0.01
99.9
99.99
10 50 90
' Weight % Less than Stated Size
Figure 2-1. Brink impactor particle size results: particulate diameter versus percent weight
less/greater than stated size - rotary drum granulator at inlet to scrubber,
run Nos. 1 through 3.
-------
1.0
0.7
0.5
0.3
^ 0.2
O
Q
1
\. 0.1
O)
= 0.07
•o
0.03
0.02
0.01
0
I TIT
O Run 1 - IS
A Run 2-IS
D Run 3 -IS
0.3 0.5 0.7 1.0 2.0 3.0
Geometric Mean of Particle Diameter (Microns)
5.0 7.0 10.0
Figure 2-2. Brink impactor particle size results: differential mass-
loading (dM/d Log D) versus particulate diameter - rotary
drum granulator at inlet to scrubber, run Nos. 1 through 3.
2-17
-------
TABLE 2-15. BRINK IMPACTOR SAMPLING PARAMETERS AND RESULTS - ROTARY
DRUM COOLER OUTLET, RUN NO. 1-CO
HAMTfCI.F SJ/INR SUMMARY
00
*MIN NUMB
PUN DATE
F»
1-CO
SAMPLING POINT S-MFT CHEM
PI IOT F ACTOH -n.nnu
F ILTFx SFI 40
WT. roPRFCT KIN -.
SAMPLING RAK
SAMPL1NG
WI'N 1-CO
VOLlJMF
PAHTTCI.C DENSITY
STACK GAS
A V . MFTPP
1.00 G/CC '
'*. DFG F
TF'"PKRATUPE 1. OFG F
TF'IPERATUPF 78. OFG F
; ppf. c,cjyp(.- 30.08 IN H«
ono^ni) GPAMS STATIC PPFSSHOF
.13'i'i ACF« JMPACTOP PPFSSURF O^OP
14. on MIN NO/VI.F OtAMETEH
-2.60 IN MPO
15.10 IM Mr,
.0790 IN
5AS COMF
PERCENT
PFRCEN1
PEPCENI
PFRCEN]
MOLFC
PFRCFM1
MOLFC
>OSITION
C02
CO
• 02
• N?
:HLAR WT.
' H20
;iJLAR WT.
0.00
0.00
21.00
79.00
28.84
2.00
28.62
?.?3h SCF
SUMMARY- BRINK IMPACTOP RESULTS
MASS HIST^IHI
WITH OUT
STAGtf
CYCLONE
1
3
5
F1LTKK
TAKt
• . 22420(1
.4231 llu
.347900
.464900
.473200
.26H3UO
FIGHT U-JL
FINAL
.314200
,4?5000
.475100
.348100
.473200
.?6«100
NF T (ADJ)
.001500
-.000200
-.000jj>00
-.000200
-.000400
-.000600
FILTER
CUM
99.^5
1.66
-.??
-.22
-.P2
-.44
;PAMS cr
99.45
101.11
100.8°
100.67
100.44
100.00
IT10N (PFPCfNT)
•/JITH
FILTER
CUM
100.11
1 .64
-.2?
-.22
-.22
-.45
-.67
1- .61*
100.1 1
101.79
101.56
101.34
101.12
100.67
100.00
GR/SCF
JET
050
VFLOCITY niAM
(CM/SFC) (MIC)
1353.
2663.
4305.
9374.
15699.
7.00
2.77
1.64
1.12
.59
.36
0 M/
D LOGO
(GR/
SCF)
.026
-.006
-,00«
-.005
-.013
GEOM
MEAN
DIAM
(MIC)
4.40
2.13
1.36
.82
.47
-------
TABLE 2-16. BRINK IMPACTOR SAMPLING PARAMETERS AND RESULTS - ROTARY DRUM
COOLER OUTLET, RUN NO. 2-CO
C,UMMAPY
VO
PUN NUMHFP ?-(_'() °A
PUN MA I E n 1-0'i- 74 A"
SAMPI. ING
piroT Far
p.Mhjr S
•i I F T C ri h '-'
-0. 000
ST
AV
.Hl'NTFTF«P"Ili
1.00 R/CC ' RAS COMPOSITION
iwe 4 l)Ffi F PEP-CENT CO?
!°MFTKM TFMPF^|U"F /! ntn F
FlUTf. WSFT Ci 0 HAPOM*rTPTCtJPFt:. S!
MI . COURT
SAMPI ING
SAMPL 1NR
SflMPuiNT,
PUN .-'-co
ST4f,F
CYCl !)MF
1
?
3
4
5
F I U T f ^
:CT ion -
HATf
TlMt.
VOI.UMK
. (i no '.oo p
w A MS SI
.1377 ACFM jr
1'. .Ill) ••
? • ? o s ^
c;nMMr,u Y
AT 1C unhssilPf
PACniP Ppf^^URI
I'-l M07/I.F ofAMFTFa
li'h TO.O? IN
-?..(>fl IN
-' 0-JOP 15.JO IN
.0740 IN
HC,
H?0
Mr,
PFRCFWT
PFPCFNT
HOI FC
PFPCENT
CO
0?
N?
MUAP WT.
H?0
0.00
0.00
21 .00
79.00
2H.84
2.00
MOLFCUUAR WT. z^.^2
- KPlrgr IMPflCTO" OFSiiUTS
TAOf. FINAL NF.T(«HJ)
. 4Hf-i40fl
.4*34 in)
.4714()ii
.50 c i nu
.483300
.?t-()?r»i
. 4 I M 7 0 n
.4^.4?on
.4 ??i no
,50fcf>00
.483700
.?f,rif,np
. n o ? 7 o n
. n n n 4 fl o
.non mo
.000100
.000000
. 0 0 0 1) 0 0
MASS 1 ) I <; T n I s I
'4 I 1 'i i ) 1 1 T
CUM
1 . 3'< Q9. f-n
.?(! go. Hf)
.IS 44. 95
.05 100.00
.00 100.00
.IT I ON (PFPCF.NT)
•-'ITH
CUM
98. ?4 9ft. ?4
.?n 49. HO
.IS 99.95
.OS 100.00
.00 100.00
.00 100.00
JF.T
(CM/SFC)
133S
?*>?.'>
4?46
9?4fr
154H5
nso
(MIC)
7.00
1.65
1.13
.60
.37
n M/
0 UORO
SCF)
.047
.oia
.013
.003
.000
GF.OM
MFflN
(MIC)
4.42
2. 14
1.37
. P2
.47
-------
TABLE 2-17. BRINK IMPACTOR SAMPLING PARAMETERS AND RESULTS - ROTARY DRUM
COOLER OUTLET, RUN NO. 3-CO
PAPTICIF SIZING SUMMARY
BOJMK IMPACTOR
BUN NUMMFP
PUN HATE
1-CO P'.PTICI.F riKNSITv
03-09-79 AMBIENT TEM°FO* TUPK.
SAMPLING POINT StalFT CHEM
PITOT FACTOR -0.000
FILTER SET Mi
wr. CORRECTION -.
SAMPL ING RA U
SAMPLING TIMF
SAMPLING
RUN 3-CO
VOLU^f
STACK (lA^ TEN'PERATURE
HAPOMETSTC PRESSURE
OOOfeOO GRAMS STATIC PPFSSII°E
.13')? ACFM IMPACTOR PMFS^URF. O^OP
14.00 MIN NOZ7LF IIIAMFTFP
SUMMARY-
1.00 G/CC GAS COMPOSITION
4 DEG F PERCENT C02
1 OEG F
77 DEG F
.10. Of IN H«
-2.60 IN
IS. 30 IN
.0790 IN
PERCENT co
PERCENT 02
PERCENT N?
H?0 MOLFCULAR WT.
Hr, PERCENT H?0
MOLECULAR WT.
0.00
0.00
21.00
79.00
28.84
2.00
2H.62
- BRINK IMPACTOR RESULTS
MASS ni^TPIRUTION (PERCENT)
WITH OUT WITH
STAGE
CYCLONE
1
2
; 3
4
5
FILTER
WFIGHT (GRAMS)
TAKE FINAL NET(AOJ)
.222500
.488400
.507600
.473600
.487600
.489100
.26S700
.330300
.490700
.507700
.473100
.487000
.488400
.265100
. 107400
.001900
-.000300
-.000900
-.001000
-.001 100
-.001000
.105000
FILTER
CUM
101 .??
1.79
-.94
-1.04
101.3? 1
103.11
102.83
101.98
101.04
100.00
GRAMS COLLECTED=
FILTER
CUM
1.81
-.29
-.8ft
-.95
-1.05
.727
102.29
104.10
103.81
102.95
102.00
100.95
100.00
GR/SCF
JET
050
VELOCITY DIAM
(CM/SEC) (MIC)
1349
2655
439?
9347
15654
7.00
2.77
1.64
1.12
.60
.36
0 M/
D LOGO
(GRX
SCF)
.033
-.009
-.038
-.025
-.036
GEOM
MEAN
DIAM
(MIC)
4.40
2.13
1.36
.82
.47
-------
99.99. 99.9
10
99 98
Weight % Greater than Stated Size
90 50 10
0.01
J>!0.7
Oi
^i 0.5
0.4
0.3
0.2
0.1
I
I
O Run I -CO
A Run 2-CO
D Run 3 - CO
I
J_
I
0.01
10 50 90
Weight % Less than Stated Size
98 99
99.9 99.99
Figure 2-3. Brink impactor particle size results: particulate diameter versus percent weight
less/greater than stated size - rotary drum cooler outlet, run Nos. 1 through 3.
-------
0.10
0.07
0.-05
0.03
^ 0.02
6
o
S
\ 0.01
T3
O>
| 0.007
J
S 0.005
0.004
0.003
0.002
0.001
i I i i r
i i i r
O Run 1 -CO
A Run 2-CO
D Run 3-CO
i i 11 i i
4 5678 9.10
J | | | I J
4 5 6 7 8 9 10
Geometric Mean of Particle Diameter (Microns)
Figure 2-4. Brink impactor particle size results: differential mass-
loading (dM/d Log D) versus particulate diameter - rotary
drum cooler outlet, run Nos. 1 through 3.
2-22
-------
TABLE 2-18. SIX MINUTE ARITHMETIC AVERAGE OPACITY READINGS FROM
THE ROTARY DRUM GRANULATOR SCRUBBER OUTLET STACK,
MARCH 7 AND 8, 1979
Time
16:40:15-16:46
16:46:15-16:52
16:52:15-16:58
16:58:15-17:04
17:04:15-17:10
17: 10:15-17:16
17:16:15-17:22
17:22:15-17:28
Average
09:20-09:25:45
09:26-09:31:45
09:32-09:37:45
Average
09:52:15-09:58
09:58:15-10:04
10:04:15-10: 10
10: 10:15-10:16
10: 16:15-10:22
10:22:15-10:28
Average
10:33:45-10:39:30
10:39:45-10:45:30
10:45:45-10:51:30
10:51:45-10:57:30
Average
11:08:15-11:14
11: 14:15-11:20
Average
11:26-11:31:45
11:32-11:37:45
11:38-11:43:45
Average
11:50:15-11:56
11:56:15-12:02
12:02:15-12:08
12:08:15-12:14
12: 14: 15-12:20
12:20:15-12:26
12:26:15-12:32
12:32: 15-12:38
12:38: 15-12:44
12:44:15-12:50
12:50:15-12:56
12:56:15-13:02
Average
13:35-13:40:45
13:41-13:46:45
13:47-13:52:45
13:53-13:58:45
Average
14:03-14:08:45
14:09-14:14:45
14:15-14:20:45
14:21-14:26:45
14:27-14:32:45
Average
14:33-14:38:45
14:39-14:44:45
14:45-14:50:45
14:51-14:56:45
Average
Average opacity MRI scrubber MRI scrubber
for - 6 min inlet test outlet test
intervals, (%) Date No. No.
5.0 03-07-79
5.0
5.0 4- IS 4-OS
5.0
5.2
5.4
. 5.2
5.6
5.2
12.9 03-08-79
13.5
13.5
13.3
14.0
15.8
14.8
14.4
14.8
15.4
14.8
17.3
15.0
15.8
15.3 5-IS 5-OS
16.0
17.9
15.6
16.8
15.6
14.6
12.9
14.4
14.4
15.0
14.2
16.5
17.5
13.1
13.8 '
13.5
12.1
13.1
14.4
13.8
14.3
19.4
15.0
14.4
17. 1
16.5 • * Opacity observations recorded from the rotary
15.4 drum granulator scrubber outlet stack cor-
16.3 respond to MRI test 1-ORDC at the uncon-
17.3 trolled outlet of the rotary drum cooler.
12.9
14.6
15.3
14.6
15.3
16.3
13.5
15.1
2-23
-------
Average Opacity, %
XJ
I
*o
CO
T
--J
"O
•17:28
09:20
09:38
09:52
10:28
10:34
10:58
11:08 -H
11:20 3
11:26 •
1 1:44 ?
11:50 3
13:02
13:35
13:59
14:03
M M
O* 03
r1
Figure 2-5. Summary of EPA Method 9 visible emissions from the rotary
drum granulator scrubber outlet stack, March 7 and 8,
1979.
2-24
-------
Pressure Drop Measurement Test Data
The inlet-to-outlet pressure drop measurements made at the rotary drum
granulator scrubber are presented in Table 2-19. The results are graphi-
cally presented in Figure 2-6. The pressure drop measurements recorded from
the rotary drum cooler are presented in Table 2-20. The results are graphi-
cally presented in Figure 2-7. :
Relative Humidity and Ambient Temperature Measurement Test Data
The data for the relative humidity and ambient temperature measure-
ments collected during emissions testing of the rotary drum granulator
scrubber are presented in Table 2-21. The relative humidity results are
graphically presented in Figure 2-8. The relative humidity and ambient
temperature measurements collected during emissions testing of the un-
controlled rotary drum cooler are presented in Table 2-22. The relative
humidity results are graphically presented in Figure 2-9.
Scrubber Liquor Test Data
The results of the chemical analysis of the scrubber liquor entering
and exiting the rotary drum granulator scrubber on March 7 and 8, 1979,
have been summarized in Table 2-23. The results of individual sample tem-
perature and pH measurements have been tabulated in Table 2-24.
Process Sample Test Data
Process sample data results of product samples collected from the ro-
tary drum granulator and rotary drum cooler have been summarized in Tables
2-25, 2-26, and 2-27. The chemical analysis data have been tabulated in
Table 2-25. The sieve analysis and bulk density determination data of the
unscreened granulator product samples collected during emissions testing
are presented in Table 2-26. The sieve analysis and bulk density deter-
mination data of the screened product samples collected at the inlet to and
outlet of the rotary drum cooler during emissions testing are presented in
Table 2-27.
2-25
-------
TABLE 2-19. ROTARY DRUM GRANULATOR SCRUBBER INLET-TO-OUTLET PRESSURE DROP
MEASUREMENTS DURING EMISSIONS TESTING, MARCH 7 AND 8, 1979
ro
i
Date
03-07-79
(Scrubber in-
let test No.
3-IS and out-
let test No.
3-OS)
Scrubber in-
let test No.
4-IS and out-
let test No.
4-OS)
Clock
time
0915
1003
1019
1030
1047
1103
1118
1130
1145
1204
1217
1230
1245
1300
Average
1445
1500
1515
1530
1545
1600
1615
1630
1645
1710
Average
AP
cm
27
H20
.1
*
in.
10
H20
.7
-•,-
* *
26
25
25
25
25
23
23
24
23
22
21
24
24
26
25
26
26
26
25
26
26
25
26
.2
.7
.1
.1
.9
.9
.9
.1
.4
.4
.8
.6
.6
.4
.1
.7
.7
.4
.9
.4
.4
.4
.0
10
10
9
9
10
9
9
9
9
8
8
9
9
10
9
10
10
10
10
10
10
10
10
.3
.1
.9
.9
.2
.4
.4
.5
.2
.8
.6
.7
.7
.4
.9
.5
.5
.4
.2
.4
.4
.0
.2
Clock
Date time
03-08-79 0916
(Scrubber in- 0932
let test No. 0947
5-IS and out- 1003
let test No. 1018
5-OS) 1033
1048
1103
1117
1134
Average
AP
cm H
33.
34.
33.
31.
31.
31.
32.
32.
32.
32.
32.
2°
8
8
5
8
8
2
0
8
0
0
6
in.
13
13
13
12
12
12
12
12
12
12
12
H20
.3
.7
.2
.5
.5
.3
.6
.9
.6
.6
.8
Plugged inlet hose, no reading available.
-------
N>
K>
6"
CM
X
o_
O
D
v»
V
ol
10
14
12
10
8
6
4
1111
Date: 3-7-79
Time Zero = 0900
Scrubber Inlet Run No. 3-IS
Scrubber Outlet Run No. 3 -OS
*"-•-•_•-%
^•-.--""
- .
l i i i
i i i
-
Scrubber Inlet Run No. 4-IS -
Scrubber Outlet Run No. 4 -OS
./*^«^ * -=
'
i i i
0
345
Elapsed Time, Hours
8
^
O
CN
X
Q.
O
0)
L-
«
2
a.
ID
14
12
10
8
6
4
C
i i i i 1
Date: 3-8-79
. Time Zero = 0900
•"*" ^*«
"Scrubber Inlet Run No. 5-IS
Scrubber Outlet Run No. 5 -OS
—
-
-
1 1 l l 1
) 1 2 34 5
i i
.
-
' - —
-
-
i i
678
Elapsed Time, Hours
Figure 2-6. Summary of rotary drum granulator scrubber inlet-to-outlet
pressure drop measurements during emissions testing,
March 7 and 8, 1979.
-------
TABLE 2-20. ROTARY DRUM COOLER PRESSURE DROP
MEASUREMENTS DURING EMISSIONS
TESTING, MARCH 8 AND 9, 1979
Date
03-08-79
(Cooler
outlet
test No.
1-ORDC)
03-09-79
(Cooler
outlet
test No.
2-ORDC)
(Cooler
outlet
test No.
3-ORDC)
Clock
time
1405
1418
1433
1448
1505
1518
1533
Average
0845
0930
0945
1000
1015
1030
1045
1100
Average
1515
1530
1545
1600
1615
Average
AP
cm HO
30.0
31.2
30.2
31.8
31.8
31.5
32.0
31.2
12.7
12.2
12.2
12.2
12.4
12.2
12.2
12.2
12.3
11.4
11.4
11.7
11.4
11.4
11.5
in. H20
11.8
12.3
11.9
12.5
12.5
12.4
12.6
12.3
5.0
4.8
4.8
4.8
4.9
4.8
4.8
4.8
4.8
4.5
4.5
4.6
4.5
4.5
4.5
2-28
-------
O
CN
16
14
12
10
8- s
1 6
in
0)
a. 4
2
0
16
14
I I
Date: 3-8-79
Time Zero = 0900
Cooler Outlet
Test No. 1-ORDC
I
I
3 4
Elapsed Time, Hours
O.
D
t/i
0)
^.
a.
12
10
Date: 3-9-79
Time Zero = 0900
Cooler Outlet
Test No. 2-ORDC
Cooler Outlet
Test No. 3-ORDC
01 234567
Elapsed Time, Hours
Figure 2-7. Summary of rotary drum cooler pressure drop measurements
during emissions testing, March 8 and 9, 1979.
2-29
-------
TABLE 2-21. AMBIENT TEMPERATURE AND RELATIVE HUMIDITY MEASUREMENTS
DURING EMISSIONS TESTING OF THE ROTARY DRUM
GRANULATOR SCRUBBER, MARCH 7 AND 8, 1979
Ambient temperature
Date
03-07-79
(Scrubber in-
let test No.
3-IS and out-
let test No.
3-OS)
Average
(Scrubber in-
let test No.
4-IS and out-
let test No.
4-OS)
Average
03-08-79
(Scrubber in-
let test No.
5-IS and out-
let test No.
5-OS)
Average
Clock
time
0915
1000
1015
1030
1045
1100
1115
1130
1145
1200
1215
1230
1245
1445
1500
1515
1530
1545
1600
1615
1630
1645
1710
0900
0915
0930
0945
1000
1015
1030
1045
1100
1115
1130
Dry
(°C)
15.0
17.0
17.7
17.9
17.8
18.8
19.1
19.3
19.9
20.1
20.1
21.1
21.9
18.9
25.2
25.2
25.1
24.9
24.9
25.0
24.8
24.3
24.1
23.9
24.7
13.3
13.5
15.0
15.5
16.1
16.6
16.9
17.1
17.1
17.6
17.9
16.1
bulb
(°F)
59.0
62.6
63.8
64.3
64.1
65.8
66.4
66.7
67.9
68.1
68.2
70.0
71.5
66.0
77.4
77.4
77.2
76.8
76.8
77.0
76.7
75.8
75.4
75.0
76.6
55.9
56.3
59.0
59.9
61.0
61.8
62.5
62.8
62.8
63.6
64.3
60.9
Wet
(°C)
10.3
10.9
11.3
11.3
11.6
11.6
11.7
11.4
11.8
11.7
12.1
12.2
12.9
11.6
13.7
13.1
14.1
13.1
13.5
13.7
13.5
13.3
13.6
13.5
13.5
9.0
9.3
9.3
9.1
9.4
9.4
9.7
9.7
9.7
10.0
10.2
9.5
bulb
(°F)
50.6
51.6
52.3
52.4
52.8
52.8
53.1
52.6
53.2
53.1
53.8
54.0
55.2
44.8
56.6
55.6
57.4
55.6
56.3
56.6
56.3
56.0
56.4
56.3
56.3
48.2
48.8
48.8
48.4
49.0
49.0
49.5
49.5
49.5
50.0
50.4
49.2
Relative
humidity,
(%)
57
46
43
43
44
40
40
37
34
34
38
33
31
40
26
26
23
23
23
26
23
25
27
27
23
55
55
47
39
40
36
37
37
37
34
34
41
2-30
-------
N>
CO
ou
X
TJ
| 60
3
X
-------
TABLE 2-22. AMBIENT TEMPERATURE AND RELATIVE HUMIDITY MEASUREMENTS
DURING EMISSIONS TESTING OF THE ROTARY DRUM COOLER,
MARCH 8 AND 9, 1979
Ambient temperature
Date
03-08-79
(Run No.
1-ORDC)
Average
03-09-79
(Run No.
2-ORDC)
Average
(Run No.
3-ORDC)
Average
Date
time
1400
1415
1430
1445
1500
1515
0845
0930
0945
1000
1015
1030
1045
1100
1515
1530
1545
1600
1615
Dry
(°C)
23.0
23.7
24.0
24.3
24.3
24.6
24.0
20.8
22.3
22.3
22.8
23.0
23.2
23.4
24.2
22.8
25.0
25.1
25.2
25.3
25.3
25.2
bulb
(°F)
74.0
74.7
75.2
75.8
75.8
76.2
75.3
69.4
72.2
72.2
73.1
73.4
73.8
74.1
75.5
73.0
77.0
77.2
77.3
77.5
77.5
77.3
Wet
(°C)
13.4
13.7
13.7
14.1
13.9
13.9
13.8
18.1
18.4
18.6
18.7
18.6
18.8
18.6
18.8
18.6
19.1
19.1
19.1
19.1
18.9
19.1
bulb
(°F)
56.2
56.7
56.6
57.4
57.0
57.0
56.8
64.6
65.2
65.4
65.6
65.4
65.8
65.4
65.8
65.4
66.3
66.4
66.4
66.3
66.0
66.3
Relative
humidity,
(%)
29
30
30
28
28
28
29
85
69
69
73
73
69
69
62
71
56
56
56
53
53
55
2-32
-------
U)
80
•§ 60
x
0)
-3 40
Qi
20
80
'E 60
«S 40
20
Date: 3-8-79
Time Zero = 0900
Cooler Outlet
Test No. 1-ORDC
3 4 5
Elapsed Time, Hours
-•
Date: 3-9-79
Time Zero = 090°
Cooler Outlet
Test No. 2-ORDC
*~
Cooler Outlet
Test No. 3-ORDC
01 234567
Elapsed Time, Hours
Figure 2-9. Summary of relative humidity measurements during emissions
testing of the rotary drum cooler, March 8 and 9, 1979.
-------
-
OJ
TABLE 2-23. SUMMARY OF CHEMICAL ANALYSIS DATA ON THE SCRUBBER LIQUOR ENTERING AND EXITING
THE ROTARY DRUM GRANULATOR SCRUBBER DURING EMISSIONS TESTING, MARCH
7 AND 8, 1979
Kim No . :
Date:
Sample location
Ammonium
n i Crate
Specific ion el
Direct
Nessler
Him
3
03-07-79
Inlet
Outlet
Kun 4
03-07-79
Inlet
Outlet
Kun 5
03-08-79
Inlet
Outlet
Average
Inlet
Outlet
-5 a
concentration (uig/U x 10 )
ectrode analysis
ana lysis
2.40
2.94
5.47
5.92
Ammonia concentration (mg/4)
Speci I i
Direct
fir
lempera Li
°C
°K
1.99
2.21
Did
7.04
7.12
not do S1E
1.57
1.56
on these
7.38
7.72
samples
2.15
2.24
6
6
.63
.91
ic ion electrode analysis
Nesslci
c
ire :
analysis
62
6.60
51
124
126
6.05
34
94
47
6.57
52
125
152
5. 19
37
99
33
7.17
62
143
164
5.84
38
100
47
6.78
55
131
147
5
3d
'J8
.69
a Milligrams per liter x 10
b Average of several individual 1 itjuor samples taken during each run.
i Average of individual I euipera tures taken shortly after collection.
-------
TABLE 2-24. SUMMARY OF pH AND TEMPERATURE MEASUREMENTS ON INDIVIDUAL
SAMPLES OF SCRUBBER LIQUOR ENTERING AND EXITING THE
ROTARY DRUM GRANULATOR SCRUBBER DURING EMISSIONS
TESTING, MARCH 7 AND 8, 1979
Run
No.
3
4
5
Sampling
Date time
03-07-79 1030
1045
1115
1145
1215
1230
1245
1300
Average
03-07-79 1500
1530
1545
1600
1615
1645
1715
1745
Average
03-08-79 0915
0945
1015
1030
1100
1115
1130
Average
Scrubber inlet
pH
6.65
-
6.70
6.60
•
6.52
-
6.51
6.60
6.59
6.55
-
6.57
-
6.55
-
6.60
6.57
7.35
7.30
7.10
-
6.99
7.10
-
7.17
°C
58
49
49
51
50
51
49
51
53
53
-
52
52
60
62
60
-
62
66
-
62
°F
136
-
120
121
-
123
-
122
124
121
124
-
127
-
128
-
125
125
140
143
140
-
144
150
-
143
Scrubber outlet
pH
_
5.99
5.80
6.18
5.74
-
6.55
6.05
5.23
-
5.00
-
5.11
5.30
5.29
5.19
6.00
5.95
-
5.80
5.76
-
-
5.84
°C
_
33
34
34
34
34
34
37
37
37
37
37
37
37
38
38
38
38
38
OF
_
92
94
94
94
-
94
94
98
-
98
-
99
99
99
-
99
99
100
-
100
100
-
100
100
2-35
-------
TABLE 2-25. SUMMARY OF CHEMICAL ANALYSIS RESULTS FOR PROCESS
PRODUCT SAMPLES COLLECTED FROM THE ROTARY DRUM
GRANULATOR AND ROTARY DRUM COOLER, MARCH 6 TO 9,
1979
Concentration
(mg/£)
301 Granulator inlet 03-06-79
AN melt
303 Granulator outlet 03-07 to
product composite 03-08-79
304 Cooler inlet 03-08 to
product composite 03-09-79
305 Cooler outlet 03-08 to
product composite 03-09-79
4.12 x 10~
2.3 x 104
2.5 x 104
2.2 x 104
Concentration
(mg/£)
Sample
No.
Sample
location
Date
collected
NH4NO by
Nessler
analysis
NH3 by
Nessler
analysis
87,660
4,964
5,312
4,587
2-36
-------
TABLE 2-26. SUMMARY OF SIEVE ANALYSIS'AND BULK DENSITY DETERMINATIONS OF THE UNSCREENED
PRODUCT SAMPLES COLLECTED DURING EMISSIONS TESTING OF THE ROTARY DRUM
GRANULATOR SCRUBBER, MARCH 7 AND 8, 1979
Inlet
3-IS
Sample collected
Scrubber emission test numbers
Outlet Inlet Outlet Inlet
3-OS 4-IS 4-OS 5-IS
Outlet
5-OS
03/07/79 Sample collected 03/07/79 Sample collected 03/08/79
Cumulative Cumulative
Percent percent Percent percent Percent
of of of of of
total total tolaii total totai
Bulk density3 mass mass Bulk density3 mass mass Bulk density3 mass
Sieve size:
Sieve No. 6 - 10.
Sieve No. 8 - 23
Sieve No. 12 - 37.
Sieve No. 14 - 12,
Sieve No. 16 - 8
Sieve No. 20 - 6.
Can - 1
Bulk density:
Grams per
250 mli 216.0
lb/ft3 53.94
a Voluinetricaliy determined.
b Percent of total mass retained
.0
.2
.8
.9
.4
.7
.3
on
100 - 18.0 100 - 21.9
90.0 - 27.2 81.6 - 18.4
67.0 - 34.0 54.4 - 31.2
29.2 - 10.5 20.4 - 12.2
16.4 - 5.8 9.9 - 8.2
8.0 - 3.6 4.1 - 6.9
1.3 - 0.5 0.5 - 1.3
218.1 221.8
54.46 55.38
indicated sieve size.
Cumulative
percent
of
total
mass
100
78.2
59.8
28.6
16.4
8.2
1.3
-------
TABLE 2-27. SUMMARY OF SIEVE ANALYSIS AND BULK DENSITY DETERMINATIONS OF THE SCREENED PRODUCT
SAMPLES COLLECTED AT THE INLET TO AND OUTLET OF THE ROTARY DRUM COOLER DURING
EMISSIONS TESTING OF THE ROTARY DRUM COOLER, MARCH 8 AND 9, 1979
N>
00
Rotary drum cooler outlet
Sample collected 03/08/79
at inlet to cooler
emissions test No. 1-ORDC
Sampled collected
03/08/79
at outlet of cooler
Cumulative
Sieve size:
Sieve No.
Sieve No.
Sieve No.
Sieve No.
Sieve No.
Sieve No.
Pan
6
8
12
14
16
20
Percent
of
a t0tal
Bulk density mass
2.9
48.0
41.3
6.2
1.4
0.1
0.04
percent
of
total
mass
100
97.0
49.0
7.7
1.5
0.1
0.0
Percent
of
total
a B
Bulk density mass
3.8
52.7
37.8
4.7
1.1
0.2
0.0
Cumulative
percent
of
total
mass
100
96.4
43.8
6.0
1.3
0.2
0.0
Bulk density:
Grams per
250 mS,
lb/ft3
214.5
53.56
223.9
55.91
(continued)
-------
TABLE 2-27. (continued)
Rotary drum cooler outlet
Sample collected 03/09/79
at inlet to cooler
emissions test No. 2-ORDC
Sampled collected
03/09/79
at outlet of cooler
Cumulative
Sieve size:
Sieve No.
Sieve No.
Sieve No.
Sieve No.
Sieve No.
Sieve No.
Pan
6
8
12
14
16
20
Percent
of
total
a D
Bulk density mass
4.6
59.3
33.3
2.7
0.3
0.04
0.08
percent
of
total
mass
100
95.7
36.4
3.1
0.4
0.1
0.1
Percent
of
a t0tao-
Bulk density mass
5.7
63.0
28.9
2.1
0.2
0 . 1
0.0
Cumulative
percent
of
total
mass
100
94.3
31.3
2.4
0.3
0.1
0.0
Bulk density:
Grams per
250 mH
lb/ft3
210.8
52.64
222.1
55.46
(continued)
-------
TABLE 2-27. (concluded)
Rotary
Sample collected
drum cooler outlet
03/09/79
at inlet to cooler
Sieve size:
Sieve No.
Sieve No.
Sieve No.
Sieve No.
Sieve No .
Sieve No.
Pan
6
8
12
14
16
20
Percent
of
total
Bulk density mass
8.0
58.4
28.8
3.8
0.8
0.04
0.07
Cumulative
percent
of
total
mass
100
91.9
33.5
4.7
0.9
0.1
0.1
emissions test No. 3-ORDC
Sampled collected
03/09/79
at outlet of cooler
Percent
of
total
Bulk density mass
7.9
57.7
28.9
4.4
1.0
0.09
0.14
Cumulative
percent
of
total
mass
100
92.2
34.5
5.6
1.2
0.2
0.1
Bulk density:
Grams per
250 m£
lb/ft3
212.7
53.11
221.7
55.36
a Volumetrically determined.
b Percent of total mass retained on indicated sieve size.
-------
SECTION 3
PROCESS DESCRIPTION AND OPERATION
Preliminary Introduction
Emission tests were conducted on the ammonium nitrate emissions from
the rotary drum granulator during March 7 and 8, 1979. The tests were de-
signed to characterize and quantify uncontrolled emissions from the solids
production (granulation) process, and to determine control equipment effi-
ciency. Figure 3-1 presents a flow diagram for the granulator and its an-
cillary equipment. Emission tests were conducted on the inlet and outlet
air streams of the rotary drum granulator scrubber. Particulate size char-
acterization tests were conducted on the rotary drum granulator scrubber
inlet stream on March 7 and 8, 1979. During these emission tests, grab sam-
ples were collected from various process streams in order to determine if
the process was operating at representative steady-state conditions. Grab
samples were collected from the ammonium nitrate melt feed (SI, Figure 3-1)
and the solid unscreened product stream (S2) of the granulator along with
the inlet (S3) and outlet (S4) liquor streams of the scrubber. The pres-
sure drop across the scrubber was monitored. Aliquots of the grab samples
collected from the scrubber inlet and outlet streams were combined to form
composite samples (one inlet and one outlet). These were analyzed for am-
monia and ammonium nitrate. The results of these analyses combined with
their respective flow rates may be useful in calculating a material balance
around the scrubber.
Tests of emissions from the rotary drum cooler before the two parallel
cyclones were conducted on March 8 and 9, 1979. These were designed to char-
acterize uncontrolled emissions from the cooler. Figure 3-1 also presents
a simplified flow sheet for the cooler. Grab samples were collected of the
cooler product in (S5) and out (S6) and analyzed for temperature, pH, and
moisture.
Process Description
Process Equipment
The ammonium nitrate neutralizer facility reacts hot nitric acid (HNO«)
and ammonia (NH_) to form ammonium nitrate (NH,NO_), steam and heat. This
facility, designed by Mississippi Chemical Company, was installed in January
of 1979. The neutralizer product (83% AN) flows to a two-stage vacuum fal-
ling film evaporator where it is concentrated to about 99% AN. From the
concentrator, the AN melt flows to a head tank and is adjusted for pH by
3-1
-------
TO ST#CK
UJ
I
§1
TO ATVOSPttt Rt
PRODUCT
Figure 3-1. Flow diagram of the rotary drum granulator and rotary drum cooler.
-------
ammonia injection. The AN melt is gravity fed to the C and I Girdler ro-
tary drum granulator which has a design rating of 400 tons per day (15.15 x
103 kg/hr). Modifications to the lift flights in the granulator have in-
creased the maximum production rate to approximately 500 tons/day (18.94 x
103 kg/hr). As the AN melt cools by countercurrent chilled air, it solidi-
fies into spherical particles which are conveyed to a screening operation
for sizing. A weigh belt records the weight of granules both before and
after the screens. Undersized granules and crushed oversize granules are
combined and sent back to the granulator as seed material. Correctly sized
granules are conveyed to the rotary drum cooler where refrigerated air cools
the granules. Clay coating of the cooled granules takes place in a rotary
drum coater. From there the granules proceed to the warehouse.
Emission Control Equipment
The exhaust air from the granulator is ducted directly to a Joy "Type
D" Turbulaire scrubber where it is combined with an ammonium nitrate-weak
liquor scrubber solution.
Emissions from the rotary drum cooler are ducted to two parallel wet
cyclones. There is one water spray in the duct itself and three sprays in
each cyclone..
Process Operation
Production Rates
The feed rate of concentrated ammonium nitrate melt as measured by a
volumetric flow meter was monitored and recorded. Two weigh belts recorded
both the screened and unscreened product out of the granulator. Recent
calibrations (February 1979) of the weigh belts presented an accurate pro-
duction rate for the granulator. Average product rates during the granula-
tor efficiency tests were calculated using the screened product weigh belt
integrator and are presented in Table 3-1. Average product rates during
the rotary drum cooler tests were calculated in the same manner as were the
rotary drum granulator scrubber tests (i.e., weigh belt integrators) and
are presented in Table 3-2. No integrator data was collected during the
Particle Size Distribution Test No. 1-CO at the outlet of the rotary drum
cooler. However, the weigh belt strip chart showed that the product rate
of the rotary drum granulator during this test was approximately 18.9 x 103
kg/hr (20.8 tons/hr).
Production and Control Equipment Operation
The flow rate, temperature, and pressure of the AN melt to the granu-
lator, the inlet and outlet air stream temperatures, the granulator bed tem-
perature, and the temperature of the granules leaving the granulator were
monitored and recorded during testing. The temperature and make-up rate of
the scrubber liquor were also recorded. Temperatures during all testing
were recorded as variations from a predetermined artificial zero. This
method of recording the data was used in order to avoid confidentiality
complications.
3-3
-------
TABLE 3-1. AVERAGE ROTARY DRUM GRANULATOR PRODUCT RATES DURING GRANULATOR
EMISSIONS TESTING
Date
03-07-79
03-07-79
03-08-79
03-07-79
03-07-79
03-08-79
Test location
Inlet and outlet rotary
drum granulator scrubber
Inlet and outlet rotary
drum granulator scrubber
Inlet and outlet rotary
drum granulator scrubber
Rotary drum granulator
scrubber inlet
Rotary drum granulator
scrubber inlet
Rotary drum granulator
scrubber inlet
MRI
Test type . test No.
Modified EPA Method 5 3-IS and 3-OS
Modified EPA Method 5 4-IS and 4-OS
Modified EPA Method 5 5-IS and 5-OS
Brink impactor particle 1-IS
size distribution
Brink impactor particle 2-IS
size distribution
Brink impactor particle 3-IS
size distribution
Product rate
(103 kg/hr)
13.15
15.82
18.60
14.71
14.00
18.59
(tons/day)
347.8
418.7
493.0
389.3
370.2
492.0
a Data obtained by Hr. Timothy L. Curtin, Environmental Engineer, GCA Corporation, Technology Division,
Chapel Hill, North Carolina.
-------
TABLE 3-2. AVERAGE ROTARY DRUM GRANULATOR PRODUCT RATES DURING EMISSIONS TESTING
OF THE ROTARY DRUM COOLER
Date
03-08-79
03-09-79
03-09-79
03-08-79
03-09-79
03-09-79
<-" a Tests
Test location
Rotary drum cooler outlet
Rotary drum cooler outlet
Rotary drum cooler outlet
Rotary drum cooler outlet
Rotary drum cooler outlet
Rotary drum cooler outlet
Test type3
Modified EPA Method 5
Modified EPA Method 5
Modified EPA Method 5
Brink impactor particle
size distribution
Brink impactor particle
size distribution
Brink impactor particle
size distribution
MRI
test No.
1-ORDC
2-ORDC
3-ORDC
1-CO
2-CO
3-CO
Product rate
(10J kg/hr)
18.96
18.87
18.96
c
17.15
20.32
(tons/day)
500.5
499.8 .
500.5
c
453.6
533.8
conducted to characterize uncontrolled emissions from the cooler.
b Data obtained by Mr. Timothy L. Curtin, Environmental Engineer, CCA Corporation, Technology Division,
Chapel Hill, North Carolina.
c No integrator data was collected during the particle.size test No. 1-CO of the rotary drum cooler
outlet. The product rate of the rotary drum granulator during this test showed the product rate
to be approximately 18.9 x 103 kg/hr or 499.2 tons/day.
-------
During emissions testing of the rotary drum cooler, the cooler inlet
air temperature was also monitored in addition to the above mentioned pa-
rameters.
Average and standard deviations of the above parameters during the
emissions tests have been calculated and are presented in Table 3-3. The
average and the standard deviation are expressed as percentages of the
overall average value. The average value of each parameter is used to cal-
culate the overall average for that parameter, but is not presented as a
percentage in Table 3-3. Standard deviations are not presented for tests
where the number of readings were three or less. Actual values of monitored
parameters are presented in Appendix M.
Granulator, Scrubber, and Cooler Operation
Minor plant upsets occurred during the entire testing program. Prob-
lems with controlling the fan damper on the rotary drum granulator and scrub-
ber and a malfunctioning scrubber liquor level controller voided the first
2 days of testing. Liquor level was maintained through the utilization of
the sight glass in the scrubber, although the level controller recorder con-
tinued to read high during all testing. A "snowing" condition occurred at
the rotary drum granulator scrubber stack outlet and was believed to have
been the result of inadequate scrubber liquor level control.
On day three (March 7, 1979) only three out of four granulator nozzles
were operative due to the limited quantity of AN melt available. The third
particulate concentration test on the inlet and outlet to the rotary drum
granulator scrubber (MRI Test Nos. 3-IS and 3-OS, respectively) were con-
ducted at this lower production rate. The fourth granulator nozzle was
brought back on line during the early afternoon (Day 3, March 7, 1979) and
continued on line for the remainder of the testing.
On day four (March 8, 1979), the granulator was put on total recycle
with no additional AN melt being added due to an excessively low level in
the head tank. Fortunately this happened between tests and should not af-
fect the results of the testing of the rotary drum cooler.
On day five (March 9, 1979), the compressor on the inlet air cooler of
the granulator went out of service causing granulator temperatures to be
excessively high. Trouble continued with the fan damper serving the granu-
lator and scrubber. The combined effect of these two problems eventually
led to a rise in the granulator bed temperature to a point where the gran-
ules were agglomerating, forming "rocks." At this point, the granulator was
shut down until the problem could be corrected. Testing did not resume until
steady-state conditions were again attained. Refer to Appendix M for actual
times of plant operations and breakdowns as they interact with test times.
3-6
-------
TABLE 3-3. RELATIVE AVERAGE VALUES OF OPERATING PARAMETERS DURING TESTING3
OJ
Particulate concentration - rotary drum
granulator scrubber inlet and outlet tests
Parameter
Production rate parameters
AN melt feed rate
AN melt pressure at nozzles
Weigh rate of product
Granulator bed temperature
AN melt temperature
Graniilator inlet air
temperature
Granulator outlet air
temperature
Granulator product
temperature
Scrubber parameters
Liquor level
Liquor temperature
Liquor feed rate
Cooler parameters
Air temperature in
Plant
guage
code
FRC-I
PR-2
WR-19
-
T1405-8
TRC6
TR4
TR439-IO
LRC45
TR439-11
FRC44
_
Tei
Avg.
79
114
75
98
102
81
88
95
99
91
98
HRI
»t No. 3
Std. dev.
0.23
0.00
1.00
0.41
0.29
1.99
0.67
0.02
1.25
1.02
0.67
HRI
Test No. 4
Avg,
94
77
91
102
102
89
19
too
98
97
98
Std. dev.
0.32
0.00
0.98
0.26
0.28
1.07
0.39
0.01
1.82
0.54
0.00
KR1
Test No. 5
Avg.
107
106
109
99
103
84
100
98
99
95
98
Std. dev.
0.47
0.00
3.01
0.34
0.25
0.70
0.55
0.01
1.27
0.49
0.00
97
Particulate concentration - uncontrolled rotary
drum cooler outlet emissions tests
HRI
Test No. 1-ORDC
Avg,
107
108
112
99
99
84
100
94
103
100
98
2.
Std. dev.
0.00
0.00
4.22
0.39
0.35
0.00
0.31
0.01
1.30
0.91
0.00
.63 101
HRI
Test No. 2-ORDC
Avg.
107
106
110
102
98
135
106
99
100
105
102
2.61
Std. dev.
0.00
0.00
4.72
0.98
0.89
3.62
0.78
0.01
1.75
0.52'
0.00
HRI
Test No. 3-ORDC
Avg. Std. dev.
97 0 . 00
83 0.00
93 9.34
99 0 . 45
98 • 0.62
147 0.99
99 0.00
118 0.03
102 0.00
105 1.05
(continued)
-------
TABLE 3-3. (concluded)
CO
00
Brink impactor particle size
rotary drum granulator scrubber inlet tests
Parameter
Production rate parameters
AN melt feed rate
AN melt pressure at nozzles
Weigh rate of product
Granulator bed temperature
AN melt temperature
Granulator inlet air
temperature
Granulator outlet air
temperature
Granulator product
temperature
Scrubber parameters
liquor level
Liquor temperature
Liquor feed rate
Cooler parameters
Air temperature in
Plant
guage
code
FRC-1
PR- 2
WR-19
-
T1405-8
TRC6
TR4
TR439-10
LRC45
TR439-11
FRC44
-
HRI
test No. 1-IS
avg.
92
106
83
102
101
82
94
99
ioo
94
98
HRI
test No. 2-IS
avg.
94
77
85
101
102
82
100
105
98
96
98
HRI
test No. 3-IS
avg.
107
108
112
98
99
84
101
93
104
100
98
Brink impactor particle size
uncontrolled rotary drum cooler outlet tests
HRI HRI
test No. 1-CO test No. 2-CO
avg. avg.
-b 107
-b 106
-b 96
-b 100
-" 99
t
-b 128
-b 104
t
-b 94
-b 98
-b 105
-b 102
-b 10.
HRI
test No. 3-CO
avg.
107
106
133
101
98
138
107
104
100
109
107
101
a Data obtained by Mr. Timothy I. Curtin, Environmental Engineer, CCA Corporation, Technology Division,
Chapel Hill, North Carolina.
b Data not obtained during testing.
-------
SECTION 4
LOCATION OF SAMPLING POINTS
Introduction
Tests were conducted on the rotary drum granulator emissions and the
uncontrolled emissions of the rotary drum cooler at the Swift Chemical Com-
pany ammonium nitrate manufacturing facility in Beaumont, Texas. The tests
were designed to determine the uncontrolled and controlled emissions at
maximum production rate considering ambient temperature conditions.
In general, sampling locations included the inlet and outlet of the
rotary drum granulator scrubber, scrubber liquors, granulator feed, granu-
lator product, and the uncontrolled outlet of the rotary drum cooler. Dur-
ing the sampling, the ambient air temperature, relative humidity, and pres-
sure drop across the emisson control equipment were recorded. .
This section presents detailed descriptions of the sampling locations
for the measurement of relative humidity and ambient air temperature, scrub-
ber pressure drop, ammonia, nitrate, pH, particulate mass, particle size
distribution, process and product samples, and visible emissions.
Physical Description of Facilities
A generalized overview of the Swift Chemical Company, Beaumont, Texas,
ammonium nitrate manufacturing facility is presented in Figure 4-1.
The exhaust air from the rotary drum granulator is passed through a Joy
"Type D" Turbulaire scrubber, located west of the AN rotary drum granulator
and rotary drum cooler building, and is then discharged to the atmosphere
through a stack.
The AN granules of product size are cooled by treated air in a rotary
drum cooler, which is located in the AN rotary drum granulator and rotary
drum cooler building. The exhaust air from the rotary drum cooler is ducted
to two parallel wet cyclones and discharged to the atmosphere.
Rotary Drum Granulator Sampling Locations
The locations of the ports used to sample the inlet to the rotary drum
granulator scrubber is presented in Figure 4-2. View A is from the south-
west and View B is from the northwest. The ports are located in a 49.5 in.
inside diameter horizontal section of duct. The two ports are positioned
90° apart and located 157 cm (62 in.), or 1.25 duct diameters, downstream
from a right-angle bend in the duct leading to the scrubber. The distance
from the two ports to the nearest upstream disturbance; which is a flange
where the outlet duct from the rotary drum granulator is reduced in size,
is 278 cm (109.5 in.), or 2.21. duct diameters.
4-1
-------
Control
Building
Cooler Discharge
Grar
Tests
O
Clay Hopper
oo
AN Granulator & Cooler
Building
^ Cooler Tests
lulator ^ +
Scrubber^/"
Stack
~— — *
\
{o] ^
^
.
•
;
\
0
"o
li i
Prill Tower
N
Scrubber Liquor Collection Locations
" Pipe Trays
Ammonium
Process
(Not in Use)
Service Road
Ammonium
Process
\
Nitric
Acid
Process
Pipe Trays
Nitric
Acid
Process
- Observer Position for Visible Emissions Observations
^ = Relative Humidity and Ambient Temperature Measurement Locations
Figure 4-1. Overview of the Swift Chemical Company's Beaumont, Texas, ammonium nitrate manu-
facturing facility.
-------
Scrubber Outlet
to Fan & Stack
I
OJ
. 4" Sample Ports
5.625" Long
Exhaust from Rotary
Drum Granulator
Through Wall to Rotary
Drum Granulator
Existing Platform
Scrubber
Wall
Scrubber
Pressure Drop
Measurement
Locations
Scrubber Outlet
to Fan & Stack
Ladder
View A
Platform and Inlet are Behind Scrubber in View A
View B
Figure 4-2. Schematic of sampling port locations used to sample the inlet of
the rotary drum granulator wet scrubber.
-------
This scrubber inlet sampling location did not meet the "8 and 2 diam-
eter" criterion as outlined in EPA Reference Method 1 (Federal Register,
Vol. 42, No. 160, Thursday, August 18, 1977). Consequently, 24 sampling
points were chosen for each axis traverse for a total of 48 sampling points
as specified in the method. Figure 4-3 shows the location of the sampling
points. The distance of the points from the outside flange edge of the sam-
ple port are presented in Table 4-1.
There was an accumulation of material in the bottom of the scrubber
inlet duct. Since the maximum depth of the material was 1.9 cm (0.75 in.),
it did not interfere with sampling, even when the probe nozzle was at sam-
pling point number 2-24. The presence of the material was noted and calcu-
lations made to correct the total area of the duct with respect to this ob-
structed region. The cross-sectional area of the obstructed region was
0.0059 m2 (0.063 ft2) in the 1.2509 m2 (13.465 ft2) duct. The 0.47% reduc-
tion in the total duct area is not considered to significantly affect the
flow rate calculations.
The locations of the sampling ports on the exhaust stack of the rotary
drum granulator scrubber are shown in Figure 4-4. The two ports are posi-
tioned 90° apart in a horizontal plane, 7.1 duct diameters downstream and
2.5 duct diameters upstream from the nearest disturbances.
This scrubber outlet sampling location also did not meet the "8 and 2
diameter" criterion as outlined in EPA Reference Method 1 (Federal Register,
Vol. 42, No. 160, Thursday, August 18, 1977). Consequently, 12 sampling
points were chosen for each axis traverse for a total of 24 sampling points
as specified in the method. Figure 4-5 shows the location of the sampling
points. The distance of the points from the outside flange edge of the
sample port are presented in Table 4-2.
Rotary Drum Cooler Sampling Locations
The locations of the ports used to sample the uncontrolled outlet of
the rotary drum cooler are presented in Figure 4-6. The two ports are lo-
cated in a 27.75 in. inside diameter horizontal section of duct. The two
ports are positioned 90° apart and located 25 cm (10 in.), or 0.4 duct diam-
eters, upstream from an air plenum and 130 cm (51 in.), or 1.8 duct diam-
eters, downstream from the opening to the duct leading to the two parallel
wet cyclones.
The rotary drum cooler uncontrolled outlet sampling location did not
meet the "8 and 2 diameter" criterion as outlined in EPA Reference Metod 1
(Federal Register, Vol. 42, No. 160, Thursday, August 18, 1977). Consequently,
24 sampling point locations were chosen for each axis traverse for a total
of 48 sampling points as specified in the method. Figure 4-7 shows the loca-
tion of the sampling points. The distance of the points from the outside
flange edge of the sample port is presented in Table 4-3.
4-4
-------
DioiMtfr Dimension* art iniio* M*oiur«m«nt
£/ Ponici* iiz« t«trj w«ri conduciea or point 2-14.
Figure 4-3. Sampling point locations at the rotary drum
granulator scrubber inlet duct.
4-5
-------
TABLE 4-1. ROTARY DRUM GRANULATOR SCRUBBER INLET SAMPLING
POINT LOCATIONS
Point No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Fraction of
inside diameter
0.0203
0.032
0.055
0.079
0.105
0.132
0.161
0.194
0.230
0.272
0.323
0.398
0.602
0.677
0.728
0.770
0.806
0.839
0.868
0.895
0.921
0.945
0.968
0.9803
Distance from outside
of sample port
(cm)
17
18
21
24
28
31
35
39
43
49
55
64
90
99
106
111
116
120
124
127
130
133
136
137
(in.)
6 5/8
7 1/4
8 3/8
9 1/2
10 7/8
12 1/8
13 5/8
15 1/4
17
19 1/8
21 5/8
25 3/8
35 3/8
39 1/8
41 5/8
43 3/4
45 1/2
47 1/8
48 5/8
49 7/8
51 1/4
52 3/8
53 1/2
54 1/8
a One inch from duct wall.
4-6
-------
Guard Rail
&
Sample Ports
Caged Ladder
C.S. 3rd Platform
Sample Ports 4" Pipe
8.5" Long
Caged
Ladder
s
'
.
1
I
'
•
•
Stac
(J
1
*
T
Flow
^
-------
N
Inside Diameter
Figure 4-5. Sampling point locations on the exhaust stack of
the rotary drum granulator scrubber.
4-8
-------
TABLE 4-2. ROTARY DRUM GRANULATOR SCRUBBER OUTLET SAMPLING
POINT LOCATIONS
Distance from outside
Fraction of of sample port
Point No. inside diameter (cm) (in.)
1
2
3
4
5
6
7
8
9
10
11
12
0.021
0.067
0.118
0.177
0.250
0.356
0.644
0.750
0.823
0.882
0.933
0.979
25
31
39
50
59
75
118
133
144
153
161
168
9 3/4
12 3/8
15 3/8
18 7/8
23 1/8
29 3/8
46 3/8
52 1/2
56 7/8
60 3/8
63 3/8
66
4-9
-------
Cyclones
4" Sample Port
Air Plenum •
Sample Ports are 4"
Pipe Nipples, 4" Long
Cyclone Outlet
Pressure Drop
Measurement
Locations
4" Sample Ports
Drive Gear
Side View
Top View
Figure 4-6. Schematic of sampling port locations used to sample the outlet duct
of the rotary drum cooler.
-------
2.5" 1.75"
Diameter Dimensions are Inside Measurement Material Build Up
Up
S/ Particle size tests were conducted at point 2-10.
North
Figure 4-7. Sampling point locations used to sample the
outlet duct of the rotary drum cooler.
4-11
-------
TABLE 4-3. ROTARY DRUM COOLER OUTLET SAMPLING POINT LOCATIONS
Distance from outside of sample port
Point No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Fraction of
inside diameter
0.011
0.032
0.055
0.079
0.105
0.132
0.161
0.194
0.230
0.272
0.323
0.398
0.602
0.677
0.728
0.770
0.806
0.839
0.868
0.895
0.921
0.945
0.968
0.989
Port No. 1
(cm)
10.3
11.8
13.4
15.1
16.9
18.8
20.9
23.2
25.7
28.7
32.3
37.6
52.0
57.3
60.8
63.8
66.3
68.7
70.7
72.6
74.4
76.1
77.9
79.2
(in.)
4 1/16
4 5/8
5 1/4
5 15/16
6 11/16
7 7/16
8 1/4
9 1/8
10 1/8
11 5/16
12 11/16
14 13/16
20 7/16
22 9/16
23 15/16
25 1/8
26 1/8
27
27 13/16
28 5/8
29 5/16
30
30 11/16
31 3/16
Port No. 2
(cm)
11.3
12.7
14.4
16.0
17.9
19.8
21.8
24.2
26.7
29.7
33.2
38.5
52.9
58.2
61.8
64.8
67.3
69.6
71.7
73.6
75.4
77.1
78.7
80.2
(in.)
4 7/16
5
5 11/16
6 5/16
7
7 13/16
8 5/8
9 1/2
10 1/2
11 11/16
13 1/16
15 3/16
20 13/16
22 15/16
24 5/16
25 1/2
26 1/2
27 7/16
28 3/16
29
29 11/16
30 3/8
31
31 9/16
4-12
-------
There was an accumulation of material on the bottom of the rotary drum
cooler test duct. This material prevented the sampling of three or four
points during the traverse of port No. 2. The depth of the material was
4.4 cm (1.75 in.) during Test No. 1-ORDC (March 8, 1979) with sampling points
2-22, 2-23, and 2-24 of port No. 2 not"sampled. The depth of the material
on the bottom of the duct increased to 6.35 cm (2.5 in.) for test Nos. 2-ORDC
and 3-ORDC (March 9, 1979) with sampling points 2-21, 2-22, 2-23, and 2-24
of port No. 2 not sampled during either test.
The cross-sectional area of the obstructed region during test No. 1-ORDC
was 0.0095 m2 (0.1027 ft2), or 2.45% of the 0.3902 m2 (4.2 ft2) duct area.
During test Nos. 2-ORDC and 3-ORDC the cross-sectional area of the obstructed
region was 0.0174 m2 (0.1872 ft2), or 4.46% of the 0.3902 m2 (4.2 ft2) duct
area.
The percentage of duct area obstructed during the EPA Modified Method
5 testing at the uncontrolled outlet of the rotary drum cooler was consid-
ered significant. Before each of the three particulate tests the depth of
the material was measured and recorded. Prior to subsequent computer com-
putations of this data, the cross-sectional area of the obstructed region
at the sampling location was determined. An example calculation and the
formula to correct for the area of obstruction is presented in Section B-3
of Appendix B. The area of the obstructed region of the duct was calculated
and subtracted from the total area of the duct. This corrected duct area
was then used for the appropriate test number in the computer computations
of the field data for the outlet of the rotary drum cooler.
Brink Impactor Particle Size Distribution Test Locations
Three particle size distribution tests were performed on the inlet duct
to the rotary drum granulator scrubber. The samples were obtained at tra-
verse point number 2-14, port No. 2. The location of the sampling ports is
shown in Figure 4-2. The sample point location is shown in Figure 4-3.
Three particle size distribution tests were also performed on the un-
controlled outlet duct of the rotary drum cooler. The samples were obtained
at traverse point No. 2-10, port No. 2. The location of the sampling ports
is shown in Figure 4-6. The sample point location is shown in Figure 4-7.
Visible Emission Observation Locations
EPA Method 9, visible emissions observations, were made of the exhaust
plume of the rotary drum granulator scrubber. The observer's three positions
utilized during the field test are shown in Figure 4-8. The observer was
at ground level varying from 24 m (80 ft) to 37 m (120 ft) from the base of
the rotary drum granulator scrubber exhaust stack. The position of the ob-
server varied depending upon cloud cover, wind speed, and wind direction.
The plume was observed against the blue sky.
4-13
-------
I
J—»
^
Pipe Trays
Ammonium
Process
(Not in Use)
x^>- Cooler Discharge
Control
Building
O
Cloy Hopper
OO
AN Granulalor & Cooler
Building
Scrubber .^^ []
Slack -_J-CT\~~ )
> ,
\
Rotary
Drum •
Gronulator
Prill Tower
-Existing Platform
Observer Position
Service Road
Ammonium
Process
V
Nitric
Acid
Process
N
Pipe Trays
Nitric
Acid
Process
Figure 4-8. Schematic plan indicating relative positions of plant equipment
and visible emission observer positions.
-------
Rotary Drum Granulator Scrubber and Rotary Drum Cooler Inlet-to-Outlet
Differential Pressure Drop Measurement Locations
The rotary drum granulator scrubber and rotary drum cooler inlet-to-
outlet differential pressure drop data were measured and recorded during
the field test by Mr. Timothy L. Curtin of GCA Corporation, Technology
Division, and by Mr. Clyde E. Riley of the U.S. EPA, Emission Measurement
Branch.
The differential pressure drop measurement locations on the rotary drum
granulator scrubber are shown in Figure 4-2. The measurement locations for
the differential pressure drop on the rotary drum cooler are shown in Figure
4-6.
Relative Humidity and Ambient Temperature Measurement Locations
The relative humidity and ambient temperature data during the field
test were measured and recorded by Mr. Timothy L. Curtin of GCA Corporation,
Technology Division, and by Mr. Clyde E. Riley of the U.S. EPA, Emission
Measurement Branch.
The two locations of the equipment used to obtain relative humidity
and ambient temperature data during emissions testing are shown in Figure
4-1. As indicated in the figure, a different location was used depending
upon the emission control device that was being tested.
Rotary Drum Granulator Scrubber Liquor Collection Locations
Scrubber liquor samples were collected by MRI field personnel during
the field test. Samples were obtained from the inlet and outlet streams of
the rotary drum granulator scrubber. The location of these sampling points
is shown in Figure 4-1.
Process Sample Collection Locations
These samples were collected and recorded by MRI field personnel dur-
ing the field test. A single sample of the AN (ammonium nitrate) melt was
collected at the inlet to the rotary drum granulator. Four samples of the
rotary drum granulator product before screening were collected. Three of
these samples, coincident with test Nos. 3, 4, and 5 on the granulator were
composited. Three samples were also collected of the screened granulator
product going into the rotary drum cooler and three samples were collected
of the screened product exiting the rotary drum cooler. These samples were
collected at their respective locations and recorded by MRI field personnel
during the field test.
4-15
-------
SECTION 5
SAMPLING AND ANALYTICAL PROCEDURES
INTRODUCTION
This section describes the sampling and analytical procedures used by
MRI at the Swift Chemical Company ammonium nitrate manufacturing plant in
Beaumont, Texas. Brief descriptions of the techniques used have been pre-
sented here. Additional details may be found in various appendices as
referenced in the text.
FEDERAL REGISTER METHODS
Standard EPA methodologies as described in the Federal Register, Vol.
42, No. 160, Part II - Thursday, August 18, 1977, were used wherever appli-
cable for Methods 1, 2, 4, and 5. The molecular weight of the stack gas
was assumed to be 28.84. Opacity measurements were conducted according to
Method 9 procedures described in the Federal Register, Vol. 36, No. 247 -
Thursday, December 23, 1971.
EPA Method 1 - Sample and Velocity Traverses for Stationary Sources
All sample locations were determined using the procedures discussed in
Method 1. The field data are presented in Appendix C.
The sample port locations at the rotary drum granulator scrubber outlet
did not meet the Method 1 criteria of 8 downstream and 2 upstream duct diam-
eters. Field measurements indicated a distance of 7.1 duct diameters down-
stream and 2.5 duct diameters upstream from the nearest disturbance. These
measurements did meet the minimum requirements of 2 downstream and 0.5 up-
stream duct diameters.
Field measurements of the sample port locations at the rotary drum
granulator scrubber inlet indicated a distance of 1.25 duct diameters down-
stream and 2.21 duct diameters upstream from the nearest disturbance. These
measurements did not meet either the 8 downstream and 2 upstream duct diam-
eter requirements, or the minimum requirements of 2 downstream and 0.5 up-
stream duct diameters. There was no indication of cyclonic flow and approval
was obtained from the EPA technical manager to use the sample location.
The sample port locations at the rotary drum cooler uncontrolled outlet
did not meet either the 8 downstream and 2 upstream duct diameter require-
ments, or the minimum requirements of 2 downstream and 0.5 upstream duct
diameters. Field measurements indicated the sample ports were 1.8 duct
diameters downstream and 0.4 duct diameters upstream from the nearest dis-
turbance. There was no indication of cyclonic flow and approval was ob-
tained from the EPA technical manager to use the sample location.
5-1
-------
At both the scrubber inlet and uncontrolled cooler outlet test loca-
tions there was an accumulation of material on the bottom of the test duct.
Section 4 described in detail this condition at these two sample locations.
Prior to each test at these locations, the depth of material was measured
and recorded. Appendix B contains the calculations used to determine the
obstructed area of the ducts. Appendix C presents the field data.
EPA Method 2 - Determination of Stack Gas Velocity and Volumetric Flow
Rate (Type S Pitot Tube)
All velocity measurements were made using standard Method 2 techniques
and equipment. There was an accumulation of material in the bottom of the
rotary drum granulator scrubber inlet duct. The presence of the material
did not interfere with sampling. The bottom of the rotary drum cooler un-
controlled outlet duct also had accumulated material present. At this loca-
tion, the accumulated material did interfere with sampling and the last few
points could not be sampled. The field data are presented in Appendix C.
EPA Method 4 - Determination of Moisture Content in Stack Gases
Standard Method 4 determinations were made at the scrubber and the cooler
locations. The moisture content of the scrubber inlet was assumed to be
2%. This was because buildup of the product in the sample line made it neces-
sary to repeatedly rinse the line with distilled water. Since this rinse
was added to the impingers, it was impractical to do a moisture determination
using Method 4.
EPA Method 5 - Determination of Particulate Emissions from Stationary
Sources
A modified EPA Method 5 train was used during this test. A complete
description of the apparatus and techniques used is contained in the follow-
ing Section entiled, "Ammonium Nitrate Emissions." The field data is given
in Appendix C.
EPA Method 9 - Visual Determination of the Opacity of Emissions from
Stationary Sources
Standard Method 9 techniques by a certified opacity reader were used
for these tests. The field data are recorded in Appendix E.
AMMONIUM NITRATE EMISSIONS
Sampling Techniques
Figure 5-1 is a schematic of the modified EPA Reference Method 5 train
used to collect isokinetic ammonium nitrate samples at the rotary drum gran-
ulator scrubber inlet and outlet and at the uncontrolled rotary drum cooler
exhaust. The sample probe used at the scrubber outlet was a conventional
stainless steel sheath with heated glass liner connected directly to the
impinger train box.
5-2
-------
•-Filter Holder
Thermometer
500ml Impingers S/
l
Check
Volve
Thermocouple
UAir
Tight
Pump
a/ Impingers 1,3,5 and 6 ore of the Modified Greenburg-Smith Type
Impingers 2 and 4 are of the Greenburg-Smith Design
Impinger 1 and 2 Contain 100ml Water
Impinger 3 and 4 contain 100ml INH2SO4
Impinger 5 Empty
Impinger 6 Contains 200-300 Grams Silica Gel
Figure 5-1. Schematic of modified EPA reference
Method 5 sampling train.
Vacuum
Line
• Console
5-3
-------
The scrubber inlet and uncontrolled cooler outlet sampling sites con-
tained vertical traverse sample locations. A conventional sampling probe
arrangement was not feasible at these two sites. The probe used for test-
ing these sites was modified by attaching a 1/2-in. OD flexible teflon tube
at the nozzle end inside a conventional probe sheath. The Teflon tube
passed through the entire probe sheath and extended for approximately 15
ft, where it was adapted to a ball socket spherical joint for attachment to
the glassware in the impinger train. An electrical heating tape wrapped
around the Teflon tube inside the probe sheath and extended approximately
5 ft beyond the sheath to prevent moisture condensation in that portion of
the sample line.
At all sampling locations (scrubber inlet, scrubber outlet, and uncon-
trolled cooler outlet) probe temperatures during sampling were maintained
at approximately stack temperature plus 10°F.
The first, third, fifth, and sixth impingers used were of the modified
Greenburg-Smith design, and the second and fourth impingers were the regular
Greenburg-Smith units with orifice plates.
A glass-fiber (Gelman type A/E) filter with stainless steel back-
up frit and glass filter holder was placed between the second and third im-
pingers. The filter was not weighed but was added to the impinger water
collection at the conclusion of each test.
The sample train was prepared for testing by placing 100 mS. of dis-
tilled, deionized water in impinger Nos. 1 and 2. Impinger Nos. 3 and 4
contained 100 m£ of 1 Normal sulfuric acid (IN H?SO,), and the fifth im-
pinger was empty. The sixth impinger contained a weighed quantity (approx-
imately 200 g) of indicating silica gel.
Sampling procedures were as described in EPA Reference Method 5, ex-
cept that the filter was not heated and the probe was heated to the stack
temperature plus 10°F.
Sample Recovery
Sample recovery at the conclusion of each test consisted of:
1. The sampling nozzle and probe (glass or Teflon as applicable) were
brushed and washed three times into a collection flask using a nylon brush
on a Teflon rod and washing with distilled, deionized water (DDW). The
probe wash was then added to the collection from the first two impingers,
along with the DDW rinse of all connecting glassware up to but not includ-
ing the third impinger. The filter and the DDW rinse from the filter holder
were also added to this collection, which was placed in a labeled, 32-oz,
widemouthed jar.
2. The contents of the third, fourth, and fifth impingers were trans-
ferred to a sample bottle. The impingers and all connecting glassware were
rinsed with 1 N H_SO, and added to the second container collection.
5-4
-------
As in EPA Method 5, the volume of the collection from the impingers
was recorded and used to determine the moisture content. An exception to
this method occurred involving the scrubber inlet tests. The heavy loading
of ammonium nitrate in that part of the process caused periodic stoppage in
the Teflon sample line. It was necessary to stop sampling when this oc-
curred and flush the obstruction into the impinger train using DDW. This
addition of DDW to the impinger train made the sample collection appear to
contain a much higher moisture content than actually existed. Therefore,
instead of using the volume of impinger water collected to determine mois-
ture content, an assumed value of 2% moisture by volume was used for all
the scrubber inlet tests.
During the first test at the rotary drum cooler exhaust (Run No. 1-ORDC),
the sample nozzle size diameter was changed from 0.1875 to 0.250 in. The
results of this test were entered into the computer in two parts. Values
entered for Total Moisture Collected and Total Particulate Collected were
calculated, using the proportions of gas volume measured for first and
second parts of the test. The proportions are:
12.47% for the first part, using 0.1875-in. nozzle
87.53% for the second part, using 0.250-in. nozzle
The results of the computer run for both parts of test No. 1-ORDC are
combined and presented as one.
Sample Analysis
Only one sample train was operated for each set of analyses using the
modified Method 5 train as described in Figure 5-1. Upon the conclusion of
each test, the samples were recovered according to the procedures described
in the previous section; "Sample Recovery." The two sample containers from
each test run were then pretreated in the following manner in the field for
subsequent laboratory analyses:
The water content of the first sample container (front half, or water
fraction) was filtered using a tared glass fiber filter and a vacuum fil-
tration assembly to remove all traces of undissolved material. A vacuum
flask, vacuum pump, Buchner funnel, and tared glass fiber filters were used
for this filtration operation. The tared glass fiber funnel filter was
stored in a petri dish for subsequent desiccation and weighing at MRI's
Kansas City laboratories.
The filtered water from the first sample container was then divided
into two equal portions with concentrated H2S04 being added to one portion
until the pH was 6.0 or less. The second equal portion of the filtered wa-
ter was not pretreated.
The sample content of the second container from each test run (back
half, or acid fraction) did not receive any pretreatment.
The collected samples from the modified EPA Method 5 test runs were
analyzed in the laboratory according to the following format:
5-5
-------
1. The untreated portion of the water sample (front half), including
the Buchner funnel filter was analyzed for nitrate using an ion specific
electrode.
2. The pH treated portion of the water sample (front half) was
analyzed for ammonia using the Direct Nesslerization method.
3. The 1 Normal H2S04 impinger contents (back half, or acid fraction)
from Impingers 3, 4, and 5 was analyzed for nitrate and ammonia using an
ion specific electrode and the Direct Nesslerization method.
Each of the laboratory methods used in the analysis of the modified EPA
Method 5 samples is briefly described in the following sections.
Specific Ion Electrode Measurements
A nitrate ion electrode (Orion) and a potentiometer (Leeds and Northrup)
were calibrated using solutions of known concentration. The electrode was
then placed into the sample and a millivolt reading was recorded as soon as
the meter stabilized. Three aliquots of each sample were measured and the
average value was used to determine the concentration of the sample. Where
necessary, the samples were diluted prior to the measurement.
This method was used on both the water and acid fractions obtained from
the modified Method 5 train.
Direct Nesslerization
A colorimeter (B&L Spectronic 20) was calibrated using solutions of
known concentration. Absorbances of each solution were measured following
appropriate dilution to keep the absorbances within the range of the cali-
bration.
This technique involves adjusting the pH of the solution to between 8
and 10, adding the Nessler reagent and diluting to known volume. The solu-
tion is allowed to stand for approximately 30 min before the absorbance is
read. Three aliquots of each sample were measured and the average was used
to calculate the concentration.
This technique was used on both the acid and water fractions obtained
from the modified Method 5 train.
Location and Time Frame of Analysis
The audit samples supplied by EPA were analyzed for nitrate in the
field at the Swift Chemical Company laboratory. These nitrate analyses
were accomplished using an ion specific electrode which was calibrated in
the field laboratory. However, do to time limitations, none of the test
samples were analyzed in the field. Therefore, all test samples were re-
turned to the MRI laboratories in Kansas City, Missouri, for analysis. The
ion specific electrode (nitrate) and Direct Nesslerization (ammonia) analyses
of the samples occurred approximately 10 days after the completion of the
field test.
5-6
-------
Interferences
Several ions can interfere with the specific ion electrode. These in-
clude: 10~7M C10~; 10~5M l"; 10~4M C10~; 10'fM Ac~. In the calculations
shown in this report, these interferences were assumed to be absent.
Interferences for the Nessler method include calcium, magnesium, iron,
and sulfide. These were also assumed to be absent for the calculations.
Insoluble Particulate Emissions
Insoluble particulates were determined by filtering the impinger solu-
tions through tared glass fiber filters. Filtering occurred as the samples
were transferred from the impingers into the sample bottles. The filters
were rinsed, air dried, and returned to the laboratory where they were
weighed under temperature and humidity controlled conditions.
Particle Size
Testing for particle size distribution in the scrubber inlet duct and
the uncontrolled rotary drum cooler exhaust was done using Brink cascade
impactors with preselector cyclones. The Brink Cascade Impactor (BMS II),
classifies particles into six (6) size ranges. A precyclone fabricated by
MRI was used during testing to provide a seventh range. Figure 5-2 shows
the Brink sampler assembled with cyclone and sampling nozzle. Also shown
in Figure 5-2 is the vacuum pump and sample rate indicating manometer used
for controlling the sampling. The entire assembly was placed inside the
duct during sampling. The impactor assembly was allowed to equilibrate
thermally in the duct at the scrubber inlet for at least 20 min before
testing was started. The cooler exhaust duct was very near ambient tem-
perature, therefore, no conditioning period was required.
During the temperature conditioning period, the nozzle was replaced
with a swagelock tube cap, and the vacuum line at the pump was closed to
prevent air from being drawn through the impactor due to the relatively high
negative static pressures in the ducts sampled. Just before starting the
sizing test, the impactor was withdrawn from the stream, the nozzle at-
tached to the cyclone inlet, and the vacuum pump started. Sample flow was
started through the impactor simultaneously with the nozzle entry into the
sample port.
During sampling, the flow was adjusted to the predetermined flow rate
as indicated by the manometer monitoring the pressure drop across the im-
pactor orifices. Sample time at the uncontrolled cooler outlet location
for all three test runs was 14 min. At the scrubber inlet location, test
runs Nos. 1 and 3 were 10 min in duration, while test run No. 2 was 12 min
in duration. At the conclusion of the sampling period, the impactor assembly
was withdrawn from the duct with a sample continuing to be drawn until the
nozzle cleared the sample port, at which time the vacuum pump was turned
off. The time required to perform this "sampling while inserting and with-
drawing" was typically not more than 5 sec each way and is a negligible por-
tion of the total sample period. This technique insures that the collec-
tion substrates and the impacted sample particulates remain in place during
the insertion and withdrawal period.
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Cyclone
Exhaust
Vacuum
Line
Drying
Tube
Vacuum
Line
Figure 5-2. Schematic of Brink impactor sampling train.
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The normally used aluminum stage substrates had to be replaced with
glass fiber (Gelman type A/E) discs for this.series of tests because of the
corrosive action of the ammonium nitrate in the process stream. These col-
lection substrates were conditioned in silica gel desiccators and tare-
weighed in the field laboratory (Swift Chemical Company laboratory).
Plastic sample beakers (5 m£ capacity) were used as impactor sample con-
tainers during the conditioning periods. These beakers were also used as
containers for the cyclone catch and the final filter.
Upon completion of each particle size test, the Brink impactor was held
in an upright, vertical position to prevent movement of impacted particles
and transported to the field laboratory. In the laboratory the impactor
was secured by a bench-clamp in a vertical position for sample recovery.
The impactor was disassembled and the sample recovered as follows:
1. The nozzle and precyclone were removed from the impactor. Partic-
ulate matter from the nozzle and the precyclone was brushed with a balance
brush into a marked, tared 5 ml capacity plastic sample beaker.
2. Impactor stages 1-5 were individually separated and recovered from
the impactor. For each stage, the metal clip was removed first with a labo-
ratory tweezers and placed in a marked, tared 5 ml plastic sample beaker.
The glass fiber filter was then removed and placed in the same sample con-
tainer. The impactor stage was then cleaned with a brush and any particu-
late matter present was added to the sample beaker containing the clip and
filter of that particular stage.
3. The final filter was removed with a tweezers from the impactor and
placed in a marked, tared 5 ml plastic sample beaker.
Upon completion of the sample recovery, the plastic sample beakers were
conditioned in silica gel desiccators and final-weighed in the field labo-
ratory.
Visible Emissions Observations
EPA Method 9 visible emissions observations were done in accordance to
accepted EPA procedures. Observations were made at 15-sec intervals from a
point sufficient to provide a clear view of the emissions with the sun ori-
ented in the 140° sector to the observer's back. These observations were
made concurrent with several of the scrubber emissions tests. The observer
had been certified within the previous 6-month period.
Pressure Drop Measurements
During emissions testing at the rotary drum granulator scrubber and
the uncontrolled rotary drum cooler outlet locations, differential pressure
drop data were recorded approximately every 15 min. The data were obtained
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using a "U" tube manometer with attached Tygon tubing extending into the
inlet and outlet locations at these sites. Pressure drop measurmeents were
observed and recorded in inches of water.
The equipment used to collect these data were provided and installed
by MRI. The EPA Technical Manager and Mr. Timothy L. Curtin of GCA col-
lected and recorded the pressure drop measurement data during the field test.
Scrubber Liquor Collection and Analysis
Sampling Method
A 1-liter aliquot was collected at the beginning and each half hour
afterwards at both the inlet and outlet.
Sample Preparation
After the test, the aliquots were combined to form one composite sam-
ple. The samples were then filtered through a tared filter and divided for
analysis.
Sample Analysis
pH and temperature readings were taken both at collection time and when
the samples reached room temperature. The samples were divided for analysis
of ammonia and ammonia nitrate by Nessler and specific ion electrode. These
analysis techniques were discussed in an earlier part of this section.
Ambient Temperature and Relative Humidity
Ambient temperature and relative humidity measurements were collected
by the EPA Technical Manager during the field test. Sampling equipment con-
sisted of a dry bulb and a wet bulb mercury thermometer. The thermometers
were positioned on top of a tripod. Both dry bulb and wet bulb tempera-
tures were observed approximately every 15 min during emissions testing at
the rotary drum granulator scrubber and the uncontrolled rotary drum cooler
outlet locations. Data were observed and recorded in degrees Fahrenheit
for both dry bulb and wet bulb thermometers. From these readings the per-
cent relative humidity was then determined. The equipment used for these
measurements were supplied and installed by MRI.
Process Sample Collection and Analysis
Sampling Method
Process samples were collected from the granulator inlet, granulator
outlet, cooler inlet, and cooler outlet. Solid samples were collected in
shallow pans and returned to the laboratory. Samples were then weighed for
the bulk density and sieve analysis. Aliquots were dissolved in distilled
water and analyzed by ion electrode for nitrate and Nessler for ammonia as
described earlier.
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Bulk Density determination
Bulk density was determined by filling a tared 250 m£ graduate and
weighing. The bulk density was then calculated according to the equation:
Bulk density (lb/ft3) = (wt. of sample)(0.2497)
Sieve Analysis, Analytical Procedure
Sieve analysis was performed to determine the particle size of the
product. The equipment used included a sieve shaker, timer, balance, and
sieves (sieves 6, 8, 12, 14, 16, 20, and a pan were used). A sample of
approximately 200 g was weighed on a single pan balance to + 0.1 g and
placed into the top sieve. The material was shaken for 20 min and the bot-
tom pan was weighed. Following the initial weighing, the pan was returned
to the shaker, the sample was shaken for an additional 10 min, and the pan
was weighed a second time. This process was repeated for a second 10 min
interval. At the conclusion of the shaking (a total of 40 min) all the
sieves and the pan were weighed. The percent of material retained in each
sieve was calculated according to the equation:
0. , _ weight of material on sieve x 100
m retained — ~~:r~ ~~:^
total weight of material
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