&EFK
United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 80-NHF-16
January 1981
Air
Ammonium Nitrate
Emission Test Report
Columbia Nitrogen
Corporation
Augusta, Georgia
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PROCESS EMISSION TESTS
AT THE COLUMBIA NITROGEN CORPORATION
AMMONIUM NITRATE PLANT
IN AUGUSTA, GEORGIA
DURING LOW DENSITY
AMMONIUM NITRATE PRODUCTION
Thomas M. Bibb
EPA Project Officer
Clyde E. Riley
EPA Technical Manager
EPA Contract 68-02-3543
Work Assignment 3
TRC Project 1474-E80-52
Willard A. Wade III, P.E.
Project Manager
Leigh A. Gammie
Project Engineer
Eric A. Pearson
Project Scientist
Margaret M. Fox
Project Chemist
November 26, 1980
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PREFACE
The work herein was conducted by personnel from TRC-Environmental Consul-
tantsr Inc. (TRC), the Radian Corporation; Midwest Research Institute (MRI),
Columbia Nitrogen Corporation (CNC) in Augusta, Georgia, and the U.S. Envi-
ronmental Protection Agency (EPA).
The scope of the work, initially issued under' EPA Contract No. 68-02-
2820, Work Assignment No. 25, and completed under Contract No. 68-02-3543,
Work Assignment 3, was under the supervision of the TRC Project Manager, Mr.
Willard A. Wade III. Mr. Leigh A. Gammie of TRC served as Project Engineer
and Mr. Eric A. Pearson was responsible for summarizing the test and analyti-
cal data in this report. Sample analyses were performed at the CNC Augusta,
Georgia plant under the direction of Ms. Margaret Fox and at the TRC labora-
tory in Wethersfield, Connecticut under the direction of Mr. Samuel S. Cha.
Radian personnel were responsible for monitoring the process operations
during the testing program and for preparing Section 3.0 (Process Description
and Operations) and Appendix P of this report. MRI personnel were responsi-
ble for performing the particle size tests and for summarizing the particle
size data for incorporation into this report.
Personnel of the CNC Augusta, Georgia plant whose assistance and guidance
contributed greatly to the success of the test program included Mr. Max Beal,
Manager, Environmental Activities and Mr. Richard A. Lawson, Environmental
Control Chemist.
Mr. Eric A. Noble, Office of Air Quality Planning and Standards, Indus-
trial Studies Branch, EPA, served as Test Process Project Engineer and was
responsible for coordinating the process operation monitoring.
Mr. Clyde E. Riley, Office of Air Quality Planning and Standards, Emis-
sion Measurement Branch, EPA, served as Technical Manager and was responsible
for coordinating the emission test program.
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TRC Environmental Consultants, Inc.
Willard A. Wade III, P.E.
Project Manager
November 26, 1980
NOTE: Mention of trade names or commercial products in this publication does
not constitute endorsement or recommendation for use by Environmental
Protection Agency.
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TABLE OP CONTENTS
SECTION PAGE
PREFACE ii
1.0 INTRODUCTION 1
1.1 Background 1
1.2 Brief Process Description 2
1.3 Measurement Program 2
1.3.1 Prill Tower 4
1.3.2 Prill Dryers 4
1.3.3 Prill Cooler 5
1.3.4 Visible Emissions from Coating and
Bagging Operations 5
1.3.5 Ambient Air Measurements 5
1.3.6 Cleanup Evaluations and Audit Samples ... 6
1.4 Description of Report Sections 6
2.0 SUMMARY OF RESULTS 7
2.1 Prill Tower Emissions 7
2.2 Prill Predryer/Dryer Emissions. . . 17
2.3 Prill Cooler Emissions 24
2.4 Particle Size Tests 28
2.5 Visible Emissions 48
2.6 Scrubber Liquor Analyses 62
2.7 Scrubber Pressure Drop Measurements 62
2.8 Ambient Air Measurements 62
2.9 Volumetric Flowrates through the Prill
Tower 69
3.0 PROCESS DESCRIPTION AND OPERATIONS 72
3.1 Process Equipment 72
3.2 Emission Control Equipment 74
3.3 Production and Control Equipment
Monitoring 75
3.4 Process Operation During Testing 79
4.0 LOCATION OF SAMPLING POINTS 80
4.1 Prill Tower 80
4.1.1 Scrubber Inlets - AN Sampling and
Velocity Traverses 80
4.1.2 Bypasses - AN Sampling and Velocity
Traverses 80
4.1.3 Scrubber Outlet - AN Sampling 84
4.2 Prill Dryers - AN Sampling 87
4.2.1 Scrubber Inlet from the Predryer 87
4.2.2 Scrubber Inlet from the Dryer 87
4.2.3 Scrubber Outlet 90
4.3 Prill Cooler - AN Sampling 90
4.3.1 Scrubber Inlet 90
4.3.2 Bypass 93
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TABLE OF CONTENTS (Continued)
SECTION
PAGE
4.4 Particle Size Test Locations 93
4.5 Visible Emissions Observations Locations. . . 96
4.6 Scrubber Liquor Sampling Locations 96
4.7 Scrubber Pressure Drop Measurements
Locations 96
4.8 Ambient Air Measurement Locations 101
5.0 SAMPLING AND ANALYSIS METHODS 102
5.1 EPA Reference Methods Used in This Program. . 102
5.2 Ammonium Nitrate Sampling and Analysis. . . . 103
5.2.1 Sampling Methods 103
5.2.1.1 Prill Tower Sampling Methods . 103
5.2.1.2 Prill Dryer Sampling Methods 106
5.2.1.3 Prill Cooler Sampling Methods ....... 108
5.2.2 Sample Recovery and Preparation 109
5.2.3 Sample Analysis 110
5.3 Ammonia Sampling and Analysis Ill
5.3.1 Sampling, Sample Recovery, and
Preparation Ill
5.3.2 Sample Analysis Ill
5.4 Undissolved Solids Analysis . 112
5.5 Particle Size Distribution Tests 112
5.5.1 Sampling and Analytical Equipment
Descriptions 113
5.5.2 Equipment Calibration 115
5.5.3 Determination of Sampling Points 118
5.5.4 Determination of Sampling Rate and
Nozzle Size 119
5.5.5 HCSS Impactor Test Procedures ........ 119
5.5.6 Sample Recovery 120
5.5.7 Field Sample Analysis 122
5.5.8 Analysis of Audit Samples 123
5.6 Visible Emissions Observations 123
5.7 Scrubber Liquor Sampling and Analysis .... 125
5.8 Scrubber Pressure Drop Measurements 125
5.9 Ambient Air Measurements 126
5.10 Volumetric Flowrates through the
Prill Tower 126
APPENDICES
A
A.I
A.2
B
A.3
COMPUTER PRINTOUT SAMPLING TEST RESULTS
Prill Tower (Inlets, Bypasses, Outlet)
.Predryer/Dryer (Predryer Inlet, Dryer Inlet,
Outlet)
Cooler (Inlet, Bypass)
SAMPLE EQUATIONS AND EXAMPLE CALCULATIONS
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TABLE OF CONTENTS (Continued)
APPENDICES
C FIELD DATA SHEETS FOR PARTICULATE TESTS
C.I Prill Tower (Inlets, Bypass, Outlet)
C.2 Predryer/Dryer (Predryer Inlet, Dryer Inlet,
Outlet)
C.3 Cooler (Inlet, Bypass)
D SAMPLING LOGS
D.I Daily Summary Log
D.2 Field Notebooks
E PARTICLE SIZE TESTS
E.I HCSS Computer Data Reduction Results
E.2 Sample Calculations
E.3 Field Data Sheets
E.4 Ammonium Nitrate Analysis Data
E.5 Sampling Logs
E.6 Sampling Train Calibration Data
F VISIBLE EMISSIONS
F.I * Observer Certification Certificates
F.2 EPA Method 9 Guidelines
F.3 Prill Tower Field Data Sheets
F.4 Predryer/Dryer Field Data Sheets
F.5 Cooler Field Data Sheets
F.6 Coating Baghouse and Bagging Baghouse
Field Data Sheets
G SCRUBBER LIQUOR DATA
H SCRUBBER PRESSURE DROP DATA
I AMBIENT AIR MEASUREMENT DATA
J VOLUMETRIC FLOWRATE MEASUREMENTS AT
PRILL TOWER
K SAMPLING TRAIN CALIBRATION DATA
K.I Orifice Calibration Data
K.2 Nozzle Calibration Data
K.3 Pitot Tube Calibration Data
L SAMPLING AND ANALYSIS PROCEDURES
L.I Ammonium Nitrate Procedures
L.2 Ammonia Procedures
L.3 Summary of Procedures
M ANALYSIS DATA
M.I Prill Tower (Inlets, Bypass, Outlet)
M.2 Discussion of Analysis Methods
M.3 Chemical Laboratory Notebook
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TABLE OF CONTENTS (Continued)
APPENDICES
N AUDIT SAMPLE ANALYSES
N.I TRC Audit Samples (Emission Tests)
N.2 MRI Audit Samples (Particle Size Tests)
O CLEANUP EVALUATION RESULTS
0.1 TRC Cleanup Results (Emission Tests)
0.2 MRI Cleanup Results (Particle Size Tests)
P PROCESS OPERATIONS LOG
Q PROJECT PARTICIPANTS
R SCOPE OF WORK
R.I TRC Work Assignment, Technical Directives,
Associated Correspondence
R.2 MRI Work Assignment and Associated Correspondence
R.3 RADIAN Associated Correspondence
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LIST OF FIGURES
FIGURE PAGE
1-1 Schematic of Low Density Prilling Process at Columbia
Nitrogen Corporation, Augusta/ Georgia 3
2-1 HCSS Particle Size Results: Particle Size versus Percent
Weight Less/Greater than Stated Size - Prill Cooler Uncon-
trolled Outlet 31
2-2 HCSS Impactor Particle Size Results: Differencial Mass
Loading (dM/d Log D) versus Particle Diameter - Prill
Cooler Uncontrolled Outlet 32
2-3 HCSS Impactor Particle Size Results: Particle Size
versus Percent Weight Less/Greater than Stated Size -
Prill Cooler Scrubber Inlet 34
2-4 HCSS Impactor Particle Size Results: Differential Mass
Loading (dM/d Log D) versus Particle Diameter - Prill
Cooler Scrubber Inlet 35
2-5 HCSS Impactor Particle Size Results: Particle Size versus
Percent Weight Less/Greater than Stated Size - Prill Tower
Inlets 37
2-6 HCSS Impactor Particle Size Results: Differential Mass
Loading (dM/d Log D) versus Particle Diameter - Prill Tower
Inlets 38
2-7 HCSS Impactor Particle Size Results: Particle Size versus
Percent Weight Less/Greater than Stated Size - Prill Tower
Bypass Stacks 40
2-8 HCSS Impactor Particle Size Results: Differential Mass
Loading (dM/d Log D) versus Particle Diameter - Prill Tower
Bypass Stacks 41
2-9 HCSS Impactor Particle Size Results: Particle Size versus
Percent Weight Less/Greater than Stated Size - Dryer Uncon-
trolled Exhaust 43
2-10 HCSS Impactor Particle Size Results: Differential Mass
Loading (dM/d Log D) versus Particle Diameter - Dryer
Uncontrolled Exhaust 44
2-11 HCSS Impactor Particle Size Results: Particle Size versus
Percent Weight Less/Greater than Stated Size - Predryer
Uncontrolled Exhaust 46
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LIST OF FIGURES (Continued)
FIGURE PAGE
2-12 HCSS Impactor Particle Size Results: Differential Mass
Loading (dM/d Log D) versus Particle Diameter - Predryer
Uncontrolled Exhaust 47
2-13 Visible Emissions Observations at the Prill Tower
Scrubber Bypasses during Low Density Ammonium Nitrate
Production at Columbia Nitrogen Corporation, Augusta,
Georgia on August 12, 1980. . ,. . 53
2-14 Visible Emissions Observations at the Predryer/Dryer
Scrubber Outlet during Low Density Ammonium Nitrate
Production at Columbia Nitrogen Corporation, Augusta,
Georgia on August 14, 1980 56
2-15 Visible Emissions Observations at the Prill Cooler
Scrubber Outlet during Low Density Ammonium Nitrate
Production at Columbia Nitrogen Corporation, Augusta,
Georgia on August 14-15, 1980 . 59
3-1 Schematic of Low Density Prilling Process at Columbia
Nitrogen Corporation, Augusta, Georgia 73
4-1 Layout of Ammonium Nitrate Production Facilities at
Columbia Nitrogen Corporation, Augusta, Georgia 81
4-2 Overhead View of Prill Tower at Columbia Nitrogen
Corporation, Augusta, Georgia 82
4-3 Prill Tower Scrubber Inlet Sampling Location at
Columbia Nitrogen Corporation, Augusta, Georgia 83
4-4 Prill Tower Bypass Sampling Location at Columbia
Nitrogen Corporation, Augusta, Georgia 85
4-5 Prill Tower Scrubber Outlet Sampling Location at
Columbia Nitrogen Corporation, Augusta, Georgia 86
4-6 Predryer Inlet-To-Scrubber Sampling Location at
Columbia Nitrogen Corporation, Augusta, Georgia 88
4-7 Dryer Inlet-To-Scrubber Sampling Location at
Columbia Nitrogen Corporation, Augusta, Georgia 89
4-8 Predryer/Dryer Scrubber Outlet Sampling Location at
Columbia Nitrogen Corporation, Augusta, Georgia 91
4-9 Prill Cooler Scrubber Inlet Sampling Location at
Columbia Nitrogen Corporation, Augusta, Georgia 92
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LIST OF FIGURES (Continued)
FIGURE • PAGE
4-10 Prill Cooler Bypass Sampling Location at Columbia
Nigrogen Corporation, Augusta, Georgia 94
V
4-11 Overhead View of Prill Cooler Outlet, Bypass Stacks and
Coater Baghouse Outlet at Columbia Nitrogen Corporation,
Augusta, Georgia 97
4-12 Prill Tower Scrubber Liquor Flow Diagram and Sampling
Location at Columbia Nitrogen Corporation, Augusta, Georgia . . 99
4-13 Predryer/Dryer Scrubber Liquor Flow Diagram and Sampling
Location at Columbia Nitrogen Corporation, Augusta, Georgia . . 100
5-1 Modified EPA Particulate Sampling Train, August 18, 1977
Federal Register 104
5-2 Schematic of the Anderson Model HCSS High Grain-Loading
Impactor 114
5-3 HCSS Orientation Schematic 116
5-4 Schematic of HCSS Sampling Train 117
5-5 Schematic of the Anderson Model HCSS Sample Fractions 121
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LIST OF TABLES
TABLE PAGE
2-la Summary of Controlled and Uncontrolled Ammonium Nitrate (AN)
Emissions from the Prill Tower during Low Density AN Produc-
tion at Columbia Nitrogen Corporation, Augusta, Georgia ...... 8
2-lb Summary of Controlled and Uncontrolled Ammonium Nitrate (AN)
Emissions from the Prill Tower during Low Density AN Produc-
tion at Columbia Nitrogen Corporation, Augusta, Georgia . . .
2-2 Summary of Ammonium Nitrate (AN) Measurements on Gases Entering
the Prill Tower Scrubber during Low Density AN Production
at Columbia Nitrogen Corporation, Augusta, Georgia 10
2-3 Summary of Ammonium Nitrate (AN) and Insoluble Particulate
Measurements on Gases in the Prill Tower Bypasses during
Low Density AN Production at Columbia Nitrogen Corporation,
Augusta, Georgia 11
2-4 Summary of Ammonium Nitrate (AN) and Insoluble Particulate
Measurements on Gases Exiting the Prill Tower Scrubber during
Low Density AN Production at Columbia Nitrogen Corporation,
Augusta, Georgia „ . 12
2-5 Summary of Ammonia, Calculated Ammonium Nitrate (AN) and
Calculated Excess Ammonia Measurements on Gases Entering
the Prill Tower Scrubber during Low Density AN Production
at Columbia Nitrogen Corporation, Augusta, Georgia 14
2-6 Summary of Ammonia, Calculated Ammonium Nitrate (AN) and
Calculated Excess Ammonia Measurements on Gases in the
Prill Tower Bypasses during Low Density AN Production at
Columbia Nitrogen Corporation, Augusta, Georgia 15
2-7 Summary of Ammonia, Calculated Ammonium Nitrate (AN) and
Calculated Excess Ammonia Measurements on Gases Exiting the
Prill Tower Scrubber during Low Density AN Production at
Columbia Nitrogen Corporation, Augusta, Georgia 16
2-8a Summary of Ammonium Nitrate (AN) Measurements on Gases
Entering and Exiting the Prill Predryer/Dryer Scrubber
during Low Density AN Production at Columbia Nitrogen
Corporation, Augusta, Georgia 18
2-8b Summary of Ammonium Nitrate (AN) Measurements on Gases
Entering and Exiting the Prill Predryer/Dryer Scrubber
during Low Density AN Production at Columbia Nitrogen
Corporation, Augusta, Georgia 19
2-9 Summary of Ammonium Nitrate (AN) Measurements on Gases Entering
the Prill Predryer/Dryer Scrubber during Low Density AN Produc-
tion at Columbia Nitrogen Corporation, Augusta, Georgia 20
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LIST OF TABLES (Continued)
PAGE
Summary of Ammonium Nitrate (AN) and Insoluble Particulate
Measurements on Gases Exiting the Prill Predryer/Dryer Scrubber
during Low Density AN Production at Columbia Nitrogen Corpora-
tion, Augusta, Georgia 21
2-11 Summary of Ammonia, Calculated Ammonium Nitrate (AN) and
Calculated Excess Ammonia Measurements on Gases Entering the
Prill Predryer/Dryer Scrubber during Low Density AN Production
at Columbia Nitrogen Corporation, Augusta, Georgia 22
2-12 Summary of Ammonia, Calculated Ammonia Nitrate (AN) and
Calculated Excess Ammonia Measurements on Gases Exiting the
Prill Predryer/Dryer Scrubber during Low Density AN Produc-
tion at Columbia Nitrogen Corporation, Augusta, Georgia 23
2-13a Comparison of Predryer Inlet Run 1 Mass Flowrate Calculations
at Columbia Nitrogen Corporation, Augusta, Georgia 25
2-13b Comparison of Dryer Inlet Mass Flowrate Calculations at
Columbia Nitrogen Corporation, Augusta, Georgia 26
2-14 Summary of Ammonium Nitrate (AN) Measurements on Gases in the
Prill Cooler Scrubber Inlet and Bypass during Low Density AN
Production at Columbia Nitrogen Corporation, Augusta, Georgia . . 27
2-15 Summary of Ammonia, Calculated Ammonium Nitrate (AN) and
Calculated Excess Ammonia Measurements on Gases in the Prill
Cooler Scrubber Inlet and Bypass during Low Density AN Produc-
tion at Columbia Nitrogen Corporation, Augusta, Georgia 29
2-16a Particle Size Results at the Prill Cooler Uncontrolled Outlet
(Bypass) at Columbia Nitrogen Corporation, Augusta, Georgia ... 30
2-16b Particle Size Results at the Prill Cooler Scrubber Inlet at
Columbia Nitrogen Corporation, Augusta, Georgia 33
2-17 Particle Size Results at the Prill Tower Scrubber Inlets at
Columbia Nitrogen Corporation, Augusta, Georgia 36
2-18 Particle Size Results at the Prill Tower Bypasses at
Columbia Nitrogen Corporation, Augusta, Georgia 39
2-19 Particle Size Results at the Dryer Scrubber Inlet at
Columbia Nitrogen Corporation, Augusta, Georgia 42
2-20 Particle Size Results at the Predryer Scrubber Inlet at
Columbia Nitrogen Corporation, Augusta, Georgia 45
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LIST OF TABLES (Continued)
TABLE PAGE
2-21 Visible Emissions Observations at the Prill Tower Scrubber
Outlet during Low Density Ammonium Nitrate Production at
Columbia Nitrogen Corporation, Augusta, Georgia . » „ 49
2-22 Visible Emissions Observations at the Prill Tower Scrubber
Bypasses during Low Density Ammonium Nitrate Production at
Columbia Nitrogen Corporation, Augusta, Georgia ... 51
2-23 Visible Emissions Observations at the Predryer/Dryer Scrubber
Outlet during Low Density Ammonium Nitrate Production at
Columbia Nitrogen Corporation, Augusta, Georgia 54
2-24 Visible Emissions Observations at the Prill Cooler Scrubber
Outlet during Low Density Ammonium Nitrate Production at
Columbia Nitrogen Corporation, Augusta, Georgia 57
2-25 Visible Emissions Observations at the Prill Cooler Scrubber
Bypass during Low Density Ammonium Nitrate Production at
Columbia Nitrogen Corporation, Augusta, Georgia ... 60
2-26 Visible Emissions Observations at the Coater and Bagging
Baghouse Outlets during Low Density Ammonium Nitrate Pro-
duction at Columbia Nitrogen Corporation, Augusta, Georgia. . . 61
2-27 Summary of Measurements on the Prill Tower Scrubber Liquor
during Low Density Ammonium Nitrate Production at Columbia
Nitrogen Corporation, Augusta, Georgia 63
2-28 Summary of Measurements on the Prill Predryer/Dryer Scrubber
Liquor during Low Density Ammonium Nitrate Production at
Columbia Nitrogen Corporation, Augusta, Georgia 64
2-29 Summary of Pressure Drop Measurements made Across the Prill
Tower Scrubber during Low Density Ammonium Nitrate Production
at Columbia Nitrogen Corporation, Augusta, Georgia 65
2-30 Summary of Ambient Air Measurements made during Emission
Tests at the Prill Tower at Columbia Nitrogen Corporation,
Augusta, Georgia 66
2-31 Summary of Ambient Air Measurements made during Emission
Tests at the Predryer/Dryer at Columbia Nitrogen Corpora-
tion, Augusta, Georgia 67
2-32 Summary of Ambient Air Measurements made during Emission
Tests at the Prill Cooler at Columbia Nitrogen Corporation,
Augusta, Georgia • 68
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LIST OF TABLES (Continued)
TABLE PAGE
2-33 Flowrates through the Prill Tower Scrubber Inlets during
Low Density Ammonium Nitrate Production at Columbia Nitrogen
Corporation, Augusta, Georgia 70
2-34 Flowrates through the Prill Tower Scrubber Bypasses during
Low Density Ammonium Nitrate Production at Columbia Nitrogen
Corporation, Augusta, Georgia 71
3-1 Summary of Production Rates and Scrubber Operating Para-
meters during Prill Tower Mass Emission and Particle Size
Tests at Columbia Nitrogen Corporation, Augusta, Georgia. ... 76
3-2 Summary of Production Rates and Scrubber Operating Para-
meters during Predryer and Dryer Emission and Particle Size
Tests at Columbia Nitrogen Corporation, Augusta, Georgia. ... 77
3-3 Summary of Production Rates and Scrubber Operating Para-
meters during Cooler Mass Emission and Particle Size
Tests at Columbia Nitrogen Corporation, Augusta, Georgia. ... 78
4-1 Sampling Points Used for Particle Size Tests at Columbia
Nitrogen Corporation, Augusta, Georgia 95
4-2 Visible Emissions Observation Locations at Columbia
Nitrogen Corporation, Augusta, Georgia 98
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1.0 INTRODUCTION
1.1 Background
Section 111 of the Clean Air Act of 1970 charges the Administrator of the
U.S. Environmental Protection Agency (EPA) with the responsibility of: estab-
lishing 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 demonstrat-
ed emission control technology. EPA utilizes emission data, obtained from
controlled sources in the particular industry under consideration, as a par-
tial basis for SPNSS.
EPA's Office of Air Quality Planning and Standards (OAQPS) selected the
Columbia Nitrogen Corporation ammonium nitrate manufacturing plant in Augus-
ta, Georgia as a site for an emission test program. This plant produces
ammonium nitrate (AN) for industrial and fertilizer use, and is considered to
employ process and emission control technology representative of high and low
density AN prilling, drying, and cooling processes. The test program was
designed to provide a portion of the emission data base required for SPNSS
for the processes associated with AN production.
EPA engaged TRC to measure AN and ammonia concentrations, mass flowrates,
and plume opacities at the prill tower, dryers, and fluidized-bed cooler.
EPA engaged MRI to measure particle size distributions in gas streams at
these same process units. All measurements made at this facility were per-
formed during times of normal low density AN production process operation, as
described in Section 3.0, Process Description and Operations.
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1.2 Brief Process Description
Figure 1-1 presents a schematic of the low density ammonium nitrate
prilling process. This process is described very basically as follows:
The 96 percent AN melt is pumped from the solution formation process
to the top of the prill tower where a spinning perforated bucket
receives the melt. The melt is forced through orifices in the
bucket and forms discrete droplets as it falls through the tower. A
countercurrent of air, induced by fans at the top of the tower,
cools the droplets which solidify as they fall. The solid prills
are conveyed from the bottom of the tower to a rotary drum predryer
and dryer for moisture removal, and then to a fluidized-bed cooler.
The prills are then screened, coated with clay (to prevent caking),
and then bagged or shipped in bulk.
Emissions from the prill tower are controlled with a shroud that
surrounds the spinning bucket and with a Monsanto HE Brinks mist
eliminator. Emissions from the predryer and dryer are ducted to a
common Peabody tray scrubber. One air stream through the cooler is
ducted through a Ducon mechanical impingement scrubber; the other
air stream is vented directly to the atmosphere. Emissions from the
screening, coating, and bagging operations are controlled with bag-
houses.
1.3 Measurement Program
The measurement program was conducted at the Columbia Nitrogen Corpora-
tion urea and ammonium nitrate manufacturing facility in Augusta, Georgia
during the week of August 10-16, 1980. The emission tests were designed to
characterize and quantify uncontrolled and controlled emissions from the AN
solids production process (prill tower, dryers, and cooler) and to determine
control equipment efficiency.
TRC and MRI personnel were responsible for sampling and analyzing process
emissions. Concurrently, Radian was responsible for monitoring pertinent
process operation parameters. The chronology of the emission tests is con-
tained in Appendix D. The components of the measuring program were as
follows.
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I
OJ
961 AN
FROM
EVAPORATOR
COOLING AIR
t
BRINKS
I1NATOR
• A BYPASS
IR^
TP
PRILL
TOWER
-SHROUD I ft
QPEABODY DUCON fH fSp/iruniicr
SCRUBBER SCRUBBER IJ .^ JJBAGHOUSE
r IP r — H !
IPREORYER 1 *ll DRYER I * •CDOLCR >l ail
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1.3.1 Prill Tower
AN, Ammonia, and Insoluble Particulate Sampling in Gas Streams
One test run at each of the three scrubber inlets and bypasses was
performed concurrently with test runs at the scrubber outlet. Insol-
uble particulate measurements were made on bypass and outlet samples
only.
Particulate Size Distribution in Gas Streams
One test run at each of the three scrubber inlets and bypasses was
performed.
Visible Emissions
The opacities of the bypass plumes and scrubber outlet plume were
monitored during the AN emission tests.
Scrubber Liquor Sampling
Samples of the prill tower scrubber liquor were collected periodical-
ly during each AN emissions test run. These samples were subsequent-
ly analyzed for AN, ammonia, and undissolved solids.
Pressure Drop Across Scrubber
The gas pressure drop across the scrubber was measured periodically
during each AN emissions test run.
Flowrates in Scrubber Inlets and Bypasses
During each emission test run, velocity traverses were performed in
each of the bypasses and scrubber inlets not being tested for emis-
sions. Flowrates were calculated from the velocity head and tempera-
ture data obtained during these velocity traverses.
1.3.2 Prill Dryers
AN, Ammonia/ and Insoluble Particulate Sampling in Gas Streams
Three runs of concurrent emission tests were performed in the scrub-
ber inlet from the predryer, the scrubber inlet from the dryer, and
in the scrubber outlet. Insoluble particulate measurements were made
on outlet samples only.
Particle Size Distribution
Three test runs were performed in both the scrubber inlet from the
predryer and the scrubber inlet from the dryer.
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Visible Emissions
The opacity of the scrubber outlet plume was monitored during the AN
emission tests.
Scrubber Liquor
Samples of the predryer/dryer scrubber liquor were collected periodi-
cally during each AN emissions test run. The samples were subse-
quently analyzed for AN, ammonia, and undissolved solids.
1.3.3 Prill Cooler
t
AN, Ammonia, and Insoluble Particulate Sampling in Gas Streams
Three runs of concurrent tests were performed in the scrubber inlet
and bypass. Insoluble particulate measurements were made on bypass
samples only.
Particle Size Distribution
Three test runs were performed in both the scrubber inlet and the
bypass.
Visible Emissons
The opacities of the scrubber outlet plume and the bypass plume were
monitored during the AN emissions test runs.
1.3.4 Visible Emissions from Coating and Bagging Operations
The opacities of the plumes from the coater and bagging operations bag-
houses were monitored during the emissions testing program.
1.3.5 Ambient Air Measurements
Ambient air temperature and relative humidity measurements were taken
periodically during all prill tower, dryer, and cooler AN emission test
runs. Measurements were made in the immediate vicinity of the processes
involved.
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1.3.6 Cleanup Evaluations and Audit Samples
Before any emissions tests were begun, three sampling trains were assem-
bled and charged as if ready to perform a test for AN and ammonia. The un-
exposed impinger contents were then recovered, prepared, and analyzed accord-
ing to procedure in order to establish background/contamination levels of AN
and ammonia from the sample collection equipment.
Ammonium nitrate standard solutions were prepared by .EPA and were anal-
yzed by TFC at the field laboratory in accordance with EPA instructions in
order to assess the accuracy of the AN analysis procedure.
1.4 Description of Report Sections
The remaining sections of this report present the Summary of Results
(Section 2.0), Process Description and Operations (Section 3.0), Location of
Sampling Points (Section 4.0), and Sampling and Analytical Methods (Section
5.0). Descriptions of methods and procedures, field and laboratory data, and
calculations are presented in the various appendices, as noted in the Table
of Contents. Appendix N contains the results of audit sample analyses, and
Appendix 0 contains the results of the clean-up evaluations performed on the
sampling train equipment.
-6-
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2.0 SUMMARY OF RESULTS
This section presents summary tables of results and narrative on the
emission tests conducted during the week of August 10-16, 1980, at the Colum-
bia Nitrogen Corporation ammonium nitrate (AN) manufacturing facility in
Augusta, Georgia. Testing was performed on emissions from the prill tower,
predryer/dryer and cooler during low density AN production.
AN concentrations were determined with a nitrate specific ion electrode
(SIE) and ammonia concentrations were determined with an ammonia SIE. Both
analysis methods are discussed in Section 5.0 and in Appendices L and M.
2.1 Prill Tower Emissions
A summary of the ammonium nitrate controlled and uncontrolled emissions
from the prill tower is shown in Table 2-1. The average AN scrubber removal
efficiency is 88.4 percent.
The results of the AN and insoluble particulate measurements at the prill
tower scrubber inlets, bypasses, and scrubber outlet are shown separately in
Tables 2-2, 2-3, and 2-4, respectively. Insoluble particulate analyses were
performed on bypass and outlet samples only. As discussed in Section 5.4,
the threshold of detection for the insoluble particulate analyses was esti-
mated to be 3.0 mg. Samples containing less than 3.0 mg were therefore
considered to contain no insoluble particulate. A rustor orange-colored
particulate matter was noticed in the bypass and outlet samples of test run
1. The insoluble particulate measured in the outlet sample may be rust or
scale from the scrubber piping, or clay coating material from the scrubber
liquor. The nature of the insoluble particulate in the bypass sample; is not
known.
-7-
-------
TABLE 2-la (English Units)
SUMMARY OF CONTROLLED AND UNCONTROLLED AMMONIUM NITRATE (AN) EMISSIONS
FROM THE PRILL TOWER DURING LOW DENSITY AN PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
I
00
Run Number
Date
Description
SCRUBBER AN EMISSIONS3
Grains/DSC F6
Pounds/Hour
Pounds/Ton
Collection Efficiency (percent)
DYPASS AN EMISSIONS^
Grains/DSCF
Pounds/Hour
Pounds/Ton
TOTAL AN EMISSIONS'3
Grains/DSCF
Pounds/Hour
Pounds/Ton ,
Run 1
8-12-80
Uncontrolled Controlled
Run 2
8-12-80
Uncontrolled Controlled
Run 3
8-13-80
Uncontrolled Controlled
0.0159
6.436
0.276
0.00162
0.708
0.030
0.0229
9.329
0.381
0.00147
0.667
0.027
89.1
92.9
0.004SS
8.419
0.361
O.OOS66
10.467
0.427
0.00659
14.855
0.637
0.00399
9.127
0.391
0.00877
19.796
0.808
0.00483
11.134
0.454
0.0239
9.468
0.371
U.00348
1.549
U.061
83.6
0.00665
12.051
0.473
0.00974
21.519
0.844
0.00603
13.600
0.534
(ivecaye
Uncontrolled Conttoiieo
0.0209 ' O.UU21U
8.41U U.*75
0.345 0.040
bb.4
0.00562
10.326
0.423
0.00837
18.744
0.768
0.00495
11.301
0.463
aScrubber Uncontrolled = Inlet totals from Table 2-2.
Scrubber Controlled = Outlet values from Table 2-4.
bGrains per Dry Standard Cubic Foot £ 68°F, 29.92 inches Hg.
cBypass totals from Table 2-3.
"Total Uncontrolled = Scrubber uncontrolled + bypass. Grains/DSCF are weighted averages (weighted by total flowrates in Tables 2-2 ana 2-3).
Total Controlled = Scrubber Controlled + bypass. Grains/DbCF are weighted averages (weighted by total tlowrates in Tables 2-3 and 2-4).
NOTE: AN analysis by Specific Ion Electrode. This method measures nitrate (NOJ)j AN(mg) = Nitrate (rag) x 80/62.
NOTE: Insoluble particulate results not included in this table. See Tables 2-3 ana 2-4 for insoluble particulate uata.
-------
TABLE 2-lb (Metric Units)
SUMMARY OF CONTROLLED AND UNCONTROLLED AMMONIUM NITRATE (AN) EMISSIONS
PROM THE PRILL TOMER DURING LOW DENSITY AN PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Run Number
Date
Description
SCRUBBER AN EMISSIONS3
Grams/DNm3*
Kg/I lour
Kg/Mg
Collection Efficiency (percent)
BYPASS AN EMISSIONS"
Kg /Hour
Kg/Mg
TOTAL AN EMISSIONS0
Graroe/DNm3
Kg /Hour
Kg/Mg
Run 1
8-12-80
Uncontrolled Controlled
Run 2
8-12-80
Uncontrolled Controlled
Run 3
8-13-80
Uncontrolled Controlled
Average
Uncontrolled controlled
0.0364
2.92
0.138
0.00371
0.321
0.015
0.0524
4.23
0.191
0.00336
0.303
0.014
0.0547
4.29
0.186
0.00796
0.703
0.031
0.0478
3.82
0.173
0.00501
0.442
0.020
0.0151
6.74
0.319
89.1
0.0104
3.82
0.181
0.0091
4.14
0.196
0.0201
8.98
0.404
92.9
0.0130
4.75
0.214
0.0111
5.05
0.227
0.0223
9.76
0.422
83.6
0.0152
5.47
0.237
0.0138
6.17
0.267
0.0192
8.50
0.384
88.4
0.0129
4.68
0.212
0.0113
5.13
0.232
aScrubber Uncontrolled » inlet totals from Table 2-2.
Scrubber Controlled ° Outlet values from Table 2-4.
^Bypass totals from Table 2-3.
cTotal Uncontrolled = Scrubber Uncontrolled + bypass. Grams/DNo3 are weighted averages (weighted by total flowrates in Tables 2-2 and 2-3).
Total Controlled * Scrubber controlled + bypass. Graras/DNra3 are weighted averages (weighted by total flowrates in Tables 2-3 and 2-4).
*Gran>s per Dry Normal Cubic Meters 8 20°C, 760 nun Hg.
NOTE: AN analyses by Specific Ion Electrode. This method measures nitrate (NOJ)j AN (rag) - Nitrate (rag) x 80/62.
NOTE: Insoluble particulate results not included in this table. See Tables 2-3 and 2-4 for insoluble partlculate data.
-------
TABLE 2-2
SUMMARY OF AMMONIUM NITRATE (AN) MEASUREMENTS ON GASES ENTERING
THE PRILL TOWER SCRUBBER DURING LOW DENSITY AN PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Run Number
Date
Location
Volume of Gas Sampled (DSCF)a
Volumetric Flowrate (DSCEM)b
Percent Moisture
Stack Temperature <°F) .
Percent Isokinetic
Production Rate (Tons/Hour)
Ambient Air Temperature (°F)
Ambient Relative Humidity (Percent)
Pressure Drop (inches water)
AMMONIUM NITRATE0
Run 1
8-12-80
Inlet B Total
80.03
15300
2.82
126
99.9
23.3
90
57
1.6
47230d
Run 2
8-12-80
Inlet A Total
84.72
16070
2.94
128
100.7
24.5
95
45
1.0
47530
Run 3
8-13-80
Inlet C Total
80.24
15250
3.28
120
100.5
25.5
85
68
1.0
46220
Average
Inlet Total
81.6o
15540
3.01*
125*
100.4
24.4
90
57
A.2
46990
O
Total Sample Weight
Grains/DSCF
Pounds/Hour
Pounds /Ton
(milligrams)
82.5
0.0159 0.0159
2.086 6.436
0.090 0.276£
125.8
0.0229
3.155
0.129
0.0229
9.329
0.381
124.4
0.0239
3.127
0.123
0.0239
9.468
0.371
11U.9
O.OiUi.* 0.02U9
*.7b9 8.41U
0.114 0.345
aDry Standard Cubic Feet 8 68°F, 29.92 inches llg.
bDry Standard Cubic Feet per Minute.
cspecific Ion Electrode analysis method. This method measures nitrate (NOj)j AN (rag) = Nitrate (mg) x 80/62.
*Total Flowrate equals sum o£ flowrates actually measured in each inlet during each run. See Section 2.9.
eTotal pounds per hour is calculated by assuming that the grain loading measured in one inlet existed in the other two inlets.
loading is then multiplied by the total flowrate.
£Total pounds per ton = (Total pounds per hourl/Production Rate.
'Weighted Averages (weighted by Clowrate).
This grain
NOTE: Insoluble particulate measurements were not made on inlet samples.
-------
Run Number
Date
Location
Volume of Gas Sampled
(DSCF)a
Volumetric Flowrate
(DSCFM)b
Percent Moisture
Stack Temperature (°F)
Percent Isokinetic
Production Rate
(Tons/Hour!
Percent Opacity**
Ambient Air Temperature<°F)
Ambient Relative Humidity
(Percent)
AMMONIUM NITRATE0
Total Sample Height
(milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
INSOLUBLE PARTICULATES
TABLE 2-3
SUMMARY OF AMMONIUM NITRATE (AN) AND INSOLUBLE P ARTICULATE MEASUREMENTS ON GASES IN THE
PRILL TOWER BYPASSES DURING LOW DENSITY AN PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Run 1
8-12-80.
ass B Total
113.2
79220
1.99
107
98.4
23.3
6.4
90
57
33.4
0.0045S
3.091
0.133
215860d
0.00455
8.419e
0.361*
Run 2
8-12-80
A Total
110.7
77360
2.35
115
98.1
24.5
6.0
95
45
40.6
0.00566
3.656
0.149
215760
0.00566
10.467
0.427
Run 3
8-13-80
pass C Total
107.9
71930
3.02
104
103.3
25.5
0.0
85
68
46.4
0.00665
4.100
0.161
211420
0.00665
12.051
0.473
Average
Bypass Total
110.6
75500 214350
2.44*
109*
99.9
24.4
4.1
90
57
40.1
0.00562* 0.00562
3.637 10.326
0.149 0.423
Total Sample Weight
(milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
13.0
0.00177
1.203
0.052
TOTAL PARTICULATE: INSOLUBLE AND AN
Total Sample Weight
(milligrams)
Grains/DSCF
Pounds /Hour
Pounds /Ton
Percent Insoluble
Participate CatchS
46.4
0.00632
4.294
0.184
28.0
3.275
0.141
11.693
0.502
<3.0***
0
0
0
40.6
0.00566
3.656
0.149
10.467
0.427
<3.0*«*
0
0
0
46.4
0.00665
4.100
0.161
12.051
0.473
aDry Standard Cubic Feet e 68°F, 29.92 inches Hg.
"Dry Standard Cubic Feet per minute.
cSpecific Ion Electrode Analysis Method. This method measures nitrate (NOJ)j AN (rog) = Nitrate (mg) x 80/62.
^Total flowrate equals sum of Clowrates actually measured in each bypass during each run. See Section 2.9.
eTotal pounds per hour is calculated by assuming that the grain loading measured in one bypass existed in the other two bypasses.
grain loading is then multiplied by the total flowrate.
^Total pounds per ton * (total pounds per hour I/Production rate.
9(insoluble particulate/total particulate) x 100.
•Weighted averages (weighted by flowrate)
*"Average of measurements made during each emission test run.
***Less than the detectable limifof the analysis.
4.3
0.00059
0.382 1.084
0.016 0.044
44.4
0.00621*
4.019 11.410
0.165 0.468
9.7
This
-------
TABU* 2-4
OP AMMOMTI1M NJTRATP (AM) AND IK'SOLIIBT.F PARTIO1LATF MFASl'PEMFMTS
CIP OASFS FXTTING TUF PRIM. TOWFR RCPHBBEP nilRINO LOW DENSITY AN PRODUCTION AT
COLUMBIA WTTRORFN CORPORATION, AUTIISTA, fiKOPRIA
Run Number
Date
Location
Run 1
H-17.-BO
outlet-
Run 2
8-17-80
Outlet
Run 3
H-13-HO
Outlet
Averaae
Outlet
Volume of Gas Sampled (DSCF)a
Volumetric Flowrate (DSCFM)b
Percent Moisture
Stack Temperature (°F)
Percent Isokinetic
Production Rate (Tons/Hour)
Percent Opacity*
Ambient Air Temperature (°F)
Ambient Relative Humidity (Percent)
to
I
AMMONIUM NITRATED
Total Sample Weight
Grains/PSCF
Pounds/Hour
Pounds/Ton
INSOLUBLE PARTICIPATE
(milligrams)
51.65
SI 120
6.66
94
105.7
23.3
0
90
57
5.4
0.00162
0.708
0.030
52.44
S7010
3.38
93
103.7
24.5
0
95
45
5.0
0.00147
0.667
0.027
49.18
51870
4.35
94
99.2
25.5
0
85
68
11.1
0.00348
1.549
0.061
51.09
5)970
4.80
94
102.9
24.4
0
90
57
7.2
0.00219
0.975
0.040
Total Sample Weiqht
Grains/PSCF
Pounds/Hour
Pounds/Ton
(milligrams)
P.I
0.00243
1.062
0.046
<3.0**
0
0
0
1.2
0.00100
n.ttf.
O.OJ7
3.8
0.00114
0.503
0.021
TOTAL PARTICULATF: niSOLUBLF AMD M>
Total Sample Weiqht (milliarams)
Crains/DSrp
Pounds/Hour
Pounds/Ton
Percent Insoluble Particulate Catch:d
13.5
0.004P5
1.770
0.076
6P.O
5.0
0.00147
0.667
0.027
14.3
0.00448
2.000
0.078
22.4
11.0
0.00333
1.479
0.061
27.5
Nitrate (mg) x 80/62.
aDry Standard Cubic Feet e 68°F. 7.9.92 inches Hg.
hDry Standard Cubic Feet per minute.
cSpecific Ion Electride analysis method. This method measures nitrate (NO3); AN (mg)
•'(Insoluble particulate/total partlculate) x 100.
*Average of measurements taken durinn each emission test run.
"Less than the detectable limit of the analysis*.
NOTP: The amount of condensed water collected during Run 1 represented a calculated percent moisture (6.66*)
slightly above saturation for the indicated stack temperature. The reason for this excessive amount of
moisture is not known.
-------
TABLE 2-3
SUMMARY OF AMMONIUM NITRATE (AN) AND INSOLUBLE PARTICULATE MEASUREMENTS ON GASES IN THE
PRILL TOWER BYPASSES DURING LOW DENSITY AN PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Run Number
Date
Location
Volume of Gas Sampled
(DSCF)a
Volumetric Flowrate
(DSCFM)b
Percent Moisture
Stack Temperature (°F)
Percent Isokinetic
Production Rate
(Tons/Hour)
Percent Opacity**
Ambient Air Temperature(°F)
Ambient Relative Humidity
(Percent)
AMMONIUM NITRATE0
Total Sample Weight
(milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
INSOLUBLE PARTICULATES
Total Sample Weight
(milligrams)
Grains/DSCP
Pounds/Hour
Pounds/Ton
Run 1
8-12-80.
ass B Total
113.2
79220
1.99
107
98.4
23.3
6.4
90
57
33.4
0.00455
3.091
0.133
13.0
0.00177
1.203
0.052
TOTAL PARTICIPATE; INSOLUBLE AND AN
Total Sample Weight
(milligrams)
Grains/DSCF
pounds/Hour
Pounds/Ton
Percent Insoluble
Participate Catch9
46.4
0.00632
4.294
0.184
28.0
215860C
0.00455
8.4196
0.361£
3.275
0.141
11.693
0.502
Run 2
8-12-80
pass A Total
110.7
77360
2.35
115
98.1
24.5
6.0
95
45
40.6
0.00566
3.656
0.149
<3.0*«*
0
0
0
40.6
0.00566
3.656
0.149
215760
0.00566
10.467
0.427
10.467
0.427
Run 3
8-13-80
pass C Total
107.9
71930
3.02
104
103.3
25.5
0.0
8S
68
46.4
0.00665
4.100
0.161
<3.0*«*
0
0
0
46.4
0.00665
4.100
0.161
211420
0.00665
12.051
0.473
12.051
0.473
aDry Standard Cubic Feet e 68°F, 29.92 inches Hg.
-Dry Stanuard Cubic Fset pet nir.ate.
cSpecific Ion Electrode Analysis Method. This method measures nitrate (NOJ); AN (ing) = Nitrate (mg) x 80/62.
dTotal Clowrate equals sum of flowrates actually measured in each bypass during each run. See Section 2.9.
eTotal pounds per hour is calculated by assuming that the grain loading measured in one bypass existed in the other two bypasses.
grain loading is then multiplied by the total flowrate.
DTotal pounds per ton « (total pounds per hour)/Production rate.
9(Insoluble particulate/total particulate) x 100.
•Weighted averages (weighted by flowrate)
«"Average of measurements made during each emission test run.
***I.ess than the detectable limifof the analysis.
Average
Bypass Total
110.6
75500 214350
2.44*
109*
99.9
24.4
4.1
90
57
40.1
0.00562* 0.00562
3.637 10.326
0.149 0.423
4.3
0.00059
0.382 1.084
0.016 0.044
44.4
0.00621*
4.019 11.410
0.165 0.468
9.7
This
-------
TABLE 2-4
SI1MMARV OP APMOHTIJM NITRATE (AP) AND INEOI.I1BLP. PARTirilLATE MFAPl'PEMFf-'TS
GASF.S FXTTTNC THE PRILL TOWFIR SCRUBBER DIIRIHO T.OW DENSITY AN PPOPUCTION AT
COLUMBIA HTTROREN CORPORATION, AUGUSTA,
Run Number
Date
Location
Volume of Gas Sampled (DSCP)a
Volumetric Plowrate (DSCFM)b
Percent Moisture
Stack Temperature (°F)
Percent Isokinetic
Production Rate (Tons/Hour)
Percent Opacity*
Ambient Air Temperature (°P)
Ambient Relative Humidity (Percent)
AMHOPUM NITRATE0
Total Sample Height (milligrams)
Rrains/nSCF
Pounds/Hour
Pounds/Ton
INSQr.l'Br.R PARTirrjLATE
Total Sample Weiqht (milligrams)
Grains/PSCF
Pounds/Hour
Pounds/Ton
TOTAL PARTICIPATE: IHSOMIBLE AND AN
Total Sample Weight (milliarams)
Grains/nSCF
Pounds/Hour
Pounds/Ton
Percent Insoluble Particulate Catch:''
Run 1
P-12-PO
nutlet-
51.65
S1120
6.A6
94
105.7
2.1.3
0
90
57
0.00162
0.708
0.030
8.1
P.00243
1.062
0.046
13.5
0.00405
1.770
0.076
6P.O
Run 2
8-l?-flO
Outlet
52.44
3.38
93
103.7
24.5
0
95
45
5.0
0.00)47
0.667
0.027
<3.0"
0
0
0
5.0
0.001*7
O.K67
0.027
Run 3
B-13-BO
Outlet
49.18
51870
4.35
94
99.2
25.5
0
85
68
11.1
0.00348
1.549
0.061
O.OOino
n.idf.
0.017
14.3
0.00448
2.000
0.078
22.4
Averaoe
Outlet
51.09
51970
4.80
94
102.9
24.4
0
90
57
7.2
0.00219
0.975
0.040
3.8
0.00114
0.503
0.021
11.0
0.00333
1.479
0.061
27.5
aDry Standard Cubic Feet g 6B°F, 29.92 inches Hg.
^Dry Standard Cubic Feet per minute.
cSpecific Ion Rlectride analysis method. This method measures nitrate (MO3)i AN (mg)
d(Insoluble particulate/total particulate) x 100.
•Average of measurements taken durinn each emission test run.
**I,ess than the detectable limit of the analysis.
Nitrate (mg) x 80/62.
: The amount of condensed water collected during Run 1 represented a calculated percent moisture (6.66»)
slightly above saturation for the indicated stacl- temperature. The rear.on for this excessive amount of
moisture is not known.
-------
The results of the ammonia measurements at the prill tower scrubber
inlets, bypasses, and scrubber outlet are shown in Tables 2-5, 2-6, and 2-7,
respectively. The excess ammonia parameter is calculated by subtracting the
ammonia that presumably originated as AN from the total measured ammonia.
\
This calculation is based on the assumption that nitrate is the limiting
species in the production synthesis of AN from ammonia and nitric acicl. The
results of this calculation indicate that 74 percent, 36 percent, and 92
percent of the total ammonia measured at the scrubber inlets, bypasses, and
scrubber outlet, respectively, was excess ammonia.
During each test run, emissions were measured at one inlet and one bypass
concurrently with measurements at the outlet. Velocity traverses were per-
formed at the other two inlets and two bypasses during each test run in order
to determine the flowrates through these ducts (as discussed in Section 2.9).
With this flowrate information, estimates of emissions from all inlets and
bypasses during each test run were made by assuming that the grain loading
measured in a given inlet or bypass existed in the other two inlets or by-
passes. The "total" columns in Tables 2-2, 2-3, 2-5, and 2-6 show these
estimated emissions.
The effects of the shroud that surrounds the spinning bucket (from which
the liquid AN droplets are ejected) are evident from a comparison of the
total inlet and bypass data. The bypass average AN and ammonia grain load-
ings are 27 percent and 11 percent, respectively, of the inlet averages.
These results are consistent with the fact that the scrubber inlets are with-
in the shroud and the bypasses are outside the shroud. Since the total flow-
rate through the bypasses is more than 5 times the flowrate through the in-
lets, the total bypass AN mass flowrate is 35 percent more than that in the
inlets, and the total bypass ammonia mass flowrate is only 45 percent less
-13-
-------
TABLE 2-5
SUMMARY OP AMMONIA, CALCULATED AMMONIUM NITRATE (AN) AND CALCULATED EXCESS AMMONIA MEASUREMENTS
ON GASES ENTERING THE PRILL TOWER SCRUBBER DURING LOW DENSITY AN PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Run Number
Date
Location
Volume of Gas Sampled (DSCF)3
Volumetric FJowrate (DSCfW)h
Production Rate (Tons/Hour)
AMMONIAC
Total Sample Weight (milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
AN CALCULATED FROM AMMONIA*3
Total Sample Weight (milligrams)
Grams/DSCF
Pounds/Hour
Pounds/Ton
EXCESS AMMONIA6
Run 1
8-12-80
Inlet B Total
80.03
15300
23.3
47210'
95.2
0.0184 0.0184
2.407 7.287*?
0.103 0.313h
448
0.0864 0.0864
11.33 34.98
0.486 1.501
Run 2
8-12-80
Inlet A Total
84.72
16070
24.4
99.2
0.0181
2.488
0.102
467
0.0851
11.71
0.478
47530
0.0181
7.374
0.301
0.0851
34.67
1.415
Run 3
8-13-80
Inlet C Total
80.24
15250
25.5
80.1
0.0154
2.014
0.079
46220
0.0154
6.101
0.239
377
0.0725 0.0725
9.48 28.72
0.372 1.126
Average
Inlet Total
81.66
15540 46990
24.4
91.5
0.0173* 0.0173
2.303 6.968
0.094 0.286
431
0.0813* 0.0813
10.84 32.75
0.444 1.342
Total Sample Weight (milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
77.7
0.0150 0.0150
1.965 6.072
0.084 0.261
72.5
0.0132
1.819
0.074
0.0132
5.378
0.219
53.7
0.0103
1.350
0.053
0.0103
4.081
0.160
67.9
0.0128* 0.0128
1.709 5.155
0.070 0.211
anry Standard Cubic Feet P 68°F, 29.92 inches Hg.
bnry Standard Cubic Feet per Minute.
cSpecific Ion Electrode analysis method.
''calculated from moles of measured ammonia. AN (mg) « Ammonia (mq) x 80/17.
°Excess Ammonia (mg) = measured ammonia (mg) - (measured AN (from Table 2-2) x 17/80).
fTotal flowrate equals sum of flowrates actually measured in each inlet during each run. See Section 2.9.
^Total pounds per hour is calculated by assuming that the gen in loading measured in one inlet existed in the other two inlets.
is then multiplied by the total flowrate.
nTotal pounds per ton = (total pounds per hour)/Production Rate.
•Weighted averages (weighted by flowrate).
This grain loading
-------
TABLE 2-6
SUMMARY OF AMMONIA, CALCULATED AMMONIUM NITRATE (AN) AND CALCULATED EXCESS AMMONIA MEASUREMENTS
ON GASES ENTERING THE PRILL TOWER BYPASSES DURING LOW DENSITY AN PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Run Number
Date
Location •
Volume of Gas Sampled (DSCF)a
Volumetric Flowrate (DSCFM)b
Production Rate (Tons/Hour)
AMMONIA0
Run 1
8-12-80
ass B Total
113.2
79220
23.3
215860f
Run 2
B-12-80
ass A Total
110.7
75360
24.5
215760
Run 3
8-13-80
pass C Total
107.9
71930
25.5
211420
110.6
75500
24.4
214350
I
M
(Jl
Total Sample Weight
(milligrams) 12.2
Grains/DSCF 0.00166 0.00166
Pounds/Hour 1.13 3.079
Pounds/Ton 0.048 0.132h
AN CALCULATED FROM AMMONIA*3
Total Sample Weight
(milliqraros) 57.4
Grains/DSCF 0.00780 0.00780
Pounds/Hour 5.29 14.43
Pounds/Ton 0.227 0.619
EXCESS AMMONIA6
Total Sample Weight
(milligrams) 5.1
Grains/DSCF 0.00070 0.00070
Pounds/Hour 0.472 1.30
Pounds/Ton 0.020 0.056
13.3
0.00185
1.20
0.049
62.6
0.00875
5.65
0.231
4.7
0.00066
0.424
0.017
0.00185
3.42
0.139
0.00875
16.18
0.660
0.00066
1.22
0.050
14.4
0.00206
1.27
0.050
67.8
0.00971
5.99
0.235
4.5
0.00064
0.397
0.016
0.00206
3.73
0.146
0.00971
17.60
0.690
0.00064
1.16
0.045
13.3
0.00186* 0.00186
1.20 3.42
0.049 0.140
62.6
0.00873* 0.00873
5.65 16.04
0.232 0.657
4.8
0.00067* 0.00067
0.433 1.23
0.018 U.050
aDry Standard Cubic Feet e 68°F, 29.92 inches llg.
bDry Standard Cubic Feet per Minute.
cSpecific Ion Electrode analysis method.
Calculated from moles of measured ammonia. AN (rag) = Ammonia (mg) x 80/17.
eExcess Ammonia (mg) = measured ammonia (mg) - (measured AN (from Table 2-3) x 17/80).
^Total flowrate equals sum of flowrates actually measured in each bypass during each run. See Section 2.9.
^Total pounds per hour is calculated by assuming that the grain loading measured in one bypass existed in the other two bypasses.
is then multiplied by the total flowrate.
''Total pounds per ton = (total pounds per hour)/Production Rate.
'Weighted averages (weighted by flowrate).
This grain loading
-------
TABLE 2-7
SUMMARY OF AMMONIA, CALCULATED AMMONIUM NITRATE (AN) AND
CALCULATED EXCESS AMMONIA MEASUREMENTS ON GASES EXITING THE PRILL TOWER SCRUBBER
DURING LOW DENSITY AN PRODUCTION AT COLUMBIA NITROGEN CORPORATION
AUGUSTA, GEORGIA
Run Number
Date
Location
Volume of Gas Sampled (DSCF)a
Volumetric Flowrate (DSCFM)b
Production Rate (Tons/Hour)
AMMONIA0
Total Sample Weight (milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
AN CALCULATED FROM AMMONIA*3
Total Sample Weight (milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
EXCESS AMMONIA6
Total Sample Weight
Grains/DSCF
Pounds/Hour
Pounds/Ton
(milligrams)
Run 1
8-12-80
Outlet
51.65
51120
23.3
18.7
0.00559
2.49
0.107
88.0
0.0264
11.54
0.495
17.6
0.00526
2.30
0.099
Run 2
8-12-80
Outlet
52.44
52910
24.5
16.7
0.00491
2.23
0.091
78.6
0.0232
10.50
0.429
15.6
0.00459
2.08
0.085
Run 3
8-13-80
Outlet
49.18
51870
25.5
18.6
0.00584
2.60
0.102
87.5
0.0274
12.19
0.478
16.2
0.00508
2.26
0.089
Average
Outlet
51.09
51970
24.4
18.0
0.00544
2.42
0.099
84.7
0.0256
11.40
0.467
16.5
0.00498
2.22
0.091
aDry Standard Cubic Feet @ 68°F, 29.92 inches Hg.
bDry Standard Cubic Feet per Minute.
°Specific Ion Electrode analysis method.
dCalculated from moles of measured ammonia. AN (mg) = Ammonia (mg) x 80/17.
eExcess Ammonia (mg) = measured ammonia (mg) - [measured AN (from Table 2-4) x 17/80J.
-------
than that in the inlets. The lowest percent excess ammonia exists in the
bypasses probably because the solidification of the liquid AN occurs primar-
ily within the shroud. Ammonia given off in the solidification process is
therefore primarily caught in the inlets. The high percent excess ammonia in
the scrubber outlet may be due to gaseous (excess) ammonia not being scrubbed
out and consequently making up a high percentage of measured ammonia.
2.2 Prill Predryer/Dryer Emissions
A summary of the ammonium nitrate measurements at the combined predryer/
dryer scrubber inlet and scrubber outlet is shown in Table 2-8. The average
AN removal efficiency is 99.5 percent.
The AN data for the individual predryer and dryer scrubber inlets are
shown in Table 2-9, and the AN and insoluble particulate data for the scrub-
ber outlet are shown in Table 2-10. Insoluble particulate measurements were
made on the outlet samples only.
The ammonia measurements at the scrubber inlets and scrubber outlet are
shown in Tables 2-11 and 2-12, respectively. The calculated percent excess
ammonia is 3.4 percent, 6.0 percent, and 79.4 percent for the predryer inlet,
dryer inlet and outlet, respectively. The relatively high percent excess
ammonia at the outlet probably is due to gaseous (excess) ammonia not being
scrubbed out and consequently making up a high percentage of measured ammonia
in the outlet samples. The negative excess ammonia sample weight for the run
1 dryer inlet samples is probably a reflection of the low excess ammonia pre-
sent in the dryer and of the inaccuracies inherent in the ammonia analysis
method.
The high AN grain loading at the two scrubber inlet locations caused
immediate nozzle and pitot tube plugging when the emission tests were begun
-17-
-------
TABLE 2-Po (English Units)
00
I
Run Number
Date
Location
SUMMARY OF AMMONIUM NITRATE (AN) MEASUREMFNTS ON GASES ENTERlNr, AND EXITING THE PRILL
Run 1
8-14-80
Inletsd Outlet
Volume of Gas Sampled (DSCP)a
Volumetric Flowrate (DSCFM)b
Percent Moisture*
Stack Temperature (°F)*
Percent Isokinetic
Production Rate {Tons/Hour)
Percent Opacity**
Ambient Air Temperature (°F)
Ambient Relative Humidity (Percent)
AMHOHIUM NITRATE0
Total Sample Weight (milligrams)
Grains/DSCF*
Pounds/Hour
Pouncis/Ton
Collection Efficiency (percent)
74.8 53.8
72080 73980
5.0 4.6
149 108
83.6 102.3
22.0
0
92
56
38240 151 48610
8.50 0.0433
4823 27.4
219 1.7.5
99.4
NG LOW DENSITY AN PRODUCTION AT
ORATION,
Run
AUGUSTA, GEORGIA
2
8-14-80
Inlets
81.8
73680
4.0
147
89.2
20.9
95
46
140
10.2
6093
291
99.6
Outlet
52.8
73100
4.8
108
101.3
0
45320
0.0409
25.6
1.22
Run
3
8-14-80
Inlets
80.1
72610
3.9
148
88.1
20.4
92
53
159
9.74
5675
278
99.
Outlet
52.8
73120
4.1
110
100.8
0.5
44060
0.0467
29.3
1.44
5
Average
Inlets Outlet
7fa.9
72790
4.3
148
87.0
21.
93
52
53.1
73330
4.5
109
101.5
0.2
150
9.48 0.0436
5531 27.4
2 62 1.30
99.5
ar>ry Standard Cubic Feet e 68°F, 29.92 inches Ho.
bl)ry Standard Cubic Feet Per Minute.
cSpecific Ion Electrode analysis method. This method measures nitrate (NOJ") ; AN (mg) = nitrate (mg) x 80/62.
^Combined predryer and dryer. Separate data are shown in Table 2-9.
*Inlet values are weighted averages (weighted by flowrates in Table 2-9) .
**Average opacity as monitored during each run.
NOTE: Insoluble particulate results are not included in this table. See Table 2-10 for insoluble particulate data.
-------
TABLE 2-8b (Metric Unite)
Run Number
Date
Location
Volume of Gas Sampled (DNm3)a
Volumetric Flowrate (DNm3/min)b
Percent Moisture*
Stack Temperature (°C)*
Percent Isokinetic
Production Rate (Mg/Hour)
Percent Opacity**
Ambient Air Temperature (°C)
Ambient Relative Humidity (percent)
AMMONIUM NITRATE0
Total Sample Weight (milligrams)
Grams/DNm3
Kg/Hour
Kg/Mg
Collection Efficiency (percent)
SUMMARY OF AMMONIUM NITRATE (AN) MEASUREMENTS ON
GASES ENTERING AND EXITING THE PRILL PREDRYER/DRYER SCRUBBER
DURING LOW
Run
DENSITY AN PRODUCTION AT COLUMBIA N
1
8-14-80
Inletsd Outlet
2.12
2041
5.0
65
83.6
20.0
33
56
1.52
2095
4.6
42
102.3
0
AUGUSTA, GEORGIA
Run 2
8-14-80
Inlets Outlet
2.32 1.50
2087 2070
4.0 4.8
64 42
89.2 101.3
19.0
0
35
46
38240
19.4
2188
110
151
0.0991
12.4
0.63
48610
23.3
2764
146
140
0.0936
11.6
0.61
Run 3
8-14-80
Inlets Outlet
2.27
2056
3.9
64
88.1
18. S
33
53
1.49
2071
4.1
43
100.8
0.5
45320
22.3
2574
139
159
0.107
13.3
0.72
Average
Inlets
2.24
2061
4.3
64
87.0
19.1
34
52
Outlet
1.50
2077
4.5
42
101.5
0.2
44060
21.7
2509
131
150
0.0999
12.4
0.65
99.4
99.6
99.5
99.5
aDry Normal Cubic Meters f 20°C, 760 mm Hg.
bDcy Normal Cubic Meters per minute.
cSpeci£ic Ion Electrode analysis method. This method measures nitrate (NOf); AN (mg)
"Combined predryer and dryer. Separate data are shown in Table 2-9.
•Inlet values are weighted averages (weighted by Clowrates in Table 2-9).
"Average opacity as monitored during each run.
NO3(mg) x 80/62.
NOTE: Insoluble particulate results are not included in this table. See Table 2-10 for insoluble particulate data.
-------
TABLE 2-9
SUMMARY OF AMMONIUM NITRATE (AN) MEASUREMENTS ON
GASES ENTER ING THE FRILL PREDYRER/DRYER SCRUBBER DURING LOW DENSITY
AN PRODUCTION AT COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
I
to
O
I
Run Number
Date
Location
Volume of Gas Sampled (DSCF)a
Volumetric Flowrate (DSCEM)b
Percent Moisture
Stack Temperature (°F)
Percent Isokinetlc
Production Rate (tons/hour)
AMMONIUM NITRATE0
Total Sample Height (milligrams)
Grains/DSCF
Pounds/Hour*
Pounds/Ton
TOTAL UNCONTROLLED AN EMISSIONS*3
Grains/DSCF**
Pounds/Hour
Pounds/Ton
Run
1
8-14-80
Predrver
45.4
38330
4.8
151
83.9
22.0
13630
4.64
1402
63.7
Dryer
29.4
33750
5.2
146
83.3
24610
12.9
3421
156
8.50
4823
219
Run
2
8-14-80
Predryer
50.8
38680
3.6
151
93.4
20.9
16280
4.94
1639
78.4
Dryer
31.0
35000
4.5
142
84.9
32330
16.1
4454
213
10.2
6093
291
Run
3
Average
8-14-80
Predryer
50.7
38720
3.5
151
93.1
20.4
Dryer
29.4
33890
4.4
144
83.0
Predryer
50.0
38580
4.0
151
90.1
21.1
Dryer
29.9
34210
4.7
144
83.7
16610
5.05
1677
82.2
28710
15.1
3998
196
9.74
5675
278
15510
4.88
1573
74.5
28550
14.7
3957
188
9.48
5531
262
aDry Standard Cubic Feet @ 68°F, 29.92 inches llg.
bDry Standard Cubic Feet per minute.
cSpecific Ion Electrode analysis method. This method measures nitrate (NOJ); AN (mg) = nitrate (nig) x 80/62.
dSum of predryer and dryer emissions.
'For runs with percent isokinetlc less than 90%, mass flowrates (pounds/hour) presented here are averages of mass flowrates calculated by
concentration method and area ratio method.
"Weighted averages (weighted by f lowrate).
NOTE: Insoluble particulate analyses were not performed on inlet samples.
-------
TABLE 2-10
SUMMARY OF AMMONIUM NITRATE (AN) AND INSOLUBLE PARTICOLATE MEASUREMENTS ON
HASPS EXITING THE PRILL PREDRYER/DRYER SCRUBBER DURING LOW DENSITY AN PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Run Number
Date
Location
volume of Gas Sampled (DSCF)a
Volumetric Flowrate (DSCFM)b
Percent Moisture
Stack Temperature (°F)
Percent Isokinetic
Production Rate (tons/hour)
Percent Opacity*
Ambient Air Temperature (°F)
Ambient Relative Humidity (percent)
AMMONIUM NITRATE0
Total Sample Weight (milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
INSOLUBLE PARTICULATE
Total Sample Height (milligrams)
Hrains/nSCF
Pounds/Hour
Pounds/Ton
TOTAL PARTICULATEi INSOLUBLE AND AN
Total Sample Height (milligrams)
GrMns/DSCF
Pounds/Hour
Pounds/Ton
Percent Insoluble Particulate Catchd
Run 1
8-14-flO
Outlet
53.8
73980
4.6
108
102.3
22.0
0
92
56
151
0.0433
27.4
1.25
<3.0**
0
0
0
151
0.0433
27.4
1.25
0
Run 2
8-14-80
Outlet
52.8
73100
4.R
108
101.3
20.9
0
95
46
140
0.0409
25.6
1.22
4.6
0.00134
O.R42
0.040
145
0.0422
26.5
1.26
3.3
Run 3
8-14-80
Outlet
52.6
73120
4.1
110
100.8
20.4
0.5
92
54
159
0.0467
29.3
1.44
<3.0«*
0
n
0
159
0.0467
29.3
1.44
Average
Outlet
53.1
73400
4.5
109
101.5
21.1
0.2
93
52
150
0.0436
27.4
1.30
1.5
o.nno447
0.281
0.013
152
0.0441
27.7
1.31
1.1
aDry Standard Cubic Feet e 68°F, 29.92 inches Hg.
''Dry Standard Cubic Feet per minute.
cSpecific Ion Eiectiuue anal/sis method. This rr..-thcc! measures nitrate (NO^!; AM (HKJ! = nitrate !"ig) x Sn/62.
d(Insoluble Particulate/Total Particulate) x 100.
'Average opacity as monitored during each run.
**Less than the detectable limit of the analysis.
-------
TABLE 2-11
SUMMARY OF AMMONIA, CALCULATED AMMONIUM NITRATE (AN) AND
CALCULATED EXCESS AMMONIA MEASUREMENTS ON GASES ENTERING THE
PRILL PREDRYER/DRYER SCRUBBER DURING LOW DENSITY AN PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Run Number
Date
Location
Volume of Gas Sampled (DSCF18
Volumetric Flowrate (DSCFm)b
Percent Isokinetic
Production Rate (tons/hour)
AMMONIA0
45.4 29.4
38330 33750
83.9 83.3
22.0
50.8 31.0
36680 35000
93.4 84.9
20.9
50.7 29.4
38720 33890
93.1 83.0
20.4
Average
Predryer Dryer
50.0 29.9
38580 34210
90.1 83.7
21.1
I
10
to
I
Total Sample Height (milligrams)
Grains/DSCF
Pounds/Hour*
Pounds/Ton
AN CALCULATED FROM AMMONIA*3
Total Sample Height
Grains/DSCF
Pounds/Hour*
Pounds/Ton
EXCESS AMMONIA0
Total Sample Height
Grains/DSCF
Pounds/Hour*
Pounds/Ton
(milligrams)
(milligrams)
2950
1.00
304
13.8
13880
4.72
1420
64.9
53.6
0.0140
5.57
0.253
5101
2.68
709
32.2
24000
12.6
3336
152
-129
3667
1.11
369
17.7
17260
5.24
1737
83.1
208
0.0603
20.9
1.00
7116
3.54
979
46.8
33490
16.7
4611
221
246
0.119
34.1
1.63
3621
1.10
366
17.9
17040
5.18
1720
84.3
91.4
0.0269
9.14
0.448
7012
3.68
976
47.8
33000
17.3
4595
225
911
0.471
127
6.23
3413
1.07
346
16.4
16060
5.05
1628
77.2
118
0.0337
11.9
0.564
6410
3.30
889
42.1
30160
15.5
4180
198
386**
0.196**
53.7**
2.55
aDry Standard Cubic Feet 8 68°F, 29.92 inches Hg.
bDry Standard Cubic Feet per minute.
°Specific Ion Electrode analysis method.
^Calculated from moles of measured ammonia. AN(mg) = ammonia (tug) x 80/17.
eExcess Ammonia (mg) = measured ammonia (mg) - [measured AN (from Table 2-9) x 17/80).
*For runs with percent isokinetic less than 90%, mass flowrates (pounds/hour) presented here are averages of mass flowrates calculated by
concentration method and area ratio method.
•'Average calculated by assuming Run 1 values are 2ero.
-------
TABLE 2-12
SUMMARY OF AMMONIA, CALCULATED AMMONIA NITRATE (AN) AND CALCULATED EXCESS AMMONIA
MEASUREMENTS ON GASES EXITING THE PRILL PREDRYER/DRYER SCRUBBER DURING LOW DENSITY AN PRODUCTION
AT COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
NJ
OJ
Run Number
Date
Location
Volume of Gas Sampled (DSCF)a
Volumetric Flowrate (DSCFM)b
Percent Isokinetic
Production Rate (tons/hour)
AMMONIAC
Total Sample Weight (milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
AN CALCULATED FROM AHMONIAd
Total Sample Weight (milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
EXCESS AMMONIA6
Run 1
8-14-80
Outlet
53.8
73980
102.3
22.0
139
0.0397
25.1
1.14
653
0.187
118
5.36
Run 2
8-14-80
Outlet
52.8
73100
101.3
20.9
190
0.0556
34.9
1.67
898
0.262
164
7.85
52.6
73120
100.8
20.4
133
0.0391
24.5
1.20
626
0.184
115
5.64
Average
Outlet
53.1
73400
101.5
21.1
154
0.0448
28.2
1.34
726
0.211
132
6.26
Total Sample Height (milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
107
0.0305
19.3
0.877
161
0.0469
29.5
1.41
99
0.0292
18.3
0.897
122
0.0355
22.4
1.06
aDry Standard Cubic Feet @ 68°F, 29.92 inches Hg.
bDry Standard Cubic Feet per minute.
cSpecific Ion Electrode analysis method.
^Calculated from moles of measured ammonia. AN(mg) = ammonia (mg) x 80/17.
eExcess Ammonia (mg) = measured ammonia (mg) - (measured AN from Table 2-10 x 17/80).
-------
at these locations. Larger diameter nozzles were then attached to the probes
and plugging problems were greatly reduced. However, the sampling train
pumps were unable to draw a sufficient flow through these larger nozzles to
maintain isokinetic sampling conditions. The first predryer run, and all
three dryer runs have isokinetics below 90 percent. In order to compensate
for the high bias introduced into the normal mass flowrate calculations due
to the subisokinetic sampling conditions, a second method was also used to
calculate mass flowrates for these runs. An average of the mass flowrates
calculated by these two methods is presented in Tables 2-9 and 2-11.
The method normally used to calculate mass flowrates is the concentration
method, whereby the calculated grain loading (sample weight divided by
sampled gas volume) multiplied by the flowrate equals mass flowrate. The
second mass flowrate calculation method is the area ratio method, whereby the
sample weight is divided by the sampling time and then multiplied by the
ratio of the stack area to nozzle area. For subisokinetic sampling, the
concentration method will overestimate mass flowrate and the area ratio
method will underestimate mass flowrate. Therefore an average of the mass
flowrates calculated by the two methods is used as a best estimate of the
true mass flowrates. The mass flowrates calculated by both methods for the
first predryer run and all three dryer runs are shown in Tables 2-13a and
2-13b, respectively. These two mass flowrate calculation methods are discus-
sed further in Section 5.2.1.2.
2.3 Prill Cooler Emissions
The results of the AN measurements at the prill cooler scrubber inlet and
bypass are shown in Table 2-14. The insoluble particulate analysis results
for the bypass samples were below the threshold of detection (less than 3.0
mg) and are therefore not included with the AN particulate results.
-24-
-------
TABLE 2-13a
COMPARISON OF PREDRYER INLET RUN 1
MASS FLOWRATE CALCULATIONS
AT COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Run 1 Mass Flowrate* (% I = 83.9)
AN
NH3
AN (NH3)
Excess N
Concentration
Method
1524
330
1552
6.09
Area Ratio
Method
1280
277
1304
5.04
Average
1402
304
1428
5.57
Average Of All Three Runs - Mass Flowrate* (%I = 90.1)
AN
NH3
AN (NH3)
Excess NH3
Concentration
Method
1613
355
1670
12.0
Area Ratio
Method
1532
337
1587
11.7
Average
1573
346
1629
11.9
*Pounds per hour
-25-
-------
TABLE 2-13b
COMPARISON OF DRYER INLET MASS FLOWRATE CALCULATIONS
AT COLIMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Run 1 Mass Flowrate* (%I «• 83.3) Run 2 Mass Flowrate* (%I = 84.9)
Concentration Area Ratio Concentration Area Ratio
Method Method Average Method Method Average
AN 3736 3105 3421 4830 4078 4454
NH3 774 643 709 1062 898 979
AN (NH3) 3643 3028 3336 4996 4225 4611
Excess NH3 — ~ — 37.2 31.0 34.1
Run 3 Mass Flowrate* (%I » 83.0) All Runs-Mass Flowrate* (%I » 83.7)
Concentration Area Ratio Concentration Area Ratio
Method Method Average Method Method Average
AN 4373 3622 3998 4313 3602 3957
NH3 1068 885 976 968 809 889
AN (NH3) 5027 4163 4595 4555 3805 4180
Excess NH3 139 115 127 58.7 48.7 53.7
*Pounds per hour
-26-
-------
TABLE 2-14
SUMMARY OF AMMONIUM NITRATE (AN) MEASUREMENTS ON GASES IN THE PRILL COOLER SCRUBBER INLET AMD BYPASS
DURING LOW DENSITY AN PRODUCTION AT COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
I
to
-O
I
Run Number
Date
Location
Volume of Gas Sampled (DSCF)a
Volumetric Flowrate (DSCFM)b
Percent Moisture
Stack Temperature (°F)
Percent Isokinetic
Production Rate (Tons/Hour)
Percent Opacity
Ambient Air Temperature (°F)
Ambient Relative Humidity (percent)
AMMONIUM NITRATE0
Total Sample Height (milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
TOTAL UNCONTROLLED AN EMISSIONS'3
Run 1
8-15-80
Inlet Bypass
94.98
40970
3.18
126
99.7
21.0
71.87
20110
2.63
113
101. 5
21.0
**
88
67
34264 356
5.63 0.0764
1975 13.2
94.0 0.63
Run 2
8-15-80
Inlet Bypass
94.47
40450
3.20
129
100.4
20.9e
58.27
19000
2.58
114
102.2
20.4
0.0
90
62
23736 328
3.88 0.1011
1344 16.4
64.3 0.80
Run 3
8-16-80
Inlet Bypass
94.38
40350
3.67
127
100.6
22.4
69.66
19190
2.75
115
103.2
22.4
0.0
83
77
2 603 5 3 67
4.26 0.0813
1472 13.4
65.7 0.60
Average
Inlet Bypass
94.61
40590
3.35
127
100.2
21.4
66.60
19430
2.65
114
102.3
21.3
0.0
87
69
28132 350
4.59 0.0811
1596 13.5
74.6 0.63
Grains/DSCF*
Pounds/Hour
Pounds/Ton
3.80
1988
94.6
2.67
1360
65.1
2.91
1485
66.3
3.13
1610
75.2
aDry Standard Cubic Feet « 68°F, 29.92 inches Hg.
bDry Standard Cubic Feet per Minute.
cSpecifjc Ion Electrode analysis method. This method measures nitrate (HOJ); AN (mg) = Nitrate (mg) x 80/62.
Combined inlet and bypass.
eWeighted average (weighted by time). This run was performed over two days because of process equipment breakdown.
•Weighted average (weighted by flowrate).
"Plume opacity not monitored during this run.
NOTE: Insoluble particulate analyses on bypass samples were all less than the limit of detection (less than 3.0 mg).
-------
The results of the ammonia measurements are shown in Table 2-15. The
results of the excess ammonia calculations indicate that very little excess
ammonia exists in the prill cooler. The average percent excess ammonia at
the scrubber inlet and bypass is 2.0 percent, and 3.5 percent, respectively.
The negative excess ammonia values for runs 2 and 3 are relatively small and
are probably artifacts of the inaccuracies inherent in the ammonia analyses
and in the excess ammonia calculation.
The cooler scrubber inlet run 2 was actually performed over 2 days. All
but one traverse was completed by late afternoon on August 15, 1980, at which
time the prill bucket elevator broke down. This run was completed early on
August 16, 1980, prior to run 3. Additional discussion is presented in Sec-
tion 5.2.1.3.
2.4 Particle Size Tests
The sampling parameters and results for the particule size tests perform-
ed at the prill cooler uncontrolled outlet (bypass) are shown in Table 2-16a
and Figures 2-1 and 2-2. The results for the prill cooler scrubber inlet
tests are shown in Table 2-16b and Figures 2-3 and 2-4.
The sampling parameters and results for the tests performed at the three
prill tower scrubber inlets are shown in Table 2-17 and Figures 2-5 and 2-6.
The results for the tests performed at the three prill tower bypasses are
shown in Table 2-18 and Figures 2-7 and 2-8.
The sampling parameters and results for the tests performed at the dryer
scrubber inlet are shown in Table 2-19 and Figures 2-9 and 2-10. The results
of the tests performed at the predryer scrubber inlet are shown in Table 2-20
and Figures 2-11 and 2-12.
-28-
-------
TABLE 2-15
SUMMARY OF AMMONIA, CALCULATED AMMONIUM NITRATE (AN) AND CALCULATED EXCESS AMMONIA MEASUREMENTS
ON GASES IN THE PRILL COOLER SCRUBBER INLET AND BYPASS DURING LOW DENSITY AN PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Run Number
Date
Location
Volume of Gas Sampled (DSCF)a
Volumetric Flowrate (DSCFM)6
Production Rate (Tons/Hour)
AMMONIA0
Run 1
8-15-80
Inlet Bypass
94.98 71.87
40970 20110
21.0 21.0
Run 2
8-15-80
Inlet Bypass
94.47 58.27
40450 19000
20.9«* 20.4
Run 3
8-16-80
Inlet Bypass
94.38 69.66
40350 19190
22.4 22.4
94.61
40590
21.4
66.60
19430
21.3
Total Sample Weight (milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
8006 81.2
1.301 0.0174
457 3.01
21.8 0.143
4992 73 .2
0.815 0.0194
283 3.16
13.5 0.155
5294 76.8
0.866 0.0170
299 2.80
13.3 0.125
6097
0.994
346
16.2
77.1
0.0179
2 .98
0.140
AN CALCULATED FROM AMMONIA"
Total Sample Weight (milligrams)
Grains/DSCF
Pounds/Hour
Pounds/Ton
EXCESS AMMONIA6
37677 382
6.12 0.0820
2149 14.1
102 0.671
23492 344
3.P4 0.0911
1330 14.8
63.6 0.725
24915 361
4.07 0.0800
1409 13.2
62.9 0.589
28695
4.68
1628
76.1
362
0.0839
14.0
0.657
Total Sample Weight
Grains/DSCF
Pounds/Hour
Pounds/Ton
(milligrams)
648 5.6
0.105 0.00120
37.0 0.207
1.76 0.010
-52
3 .5
0.00057
0.093
0.005
-238
-1.2
216*
0.0350*
12.3*
0.575*
2.7
0.00059'
0.100*
0.005*
aDry Standard Cubic Feet P 68°F, 29.92 inches Hg.
hDry Standard Cubic Feet per Minute.
cSpecific Ion Electrode analysis method.
''calculated from moles of measured ammonia. AN (mo) = Ammonia (mq) x 80/17.
eExcess Ammonia (mg) = measured ammonia (mg) - (measured AN (from Table 2-13) x 17/80).
'Averages calculated by assuming negative numbers are zero.
** Weighted average (weighted by time). This run was performed over two days because of process equipment breakdown.
-------
TABLE 2-16a
PARTICLE SIZE RESULTS AT THE PRILL COOLER UNCONTROLLED OUTLET (BYPASS)
AT COLUMBIA NITROGEN CORPORATION
AUGUSTA, GEORGIA
Run No./ Test
Stage Date
1/0 8-12-80
1
Cyclone
Impingerc
2/0 8-12-80
1
Cyclone
Impinger
3/0 8-13-80
1
Cyclone
Impinger
Aerodynamic
Particle Size
Concentration3 (microns)
0.036 >9.95
9.95-5.52
5.52-1.21
<1.21
0.024 >9.64
9.64-5.28
5.28-1.12
<1.12
0.062 >9.61
9.61-5.26
5.26-1.11
<1.11
Mass in
Size
Range15
85.06
7.81
3.25
3.88
82.41
11.15
2.46
3.98
90.59
6.42
1.59
1.40
Cumulative
(%)
85.06
92.87
96.12
100.00
82.41
93.56
96.02
100.00
90.59
97.01
98.60
100.00
a Grains/dry standard cubic foot
b Percent including impinoer train catch
c Impinger train catch
-30-
-------
WEIGHT % GREATER THAN STATED SIZE
999 99.6 99 98 95 90 8O 70 60 50 W 30 20 10 5 2 I 0.3 0.2 O.I
100 I I I I I I I I I 1 II II I I I I I 100
so
20
10
o
-------
U. 1U
On?
Om
<*-
o
^
U.UZ
a
O)
3
^* 0.01
-0
c n nri7
-D
O
M 0.005
\/t
0.004
.OOi
0 001
0 - ftun
A - Run
• - Run
1
2
3
/
/
V
/
//
^/
/
/
/
'/
7
/
/
/
/
/i
//
/
/\
j
//
*
t
r
2 I 3 4 5 6 7 8 9 10 2 3 4 5 6 7 8 9 10
A
0.0008
Geometric Mean of Particle Diameter (Microns)
Figure 2-2J HCSS impactor particle size results: differential mass loading
(dM/d log D) versus particle diameter - prill cooler uncon-
trolled outlet.
-32-
-------
TABLE 2-16b
PARTICLE SI2E RESULTS AT THE PRILL COOLER SCRUBBER INLET
AT COLUMBIA NITROGEN CORPORATION
AUGUSTA, GEORGIA
Run No./ Test
Stage Date
1/0 8-13-80
1
Cyclone
Impingerc
2/0 8-13-80
1
Cyclone
Impinger
3/0 8-13-80
1
Cyclone
Impinger
Aerodynamic
Particle Size
Concentration3 (microns)
4.147 >9.49
9.49-5.17
5.17-1.10
<1.10
3.627 >9.50
9.50-5.17
5.17-1.10
<1.10
4 . 02 7 >9 . 52
9.52-5.18
5.18-1.10
<1.10
Mass in
Size
Rangeb
92.07
7.86
0.06
0.01
96.07
3.67
0.05
0.01
92.92
6.96
0.07
0.05
Cumulative
(%)
92.07
99.93
99.99
100.00
96.07
99.94
99.99
100.00
92.92
99.88
99.95
100.00
a Grains/dry standard cubic foot
b Percent including impinger train catch
c Impinger train catch
-33-
-------
WEIGHT % GREATER THAN STATED SIZE
99.8 99 98 95 9O 80 70 60 3O &
^~
\
2
3
^A
"s&
t^
fjk
IOO
90
20
10
O.S
0.2
O.I
0.1 0.2 0.3 I 2 5 10 20 30 «O SO 6O TO 80 90 93 98 99 998 99.9
WEIGHT % LESS THAN STATED SIZE
Figure 2-3: HCSS impactor particle size results: particle size versus percent
weight less/greater than stated size - prill cooler scrubber
inlet.
-34-
-------
1.2
0.10
0.07
0.05
^ 0.03
O 0.02
o>
Q
0.01
•a
a>
.£ 0.007
-5
~* 0.005
VI
(A
0.004
0.003
0.002
0.001
1.04
0.52
• • - Run 1 •
A - Run 2
' • - .Run 3
4 5 4789 10
5 6739 10
Geometric Mean of Particle Diameter (Microns)
Figure 2-4: HCSS impactor particle size results: differential mass loading
(dM/d log D) versus particle diameter - prill cooler scrubber
inlet.
-35-
-------
TABLE 2-17
PARTICLE SIZE RESULTS AT THE PRILL TOWER SCRUPBER INLETS
AT COLUMBIA NITROGEN CORPORATION
AUGUSTA, GEORGIA
Run No./
Stage
1/0
1
Cyclone
Impingerc
2/0
1
Cyclone
Impinger
3/0
1
Cyclone
Impinger
Aerodynamic
Test Inlet Particle Size
Date Location Concentration3 (microns)
8-14-80 A 0.038 >9.8fi
9.86-5.44
5.44-1.19
<1.19
8-14-80 B 0.011 >10.25
10.25-5.74
5.74-1.30
.<1.30
8-16-80 C 0.008 >10.04
10.04-5.57
5.57-1.25
<1.25
Mass in
Size
Rangeb
8.35
1.34
34.66
55.64
15.46
7.15
38.65
38.74
8.92
2.04
29.41
59.63
Cumulative
(%)
8.35
9.69
44.36
100.00
15.46
22.61
61.26
100.00
8.92
10.96
40.37
100.00
a Grains/dry standard cubic foot
b Percent including impinger train catch
c Impinger train catch
-36-
-------
WEIGHT % GREATER THAN STATED SIZE
a
<£
O
-------
U. IU
On-r
rt /i*i
Ck.
O
*
On rtO
Q
o>
3
-^ U.U1
-o
O)
C A Ofi7
-a
u.uuo
t/l
l/»
o
5 o.oc*
T AO?
0.001
• - 1-
A- In
• - In
ft* ^ . ,.,
at 3
Bf C """'
•
\
A
•
\
\
\
\
Si
\
\
\
\
A
\
\
\
\
\
i
•
4 5 6 " 3 9 10
4 5678910
O.OOOo
Geometric Mean of Particle Diameter (Microns)
Figure 2-6: HCSS impactor particle size results: differential mass loading
(dM/d log D) versus particle diameter - prill tower inlets.
-38-
-------
TABLE 2-18
PARTICLE SIZE RESULTS AT THE PRILL TOWER BYPASSES
AT COLUMBIA NITROGEN CORPORATION
AUGUSTA, GEORGIA
Run No./ Test
Stage Date
1/0 8-15-80
1
Cyclone
Impingerc
2/0 8-14-80
1
Cyclone
Impinger
3/0 8-15-80
1
Cyclone
Impinger
Aerodynamic
Inlet Particle Size
Location Concentration3 (microns)
A 0.006 >9.06
9.06-4.93
4.93-0.96
<0.96
B 0.006 >8.88
8.88-4.83
4.83-0.95
<0.95
C 0.005 >9.12
9.12-4.96
4.96-1.00
<1.00
Mass in
Size
Rangeb
35.74
3.50
44.37
16.39
30.80
5.74
44.52
18.94
29.02
2.94
40.03
28.00
Cumulative
(%)
35.74
39.24
83.61
100.00
30.80
36.54
81.06
100.00
29.02
31.97
72.00
100.00
a Grains/dry standard cubic foot
b Percent including impinger train catch
c Impinger train catch
-39-
-------
WEIGHT % GREATER THAN STATED SIZE
99.9 99.6 J9 98 95 90 80 70 SO 30 40 JO 20 10 3 2 I O.S 02 O.I
SO
20
10
VI
O
cc
o
I s
Ul
I
a
CJ
K
0.3
0.2
0.1
. • - Byposs A
* - Bypass B
• - Bypass C
I
100
so
20
10
0.3
0.2
01
O.I 0.2 O.S I 2 3 10 20 30 <»O SO 60 TO 8O 90 93 98 99 998 99.9
WEIGHT % LESS THAN STATED SIZE
Figure 2-7: HCSS impactor particle size results: particle size versus percent
weight less/greater than stated size - prill tower bypass stacks.
-40-
-------
U.UIU
0.007
0.005
^ 0.003
t^
U
*
O 0.002
Q
O)
3
^> 0.001
T3
O)
.= 0.0007
-5
o
o
-1 0.0005
tf)
t/1
J 0.0004
0.0003
0.0002
0.0001
• -Byf
xaj A
A - 3ypo« 3
A
V
\-
\
^
\\
\
s
\
^
\
\
s
\
\
\
\
s
1A
k
•\
^
•
4 5 6 7 8 9 10
4 5 6 7 8 910
Geometric Mean of Particle Diameter (Microns)
Figure 2-8: HCSS impactor particle size results: differential mass loading
(.dM/d log D) versus particle diameter - prill tower bypass
stacks.
-41-
-------
TABLE 2-19
PARTICLE SIZE RESULTS AT THE DRYER SCRUBBER INLET
AT COLUMBIA NITROGEN CORPORATION
AUGUSTA, GEORGIA
Run No./ Test
Stage Date
1/0 8-15-80
1
Cyclone
Impingerc
2/0 8-15-80
1
Cyclone
Impinger
3/0 8-15-80
1
Cyclone
Impinger
Aerodynamic
Particle Size
Concentration3 (microns)
10.689 >10.24
10.24-5.70
5.7 -1.32
<1.32
2.841 >10.82
10.82-6.14
6.14-1.49
<1.49
2.234 >8.91
8.91-4.84
4.84-1.00
<1.00
Mass in
Size
Range*3
93.50
5.46
0.19
0.86
95.60
3.27
0.17
0.97
96.27
3.23
0.25
0.25
Cumulative
(%)
93.50
98.96
99.14
100.00
95.60
98.86
99.03
100.00
96.27
99.50
99.75
100.00
a Grains/dry standard cubic foot
b Percent including impinger train catch
c Impinger train catch
-42-
-------
WEIGHT % GREATER THAN STATED SIZE
99.9 99fl 99 96 99 9O 80 70 60 50 «O 30 20 10 9 21 0.5 0.2 O.I
IOO I I I I ' I I I I ' I I I I I i i i i i 100
30
20
10
§
X
-------
1.0
0.7
0.5
~> 0.3
O 0.2
a
CD
3
0.1
0.07
0.05
O.C4
0.03
0.02
0.01
O>
O
O
• • - Run I .
A - Run 2
' • - Run 3
2.25
•
3j 45 6 7 8 9 10
• A
0.008 0.007
Geomerric Mean of Particie Diameter (Microns)
4 5 6 7 8 9!0
Figure 2-10! HCSS impactor particle size results: differential mass loading
(dM/d log D) versus particle diameter - dryer uncontrolled exhaust.
-44-
-------
TABLE 2-20
PARTICLE SIZE RESULTS AT THE PREDRVER SCRUBBER INLET
AT COLUMBIA NITROGEN CORPORATION
AUGUSTA, GEORGIA
Run No./ Test
Stage Date
1/0 8-16-80
1
Cyclone
Impingerc
2/0 8-16-80
1
Cyclone
Impinger
3/0 8-16-80
1
Cyclone
Impinger
Aerodynamic
Particle Size
Concentration3 (microns)
1.900 >9.04
9.04-4.92
4.92-1.05
<1.05
2.934 >9.10
9.10-4.95
4.95-1.06
<1.06
2.109 >9.42
9.42-5.13
5 . 13 -1 . 12
<1.12
Mass in
Size
Rangeb
92.37
5.45
0.42
1.76
93.76
5.22
0.48
0.54
. 90.33
8.69
0.49
0.48
Cumulative
(%)
92.37
97.82
98.24
100.00
93.76
93.98
99.46
100.00
90.33
99.02
99.52
100.00
a Grains/dry standard cubic foot
b Percent including impinger train catch
c Impinger train catch
-45-
-------
WEIGHT % GREATER THAN STATED SIZE
999 99.8 99 98 95 9O 80 70 60 30 4O 30 20 10 '-
100
90
20
10
X
o
I !
IT
UJ
o
-------
1.0
0.7
0.5
^ 0.3
O 0.2
O)
Q
.0.1
O)
0.07
0.05
0.04
0.03
0.02
0.01
, • - Run 1.
A - Run 2
' • - Sun 3 '
4 5 6 7 8 9 10
4 5 6 7 8 910
Geometric Mean of Particle Diameter (Microns)
Figure 2-12: HCSS impactor particle size results: differential mass loading
(dM/d log D) versus particle diameter - predryer uncontrolled exhaust.
-47-
-------
2.5 Visible Emissions
The opacities of the prill tower scrubber outlet and bypass plumes, the
predryer/dryer scrubber outlet plume, the cooler scrubber outlet and bypass
plumes, and the coater and bagging operations baghouse plumes were monitored
during the emission testing program by certified visible emission observers.
All observation locations conformed to the guidelines of EPA Method 9.
The prill tower scrubber outlet plume and the plume from the bypass being
tested for emissions were monitored during each prill tower emission test
run. All outlet opacities were zero, and the bypass 6-minute average opaci-
ties ranged from 0 percent to 8 percent. All the outlet and bypass data are
shown in Tables 2-21 and 2-22, respectively, and the non-zero bypass data are
graphed in Figure 2-13.
The predryer/dryer scrubber outlet plume was monitored during each emis-
sion test run at this location. The 6-minute average opacities ranged from 0
percent to 3 percent; non-zero opacities were observed only during test run
3. All data are shown in Table 2-23, and the non-zero data are graphed in
Figure 2-14.
The cooler scrubber outlet plume was monitored prior to the emission test
runs at the cooler scrubber inlet and bypass and during the first emission
test run at these locations. The 6-minute average opacities ranged from 0
percent to 5 percent. These data are shown in Table 2-24 and are graphed in
Figure 2-15. The cooler bypass plume was monitored just prior to and during
emission test runs 1 and 2 at the scrubber inlet and bypass. All opacities
were zero, and these data are shown in Table 2-25.
The plumes from the coater baghouse outlet and the bagging operation bag-
house outlet were monitored during the prill tower and predryer/dryer emis-
sion test runs. All opacities were zero, and these data are shown in Table
2-26.
-48-
-------
TABLE 2-21
VISIBLE EMISSIONS OBSERVATIONS AT THE PRILL TOWER
SCRUBBER OUTLET DURING LOW DENSITY AMMONIUM NITRATE
Date
8-12-80
8-12-80
CTION AT COLUMBIA NITROGEN
Run Six-Minute
Number Time Period
1 1046 - 1051
^
1052 - 1057
1058 - 1103
1104 - 1109
1110 - 1115
1116 - 1121
1122 - 1127
1128 - 1133
1134 - 1139
1140 - 1145
1147 - 1152
1153 - 1158
1159 - 1204
1205 - 1210
1211 - 1216
1217 - 1222
1223 - 1228
1229 - 1234
1235 - 1240
1241 - 1246
Average
2 1520 - 1525
1
1526 - 1531
1532 - 1537
1538 - 1543
1544 - 1549
1550 - 1555
1556 - 1601
1602 - 1607
1608 - 1613
1614 - 1619
1620 - 1625
1626 - 1631
1632 - 1637
1638 - 1643
1644 - 1649
1650 - 1655
1656 - 1701
1702 - 1707
1708 - 1713
1714 - 1719
Average
Average Opacity Observer
(Percent) Location
0 PT-2
0 30 Feel: E
0 of Outlet
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0 ' PT- 3
0 50 Feet NW
0 of Outlet
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
-49-
-------
TABLE 2-21 (Continued)
Date
8-13-80
VISIBLE EMISSIONS OBSERVATIONS AT THE PRILL TOWER
SCRUBBER OUTLET DURING LOW DENSITY AMMONIUM NITRATE
Average Opacity Observer
(Percent) Location
0 PT-3
0 30 Feet E
0 of Outlet
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0 PT-2
0 30 Feet E
0 of Outlet
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
CTION AT COLUMBIA NITROGEN
Run Six-Minute
Number Time Period
3 0845 - 0850
i
0851 - 0856
0857 - 0902
0903 - 0908
0909 - 0914
0915 - 0920
0921 - 0926
0927 - 0932
0933 - 0938
0939 - 0944
0945 - 0950
0951 - 0956
0957 - 1002
1003 - 1008
1009 - 1014
1015 - 1020
1021 - 1026
1027 - 1032
1033 - 1038
1039 - 1044
1045 - 1050
1051 - 1056
1255 - 1300
1301 - 1306
1307 - 1312
1313 - 1318
1319 - 1324
1325 - 1330
1331 - 1336
1337 - 1342
1343 - 1348
1349 - 1354
1355 - 1400
1401 - 1406
1407 - 1412
1413 - 1418
1419 - 1424
1425 - 1430
1431 - 1436
1437 - 1442
1443 - 1448
1449 - 1454
Average
-50-
-------
TABLE 2-22
VISIBLE EMISSIONS OBSERVATIONS AT THE PRILL TOWER SCRUBBER BYPASSES
Location
Bypass B
Date
8-12-80
Run
Number
Bypass A
AMMONIUM NITRATE PRODUCTION AT
CORPORATION ,
Six-Minute
Time Period
1049 - 1054
1055 - 1100
1101 - 1106
1107 - 1112
1113 - 1118
1119 - 1124
1125 - 1130
1131 - 1136
1137 - 1142
1143 - 1148
1149 - 1154
1155 - 1201
1202 - 1206
1207 - 1212
1213 - 1218
1219 - 1224
1225 - 1230
1231 - 1236
1237 - 1242
1243 - 1248
Average
1520 - 1525
1526 - 1531
1532 - 1537
1538 - 1543
1544 - 1549
1550 - 1555
1556 - 1501
1602 - 1607
1608 - 1613
1614 - 1619
1620 - 1625
1626 - 1631
1632 - 1637
1638 - 1643
1644 - 1649
1650 - 1655
1656 - 1701
1702 - 1707
1708 - 1713
1714 - 1719
Average
AUGUSTA, GEORGIA
Average Opacity
(Percent)
7.7
7.5
7.1
5.6
7.1
4.8
5.8
6.9
6.3
8.3
7.1
6.3
6.0
6.5
6.3
5.2
5.4
6.7
6.9
5.6
6.4
8.3
7.3
7.5
6.7
6.5
6.3
6.5
5.2
5.6
5.4
6.3
7.5
6.0
5.6
5
5
5
5
5
5
6.0
Observer
Location
PT-1
15 Feet SSW
of Bypass
PT-3
25 Feet WNW
of Bypass
-51-
-------
TABLE 2-22 (Continued)
VISIBLE EMISSIONS OBSERVATIONS AT THE PRILL TOWER SCRUBBER BYPASSES
DURING LOW DENSITY AMMONIUM NITRATE PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Location
Bypass C
Date
8-13-80
Run
Number
Six-Minute
Time Period
0952 - 0957
0958 - 1003
1004 - 1009
1010 - 1015
1016 - 1021
1022 - 1027
1028 - 1033
1034 - 1039
1040 - 1045
1046 - 1051
1052 - 1057
1058 - 1103
1104 - 1109
1110 - 1115
1116 - 1121
1122 - 1119
1120 - 1133
1134 - 1139
1140 - 1145
1146 - 1151
Average
Average Opacity
(Percent)
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Observer
Location
PT-1
35 Feet SE
of Bypass
-52-
-------
9.0
8.0
LU
O
o:
III
I-LJ
"7.0
>-
h-
h-H
O
Q.
1 0
Ln
U> UJ
1 ^ 6.0
UJ
et
5.0
4.0
1
_
\
-
-
•
•
-
•
•
1 I 1 l i i I
1
T "1
m n
1 j| L
n *n n
u[ v\ •
— —
BYPASS B BYPASS A
i l l i i i i i
1000
1100
1200
1300 1400 1500
TIME (SIX MINUTE INTERVALS)
1600
1700
1800
FIGURE 2-13: VISIBLE EMISSIONS OBSERVATIONS AT THE PRILL TOWER SCRUBBER
BYPASSES DURING LOW DENSITY AMMONIUM NITRATE PRODUCTION
AT COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA ON
AUGUST 12, 1980.
1430-E01
-------
TABLE 2-23
VISIBLE EMISSIONS OBSERVATIONS AT THE PREDRYER/DRYER SCRUBBER OUTLET
Date
8-14-80
Run
Number
8-14-80
Six-Minute
Time Period
1105 - 1110
1111 - 1116
1117 - 1122
1123 - 1128
1129 - 1134
1135 - 1140
1141 - 1146
1147 - 1152
1153 - 1158
1159 - 1204
1205 - 1210
1211 - 1216
1217 - 1222
1223 - 1228
1229 - 1234
1235 - 1240
1241 - 1246
1247 - 1252
1253 - 1258
1259 - 1304
Average
1510 - 1515
1516 - 1521
1522 - 1527
1528 - 1533
1534 - 1539
1540 - 1545
1546 - 1551
1552 - 1557
1558 - 1603
1604 - 1609
1610 - 1615
1616 - 1621
1622 - 1627
1628 - 1633
1634 - 1639
1640 - 1645
1646 - 1651
1652 - 1657
1658 - 1703
1704 - 1709
Average
TITRATE PRODUCTION AT
3N, AUGUSTA, GEORGIA
Average Opacity
(Percent)
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Observer
Location
PD-1
125 Feet
SE
of Outlet
PD-2
125 Feet
S
Outlet
-54-
-------
TABLE 2-23 (Continued)
VISIBLE EMISSIONS OBSERVATIONS AT THE PREDRYER/DRYER SCRUBBER OUTLET
DURING LOW DENSITY AMMONIUM NITRATE PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Date
8-14-80
Run
Number
Six-Minute
Time Period
1710 - 1715
1716 - 1721
1722 - 1727
1728 - 1733
1734 - 1739
1740 - 1745
1746 - 1751
1752 - 1757
1758 - 1803
1804 - 1809
1810 - 1815
1816 - 1821
1822 - 1827
1828 - 1833
1834 - 1839
1840 - 1845
1846 - 1851
1852 - 1857
1858 - 1903
1904 - 1909
Average
Average Opacity
(Percent)
0.6
2.3
3.1
1.5
0.8
1.5
0
0.2
0.6
0.2
0
0
0
0
0
0
0
0
0
0
0.5
Observer
Location
PD-2
125 Feet
S of
Outlet
-55-
-------
5.0
4.0
C£
LU
o.
-------
TABLE 2-24
VISIBLE EMISSIONS OBSERVATIONS AT THE PRILL COOLER SCRUBBER OUTLET
Date
8-14-80
Run*
Number
8-15-80
Six-Minute
Time Period
1450 - 1455
1456 - 1501
1502 - 1507
1508 - 1513
1514 - 1519
1520 - 1525
1526 - 1531
1532 - 1537
1538 - 1543
1544 - 1549
1550 - 1555
1556 - 1501
1602 - 1607
1608 - 1613
1614 - 1619
1620 - 1625
1626 - 1631
1632 - 1637
1638 - 1643
1644 - 1649
Average
1100
1106
1112
1118
1124
1130
1136
1142
1148
1154
1105
1111
1117
1123
1129
1135
1141
1147
1153
1159
ETRATE PRODUCTION AT
*, AUGUSTA, GEORGIA
Average Opacity
(Percent)
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
0
0
0
0
0
0
0
0
0
0
Observer
Location
PC-1
35 Feet
NE
of Outlet
PC-1
35 Feet
NE
of Outlet
-57-
-------
TABLE 2-24 (Continued)
VISIBLE EMISSIONS OBSERVATIONS AT THE PRILL COOLER SCRUBBER OUTLET
DURING LOW DENSITY AMMONIUM NITRATE PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Date
8-15-80
Run
Number
Six-Minute
Time Period
1200 - 1205
1206 - 1211
1212 - 1217
1218 - 1223
1224 - 1229
1230 - 1235
1236 - 1241
1242 - 1247
1248 - 1253
1254 - 1259
Average**
Average Opacity
(Percent)
0
0
0
0
0
1.9
5
5
5
5
2.2
Observer
Location
PC-1
35 Feet
NE
of Outlet
*Run number of concurrent inlet and bypass emission tests.
**Average for 1200 - 1259 observation period.
-58-
-------
5.0
4.0
o
(£.
3.0
_
-------
TABLE 2-25
VISIBLE EMISSIONS OBSERVATIONS AT THE PRILL COOLER SCRUBBER BYPASS
DURING LOW DENSITY AMMONIUM NITRATE PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Date
8-15-80
Run
Number
8-15-80
8-15-80
Six-Minute
Time Period
1100 - 1105
1106 - 1111
1112 - 1117
1118 - 1123
1124 - 1129
1130 - 1135
1136 - 1141
1142 - 1147
1148 - 1153
1154 - 1159
Average
1210 - 1215
1216 - 1221
1222 - 1227
1228 - 1233
1234 - 1239
1240 - 1245
1246 - 1251
1252 - 1257
1258 - 1303
1304 - 1309
Average
1545 - 1550
1551 - 1556
1557 - 1602
1603 - 1608
1609 - 1614
1615 - 1620
1621 - 1626
1627 - 1632
1633 - 1638
1639 - 1644
Average
Average Opacity
(Percent)
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Observer
Location
PC-3
15 Feet
N
of Bypass
PC-3
15 Feet
N
of Bypass
PC-2
45 Feet
E
of Bypass
-60-
-------
TABLE 2-26
VISIBLE EMISSIONS OBSERVATIONS AT THE COATER AND BAGGING BAGHOUSE
Coater Baghouse
en
M
i
Date
8-13-80
8-13-80
8-13-80
Six-Minute
Time Period
0845 - 0850
0851 - 0856
0857 - 0902
0903 - 0908
0909 - 0914
0915 - 0920
0921 - 0926
0927 - 0932
0933 - 0938
0939 - 0944
Average
1255 - 1300
1301 - 1306
1307 - 1312
1313 - 1318
1319 - 1324
1325 - 1330
1331 - 1336
1337 - 1342
1343 - 1348
1349 - 1354
1355 - 1359
Average
1355 - 1400
1401 - 1406
1407 - 1412
1413 - 1418
1419 - 1424
1425 - 1430
1431 - 1436
1437 - 1442
1443 - 1448
1449 - 1454
Average
Average Opacity
(Percent)
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Observer
Location
CB-1
20 Feet
ENE
of Outlet
CB-2
40 Feet
SE
of Outlet
CB-2
40 Feet
SE
of Outlet
ONIUM NITRATE PRODUCTION AT
TION, AUGUSTA, GEORGIA
Bagging Baghouse
Six-Minute Average Opacity
Date
8-14-80
8-14-80
8-14-80
Time Period
1014 - 1019
1020 - 1025
1026 - 1031
1032 - 1037
1038 - 1043
1044 - 1049
1050 - 1055
1056 - 1101
1102 - 1107
Average
1123 - 1128
1129 - 1134
1135 - 1140
1141 - 1146
1147 - 1152
Average
1235 - 1240
1241 - 1246
1247 - 1252
1253 - 1258
1259 - 1304
1305 - 1310
1311 - 1316
1317 - 1322
1323 - 1328
1329 - 1334
1335 - 1340
1341 - 1346
1347 - 1352
1353 - 1358
Average
(Percent)
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Observer
Location
BG
100 Feet
SB
of Outlet
BG
100 Feet
SE
of Outlet
BG
100 Feet
SE
of Outlet
-------
2.6 Scrubber Liquor Analyses
Samples of the prill tower Brinks scrubber liquor were collected periodi-
cally from the recirculation stream during each prill tower emission test
run. Samples of the predryer/dryer Peabody scrubber liquor were collected
periodically from the sprayer feed line during each emission test run at this
location. The temperature of each sample was measured immediately after col-
lection, and when the sample reached room temperature its pH was measured.
After each emission test run, the liquor samples collected during that run
were combined into one composite sample. The composite samples were then
analyzed for AN, ammonia, and undissolved solids. Summaries of the prill
tower scrubber and predryer/dryer scrubber liquor analyses are shown in
Tables 2-27 and 2-28, respectively.
2.7 Scrubber Pressure Drop Measurements
Pressure drops across the prill tower scrubber were measured periodically
during each prill tower emission test run. During each test run, one side of
a vertical U-tube water manometer was connected to a tap in the inlet duct
being tested for emissions. The other side of the manometer was open to the
atmosphere. An exception to this procedure occurred during test run 2 when
the manometer was left in inlet B while inlet A was tested for emissions.
During run 3, pressure drops were measured at inlets C and A. All pressure
drop measurement data are shown in Table 2-29.
2.8 Ambient Air Measurements
The temperature and relative humidity of the ambient air were measured
periodically during all emission test runs in the immediate vicinity of each
process unit of concern. These data for the prill tower, predryer/dryer, and
cooler test runs are shown in Tables 2-30, 2-31, and 2-32, respectively.
-62-
-------
TABLE 2-27
SUMMARY OF MEASUREMENTS ON THE PRILL TOWER SCRUBBER
LIQUOR DURING LOW DENSITY AMMONIUM NITRATE PRODUCTION
AT COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Date
8-12-80
8-12-80
8-13-80
Run Sampling
Number Time
1 1100
1130
1200
1230
1300
Average
2 1530
1600
1630
1700
1730
1800
Average
3 0900
0930
1000
1030
1100
Average
JESl
4.40
3.88
3.95
3.65
4.42
4.06
5.88
5.70
4.75
5.22
5.70
4.92
5.36
4.22
3.72
3.88
4.05
3.50
3.87
Temp.
(°F)
91
92
92
93
92
92
93
94
92
92
93
92
93
90
90
92
92
92
91
Ammonium
Nitrate**
73.4
76.6
71.8
Measurements on Composite Samples (ppm)
Undissolved
Ammonia** Solids***
17.6
26.0
18.0
56.6
17.6
46.2
* pH measured at room temperature (75°F).
** Specific Ion Electrode Analysis Procedure
*** Milligrams/Liter
-63-
-------
TABLE 2-28
SUMMARY OF MEASUREMENTS ON THE PRILL DRYER SCRUBBER
LIQUOR DURING LOW DENSITY AMMONIUM NITRATE PRODUCTION
AT COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Date
8-14-80
Run
Number
8-14-80
8-14-80
Sampling
Time
1030
1100
1130
1200
1230
Average
1500
1530
1600
1630
1700
1730
Average
1800
1830
1900
1930
1200
Average
6.32
6.38
6.32
6.32
6.32
6.33
Temp.
Measurements on Composite Samples (ppm)
Ammonium Undissolved
Nitrate** Ammonia** Solids***
6.45
6.45
6.25
6.20
6.12
6.29
100
96
98
102
104
100
570
136
44.7
6.15
6.55
6.58
6.55
6.58
6.40
6.47
106
104
103
104
102
102
104
645
156
20.1
103
103
103
103
103
103
677
168
8.3
* pH measured at room temperature (75°F).
** Specific Ion Electrode Analysis Procedure
***
Milligrams/Liter
-64-
-------
TABLE 2-29
SUMMARY OF PRESSURE DROP MEASUREMENTS MADE ACROSS
THE PRILL TOWER SCRUBBER DURING LOW DENSITY
AMMONIUM NITRATE PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Date
8-12-80
8-12-80
Ul
Run
Location Number Time
B Inlet 1 1100
1130
1200
1230
1300
Average
B Inlet* 2 1530
1600
1630
1700
1730
1800
Average
Pressure Drop Run Pressure Drop
(inches H2O)
1.8
1.6
1.6
1.6
1.6
1.6
1.4
1.4
1.6
1.6
1.6
1.4
1.5
Date Location Number Time (inches H-jO)
8-13-80 C Inlet 3 0900
0930
1000
1030
1100
1130
Average
8-13-80 A Inlet 3 0900
0930
1000
1030
1100
1130
Average
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
*Run 2 emission test was performed on Inlet A. Pressure drops were measured at Inlet B during this run.
-------
TABLE 2-30
SUMMARY OF AMBIENT AIR MEASUREMENTS MADE DURING
EMISSIONS TEST AT THE PRILL TOWER AT COLUMBIA NITROGEN CORPORATION,
AUGUSTA, GEORGIA
Date
8-12-80
8-12-80
en
en
Run
Number
1
2
Time
1000
1100
1130
1200
1230
1300
Average
1530
1600
1630
1700
1730
1800
Average
Ambient
Temp (°F)
85
87
89
91
92
93
90
95
95
96
94
95
94
95
Relative
Humidity (%)
70
64
58
53
50
49
57
44
44
44
47
44
44
45
Run
Date Number Time
8-13-80 3 0900
0930
1000
1030
1000
1130
Average
Ambient
Temp (°F)
82
82
84
86
87
87
85
Relative
Humidity (%)
72
74
73
66
64
58
68
-------
TABLE 2-31
SUMMARY OF AMBIENT AIR MEASUREMENTS MADE DURING
EMISSIONS TESTS AT THE PREDRYER/DRYER AT COLUMBIA NITROGEN CORPORATION,
AUGUSTA, GEORGIA
Run
Date Number Time
8-14-80 1 1030
1100
1130
1200
1230
1300
1330
Average
8-14-80 2 1500
I 1530
5 . 1600
1 1630
1700
1730
Average
Ambient
Temp (°F)
87
89
90
93
93
95
96
92
96
97
93
95
94
93
95
Relative
Humidity (%)
67
61
59
51
54
50
47
56
42
41
49
44
49
51
46
Date
8-14-80
Run
Number
3
Time
1800
1830
1900
1930
2000
Average
Ambient
Temp (°F)
93
92
92
92
92
92
Relative
Humidity (%)
51
54
54
54
54
53
-------
TABLE 2-32
SUMMARY OF AMBIENT AIR MEASUREMENTS MADE DURING
EMISSIONS TESTS AT THE PRILL COOLER AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Date
8-15-80
8-16-80
Run
Number
1
2
3
Time
1100
1130
1200
1230
1300
1330
1400
1430
Average
1500
1530
1600
1630
1700
1730
Average
0900
0930
1000
1030
1100
1130
1200
Average
Ambient
Temp (°F)
84
86
86
87
90
90
91
91
88
91
91
90
89
89
87
90
78
79
83
85
85
85
87
83
Relative
Humidity (%)
77
70
74
70
62
62
59
59
67
59
59
62
61
61
67
62
91
87
76
70
73
73
67
77
-68-
-------
2.9 Volumetric Flowrates through the Prill Tower
Emissions were measured at one scrubber inlet, one bypass, and the scrub-
ber outlet during each prill tower emission test run. At the beginning and
end of a given test run velocity traverses were performed at the two inlets
and two bypasses not being tested for emissions. With the velocity traverse
data, flowrates through all three inlets and all three bypasses during each
test run were calculated. The scrubber inlet flowrates and bypass flowrates
are shown in Tables 2-33 and 2-34, respectively.
Emission test run 2 was begun within one hour after the completion of run
1. Under the direction of the Technical Manager the run 1 "after" traverses
at inlet C and bypass C were used as the run 2 "before" traverses. No run 2
"before" traverses were performed at inlet B and bypass B because of time
constraints in completing the run 1 emission tests at these B locations.
The average total flowrate through the scrubber inlets was approximately
47,000 dry standard cubic feet per minute (DSCFM). The average total flow-
rate through the bypasses was approximately 214,000 DSCFM.
-69-
-------
TABLE 2-33
FLOWRATES* THROUGH THE PRILL TOWER SCRUBBER INLETS
DURING LOW DENSITY AMMONIUM NITRATE PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Location
Time
8-12-80
Run 1
8-12-80
Run 2
8-13-80
Run 3
Inlet B
Inlet A
Inlet C
Total0
During
Before3
Afterb
Average
During
Before
After
Average
During
Before
After
Average
15,300
16,261
15,527
15,894
15,805
16,272
16,039
**
15,552
15,552
16,070
47,200
16,258
15,566
15,912
47,500
16,088
16,495
16,291
15,250
46,200
c
*
**
Flowrates calculated from velocity traverse performed before the
indicated run.
Flowrates calculated from velocity traverse performed after the
indicated run.
Sum of during and average values, rounded to nearest 100 DSCFM.
Dry Standard Cubic Feet per minute @ 68°F, 29.92 inches Hg.
Velocity traverse not performed because emission test in inlet had
not been completed.
-70-
-------
TABLE 2-34
FLOWRATES* THROUGH THE PRILL TOWER SCRUBBER BYPASSES
DURING LOW DENSITY AMMONIUM NITRATE PRODUCTION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
8-12-80 8-12-80 8-13-80
Location Time Run 1 Run 2 Run 3
Bypass B During 79,220
Before3 ** 72,087
Afterb 72,919 70,976
Average 72,919 71,531
Bypass A During 75,360
Before 69,836 67,129
After 68,894 68,784
Average 69,365 67,956
Bypass C During 71,930
Before 66,353 67,371
After 68,187 67,593
Average 67,270 67,482
Total0 216,000 216,000 211,000
aFlowrates calculated from velocity traverse performed before the indicated run.
"Flowrates calculated from velocity traverse performed after the indicated run.
cSum of during and average values, rounded to nearest 1000 DSCFM.
*Dry Standard Cubic Feet per minute @ 68°F, 29.92 inches Hg.
**Velocity traverse not performed because emission test in inlet had not been
completed.
-71-
-------
3.0 PROCESS DESCRIPTION AND OPERATIONS
Emission tests were performed at Columbia Nitrogen Corporation (CNC) in
Augusta, Georgia during August 11 through 16, 1980, to characterize emissions
from a low density prilling process. Emission data was obtained for the
development of a new source performance standard for the ammonium nitrate
(AN) manufacturing industry.
The tests were designed to characterize and quantify uncontrolled emis-
sions from solids production facilities (prill tower, predryer, dryer, and
)
cooler) and to determine control equipment efficiency. Also, visible emis-
sions were observed from the bagging and coater discharge stacks. A flow
diagram of the solids formation and finishing process is presented in Figure
3-1.
3.1 Process Equipment
A description of process operation and equipment used in the production
of low density prills is presented below. This report deals only with emis-
sions from solids formation and finishing equipment; therefore, only these
solids production facilities are discussed.
The solid ammonium nitrate is produced in a prill tower which is designed
to produce both high and low density prills. The type of product produced
depends upon the concentration of the AN melt used. A 99.8 percent AN melt
is used to produce high density prills, and a 96 percent AN melt is used to
produce low density prills.
During this testing program low density prills were being produced. The
96 percent AN melt is delivered from the evaporators to the top of the prill
tower where a spinning bucket receives the melt. The bucket rotates to force
a stream of melt through orifices in the bucket. The melt stream breaks up
-72-
-------
CO
I
MONSANTO BRINKS 1 I
MIST ELIMINATOR | |
FROM
EVAPORATOR
COOLING AIR '
i
1
|
1 T H—
PRILL
TOWER
BYPASS
-SHROUD 4 ft'
PPEABODV OUCON fh f^BAGHOUSE ^
SCRUBBER SCRUBBER (I . ^yBAGHUUSE 1
. I , j I •
1 ! * i .
_ fontflpY DRUM •*- '"HROTARY DRUMH— fll" ^i1" j crp'FrHs 1 »
fcREDRYER M DRYER 1 * LUULL" »| ^trfLLna |
i ! |
COOLING AIR T
OFFSIZE PRODUCT
RECYCLE
> I
JBAGHOUSE BAGHOUSEM
r~n CLAY
1 IBIN
ROTARY DRUMl *1_|
COATER 1 ^~^J
BULK
LOADING
FIGURE 3-1: SCHEMATIC OF LOW DENSITY PRILLING PROCESS AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
-------
into discrete droplets as it falls through the tower. Four fans located at
the top of the prill tower create a countercurrent airflow which cools the
falling droplets. The prills are conveyed from the bottom of the tower to
the finishing units: the predryer, dryer, and cooler.
The finishing operation both removes excess moisture and cools the
prills. The low density prills are first conveyed to a rotary drum predryer,
where moisture is removed. They are then conveyed to a rotary drum dryer
where more moisture is removed. Finally, a fluidized-bed cooler is used to
remove nominal amounts of moisture and to cool the prills.
The cooled prills are then screened to yield a properly sized product.
The offsize prills are redissolved and recycled to the melt concentration
process. The product-sized prills are coated in a rotary drum coater with
kaolin (clay) which prevents the solids from becoming moist and caking. The
coated product is then either bulk shipped or bagged.
3.2 Emission Control Equipment
Emissions from the prill tower are controlled with a collection device
(shroud) within the tower and a Monsanto HE Brinks mist eliminator located
atop the tower. The tower is equipped with four fans which draw air through
the tower. Three bypass fans are located at the top of the tower along the
periphery, and the other fan is located at the top of the tower after the
mist eliminator. The inlets to the mist eliminator are located within the
collection device. The stainless steel collection device surrounds the spin-
ning bucket. Since most of the fuming and ammonium nitrate emissions occur
as the melt exits the bucket, the collection device captures a large portion
of the emissions and ducts this portion to the mist eliminator. The air that
does not get ducted to the mist eliminator is discharged through the three
bypass stacks.
-74-
-------
The Brinks mist eliminator contains atomizing sprays and spray catcher
elements to remove large participates, and high efficiency elements to remove
fine particulates. The liquor for the sprays comes from the evaporator con-
densate. The liquor is pH adjusted with nitric acid to maintain the pH near
neutral; otherwise, the fiberglass filter elements would corrode. The liquor
is recycled through the Brinks until it reaches an AN concentration near 5
percent. The liquor is then recycled to the AN solution formation process.
Emissions from the rotary drum predryer and dryer are combined and ducted
to a single Peabody tray scrubber. The fluidized-bed cooler uses two inlet
air streams to cool the prills. One of these air streams is discharged to a
Ducon mechanical impingement scrubber, and the other stream is vented direct-
ly to the atmosphere.
Emissions from the screening operation are ducted to a baghouse fabric
filter. Rotary drum coater and bagging operation emissions are also control-
led by a baghouse. The clay dust captured by the fabric filters is returned
to the clay storage bins and is reused.
3.3 Production and Control Equipment Monitoring
During the emission testing program several process parameters were moni-
tored to determine if the process was operating normally. Prill temperatures
and moisture; melt temperatures and flowrates; scrubber pressure drop; scrub-
ber liquor concentration, flowrate and pH; fan amperage, and production rate
were monitored. These data are presented in Appendix P. Due to confiden-
tiality claims by CNC, only scrubber pressure drops; fan amperage; scrubber
liquor pH, flowrate and concentration; and production rates are presented in
this section. These parameters are summarized in Tables 3-1 through 3-3.
-75-
-------
TABLE 3-1
SUMMARY OF PRODUCTION RATES AND SCRBUBER OPERATING PARAMETERS
DURING PRILL TOWER MASS EMISSION AND PARTICLE SIZE TESTS AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Production Rate
Test Type*
Location of Test and Number
Prill Tower Scrubber ME 1
Inlet, Outlet and
Bypass ME 2
ME 3
Prill Tower PS 1
1 Scrubber Inlet
oi PS2
1
PS 3
Prill Tower PS 1
Scrubber Bypass
PS 2
PS 3
Prill Tower
Mg/Hr
28.7
28.7
30.2
30.6
27.1
27.1
29.2
27.1
27.1
(TPH)
(31.6)
(31.6)
(33.3)
(33.7)
(29.9)
(29.9)
(32.2)
(29.9)
(29.9)
Scrubber
Final Product* Pressure Drop
Mq/Hr
21.1
22.2
23.1
21.9
16.9
20.1
20.0
19.0
16.5
(TPH) kPa in. H2o
(23.3) 3.4 13.7
(24.5) 3.5 14.2
(25.5) 3.4 13.6
(24.1)
(18.6)
(22.1)
(22.0)
(20.9)
(20.4)
Parameters (Brinks Mist Eliminator)
Fan Flow Pressure
Amperage pll % AN kPa psi
34 3.8 7.2 359 52
34 5.7 7.4 365 53
34 3.4 7.2 359 52
*ME = Mass Emission Test
PS = Particle Size Test
^ Corrected to remove coating material.
-------
TABLE 3-2
StMMARY OF PRODUCTION RATES AND SCRUBBER OPERATING PARAMETERS
DURING PREDRYER AND DRYER MASS EMISSION AND PARTICLE SIZE TESTS AT
COLUMBIA NITROGEN CORPORTION, AUGUSTA, GEORGIA
-J
^1
I
Production
Prill Tower
Location of
Test Test Type and Number* Mg/Hr
Predryer Scrubber Inlet
Dryer Scrubber Inlet ME 1
Predryer and Dryer Scrubber
Outlet
Predryer
Outlet
Predryer
Outlet
and Dryer
and Dryer
Dryer Scrubber
Dryer Scrubber
Dryer Scrubber
Predryer
Predryer
Predryer
Scrubber
ME 2
Scrubber
ME 3
Inlet PS 1
Inlet PS 2
Inlet PS 3
Scrubber
Scrubber
Scrubber
Inlet PS 1
Inlet PS 2
Inlet PS 3
30.3
27.1
27.4
27.1
27.1
27.1
27.1
27.1
27.1
(TPH)
(33.
(29.
(30.
(29.
(29.
(29.
(29.
(29.
(29.
4)
9)
2)
9)
9)
9)
9)
9)
9)
Rate
Final Produc
Mq/Hr
20.
19.
18.
18.
18.
18.
20.
20.
20.
0
9
5
7
7
4
5
5
5
Scrubbi
t1
;r Parameters (Pcabody Tray Scrubber)
Liquor Flowrate
(TPH) MJ/min (qpm)
(22.
(20.
(20.
(20.
(20.
(20.
(22.
(22.
(22.
0)
9)
1)
6)
6)
3)
6)
6)
6)
.035 (9.3)
.069 (IB. 3)
.049 (12.9)
* ME = Mass Emission Test
PS = Particle Size Test
' Corrected to remove coating material.
-------
TABLF 3-3
SUMMARY OF PRODUCTION RATES AND SCRUBBER OPERATING PARAMETERS
DURING COOLER MASS EMISSION AND PARTICLE SIZE TESTS AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
00
I
Production
Prill
Tower
Rate
Final Product1 Scrubber Liauor Parameters
Liquor Flowrate
location of Test
Cooler Scrubber Inlet
and Bypass
Cooler Scrubber Inlet
Cooler Scrubber Bypass
Cooler Scrubber Inlet
Test Type and Number*
ME 1
ME 2
ME 3
ME 2 (final Traverse)
PS 1
PS 2
PS 3
PS 1
PS 2
PS 3
Mo/Hr
27.1
27.1
27.1
27.1
28.7
28.7
30.1
30.0
30.3
30.3
(TPH)
(29.9)
(29.9)
(29.9)
(29.9)
(31.6)
(31.6)
(33.2)
(33.1)
(33.4)
(33.4)
Mg/Hr
19.1
18.5
20.3
20.5
22.0
22.3
22.7
24.2
24.1
24.1
(TPH) pH % AN MJ/min
(21.0) 7.0 42.2 0.24
(20.4) 6.8 50.1 .016
(22.4) 6.9 38.6 .020
(22.6) 6.9 38.6 .020
(24.3)
(24.6)
(25.0)
(2*. 7)
(26.6)
(26.6)
gpm
(6.3)
(4.3)
(5.2)
(5.2)
* ME = Mass Emission Test
PS = Particle Size Test
1 Corrected to remove coating material.
-------
Scrubber operating parameters were only monitored during the emission
tests; therefore, for the particle size tests only production rates are
reported. Operating parameters monitored during prill tower, predryer/dryer,
and cooler tests are presented in Tables 3-1, 3-2, and 3-3, respectively. As
can be seen from the tables, different operating variables are presented for
each scrubber. This is due to inconsistencies in the plant scrubber monitor-
ing techniques.
3.4 Process Operation During Testing
A review of the operating logs during testing revealed that during the
test period there were no anomalies in process operation that affected emis-
sions. Slight variations in operations which occurred were all within normal
operative conditions.
A few minor problems did occur. At 9:00 a.m. on August 13, 1980, there
was a ten minute decrease in production due to steam loss in the evaporator.
On August 14, 1980 the system was down at 8:00 a.m., and was returned to
normal operation at 9:30 a.m. Also on August 14, 1980 at 1:30 p.m. ammonium
nitrate production was cut back five percent. The bucket elevator conveying
prills from the prill tower to the dryers broke down during the second cooler
emission test late in the afternoon of August 15, 1980. As a result, this
test was completed the following morning. *
-79-
-------
4.0 LOCATION OF SAMPLING POINTS
This section presents descriptions of the sampling locations used during
the emissions testing program conducted at the Columbia Nitrogen Corporation
ammonium nitrate plant in Augusta, Georgia in August 1980. An overhead view
of the plant site and pertinent process facilities is shown in Figure 4-1.
An overhead schematic of the prill tower is shown in Figure 4-2.
4.1 Prill Tower
4.1.1 Scrubber Inlets - AN Sampling and Velocity Traverses
The three prill tower scrubber inlet sampling locations were each located
in 32 1/2-inch ID vertical sections of stainless steel duct. A schematic of
one of the three identical inlets is shown in Figure 4-3.
Two 4-inch holes cut through the duct wall were used as sampling ports.
These ports were positioned 90 degrees apart in a horizontal plane and were
located 12 inches (0.4 duct diameters) upstream from an elbow leading to the
scrubber and 27 inches (0.8 duct diameters) downstream from a flow straight-
ening baffle. The inlet locations did not meet the "eight and two diameters"
criteria of EPA Method 1. For the AN sampling tests, 24 sampling points were
used on each of the two traverse axes, for a total of 48 sampling points in
each inlet. For the velocity traverses, 14 sampling points were used on each
axis, for a total of 28 sampling points. Figure 4-3 shows a cross-sectional
view of an inlet duct at the sampling location, and shows the exact distance
of each sampling point from the duct wall for both the AN sampling and the
velocity traverses.
4.1.2 Bypasses - AN Sampling and Velocity Traverses
The three prill tower scrubber bypass sampling locations were each locat-
ed in 59 1/4-inch ID vertical sections of stainless steel duct. A schematic
-80-
-------
03
H
BB
OUTLET
BAGGING OPERATION
BULK
STORAGE
PD-1
A
PD-2
A
PREDRYER/
DRYER
SCRUBBER
OUTLET
AN
BUILDING
SCRUBBER
["OUTLET
COOLER
BYPASS
//
SCREENING
AREA
COOLER AIR
" INTAKES
I
FIELD
LABORATORY
A AMBIENT AIR
* MEASUREMENT LOCATIONS
A VISIBLE EMISSION
OBSERVER LOCATIONS
(See Table 4-2
for Codes)
AN
CONTROL
BUILDING
NOT TO SCALE
FIGURE 4-1: LAYOUT OF AMMONIUM NITRATE PRODUCTION FACILITIES
AT COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
1430-E16
-------
AN BUILDING
^-^
INLET A
VISIBLE EMISSION
OBSERVER LOCATIONS
(SEE TABLE 4-1 FOR
CODES)
AMBIENT AIR
TEMPERATURE
MEASUREMENT •
LOCATIONS
LADDER
FIGURE 4-2: OVERHEAD VIEW OF PRILL TOWER AT COLUMBIA
NITROGEN CORPORATION, AUGUSTA, GEORGIA
1430-E04
-82-
-------
32V
I.D.
EAST
INLET A,B)
WEST
(INLET C)
FLOOR
SOUTH (INLET A,B )
NORTH (INLET C)
NOT TO SCALE
TRAVERSE POINT LOCATIONS
PARTI CULATE TESTS
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
TRAVERSE POINT
LOCATION FROM
OUTSIDE OF DUCT
(INCHES)
1.0
1.0
1.8
2.6
3.4
4.3
5.2
6.3
7.5
8.8
10.5
12.9
19.6
22.0
23.7
25.0
26.2
27.3
28.2
29.1
29.9
30.7
31.5
31.5
VELOCITY TESTS
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
TRAVERSE POINT
LOCATION FROM
OUTSIDE OF DUCT
(INCHES)
1.0
1.9
3.2
4.8
6.5
8.7
11.9
20.6
23.8
26.0
27.8
29.3
30.7
31.5
FIGURE 4-3: PRILL TOWER SCRUBBER INLET SAMPLING LOCATION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
1430-E05
-83-
-------
of one of the three identical bypasses is shown in Figure 4-4.
Two 4-inch holes cut through the duct wall were used as sampling ports.
These ports were positioned 90 degrees apart in a horizontal plane and were
located 6 feet (1.2 duct diameters) upstream from a barometric damper, and 20
feet 10 inches (4.2 duct diameters) downstream from an axial fan. The bypass
locations did not meet the "eight and two diameters" criteria of EPA Method
1. For the AN sampling tests, 18 sampling points were used on each traverse
axis, for a total of 36 sampling points in each bypass. For the velocity
traverses, 12 sampling points were used on each traverse axis, for a total of
24 sampling points. Figure 4-4 shows a cross-sectional view of a bypass duct
at the sampling location, and shows the exact distance of each sampling point
from the duct wall for both the AN sampling and the velocity traverses.
4.1.3 Scrubber Outlet - AN Sampling
The prill tower scrubber outlet sampling location was located in a 48
1/2-inch ID vertical section of stainless steel duct. A schematic of the
outlet is shown in Figure 4-5.
Two 4-inch pipe flange sampling ports (extending 8 inches from th€i stack
wall) were positioned 90 degrees apart in a horizontal plane. The ports were
located 8 feet (2 duct diameters) upstream from the top of the stack and 16
feet 6 inches (4.1 duct diameters) downstream from a bend leading from the
outlet blower. Since the outlet sampling location did not meet the "eight
and two diameters" criteria of EPA Method 1, 18 sampling points were used on
each traverse axis, for a total of 36 sampling points. Figure 4-5 shows a
cross-sectional view of the outlet duct at the sampling location, and shows
the exact distance of each sampling point from the outside flange edge.
-84-
-------
•59V
9'
O D--
T
CO
FAN
FLOOR-
20'-10"
SOUTH
I BYPASS A,B)
19TA NORTH
T( BYPASS C)
WEST (BYPASS A.B.C)
NOT TO SCALE
TRAVERSE POINT LOCATIONS
PARTI CULATE TESTS
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
TRAVERSE POINT
LOCATION FROM
OUTSICE OF DUCT
(INCHES)
1.0
2.6
4.5
6.5
8.7
11.2
14.0
17.6
22.7
36.8
41.9
45.5
48.3
50.8
53.0
55.0
56.9
58.5
VELOCITY TESTS
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
TRAVERSE POINT
LOCATION FROM
OUTSIDE OF DUCT
(INCHES)
1.3
4.0
7.0
10.5
14.9
21.2
38.3
44.6
49.0
52.5
55.5
58.3
FIGURE 4-4: PRILL TOWER BYPASS SAMPLING LOCATION AT
COLUMBIA NITROGEN CORPORATION
AUGUSTA, GEORGIA
1430-E06
-85-
-------
FROM
BRINKS
SCRUBBER
56".
i
NOT TO SCALE
TRAVERSE POINT LOCATIONS
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
TRAVERSE POINT
LOCATION FROM
OUTSIDE OF DUCT
(INCHES)
8.5
9.6
11.1
12.8
14.6
16.6
19.0
21.9
26.0
37.5
41.6
44.6
46.9
48.9
50.7
52.4
53.9
55.0
FIGURE 4-5: PRILL TOWER SCRUBBER OUTLET SAMPLING LOCATION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
1430-E07
-86-
-------
4.2 Prill Dryers - AN Sampling
4.2.1 Scrubber Inlet from the Predryer
The scrubber inlet-from-the-predryer sampling location was a 48-inch
section of stainless steel duct positioned approximately 30 degrees from the
vertical. A schematic of this duct is shown in Figure 4-6.
Two 4-inch holes cut through the duct wall were used as sampling ports.
These ports were positioned 90 degrees apart in a plane perpendicular to the
duct axis. The ports were 38 inches (0.8 duct diameters) downstream from a
right angle bend (where the duct goes through the AN building wall) and 16
inches (0.3 duct diameters) upstream from another right angle bend leading to
the scrubber. Since this sampling location did not meet the "eight and two
diameters" criteria of EPA Method 1, 24 sampling points were used on each
traverse axis/ for a total of 48 sampling points. Figure 4-6 shows a cross-
sectional view of this duct at the sampling location, and shows the exact
distance of each sampling point from the duct wall.
4.2.2 Scrubber Inlet from the Dryer
The scrubber inlet-from-the-dryer sampling locations was in a 53 1/2-inch
ID section of stainless steel duct positioned approximately 30 degrees from
the vertical. A schematic of this duct is shown in Figure 4-7.
Two 4-inch holes cut through the duct wall were used as sampling ports.
These ports were positioned 90 degrees apart in a plane perpendicular to the
duct axis. The ports were 6 feet upstream from a bend leading to the scrub-
ber and 12 feet downstream from a bend (where the duct goes through the AN
building wall). Since this sampling location did not meet the "eight and two
diameters" criteria of EPA Method 1, 22 sampling points were used on each
-87-
-------
FROM
PREDRYER
H-48"—|
TO
SCRUBBER-*-
FAN
PORT A
(NORTH)
PORT B
(EAST)
NOT TO SCALE
TRAVERSE POINT LOCATIONS
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
TRAVERSE POINT
LOCATION FROM
OUTSIDE OF DUCT
(INCHES)
1.0
1.5
2.6
3.8
5.0
6.3
7.7
9.3
11.0
13.0
15.5
19.1
28.9
32.5
34.9
37.0
38.7
40.3
41.7
43.0
44.2
45.4
46.5
47.0
FIGURE 4-6:
PREDRYER INLET-TO-SCRUBBER SAMPLING LOCATION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
1430-EOS
-88-
-------
NOT TO SCALE
TO
SCRUBBER
FAN
TRAVERSE POINT LOCATIONS
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
TRAVERSE POINT
LOCATION FROM
OUTSIDE OF DUCT
(INCHES)
1.0
1.9
3.2
4.7
6.2
7.8
9.6
11.7
14.0
16.9
21.0
32.5
36.7
39.5
41.8
43.9
45.7
47.3
48.9
50.3
51.6
52.5
FIGURE 4-7: DRYER INLET-TO-SCRUBBER SAMPLING LOCATION
AT COLUMBIA NITROGEN CORPORATION,
AUGUSTA, GEORGIA
1430-E09
-89-
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traverse axis, for a total of 44 sampling points. Figure 4-7 shows a cross-
sectional view of this duct at the sampling location, and shows the exact
distance of each sampling point from the duct wall.
4.2.3 Scrubber Outlet
The scrubber outlet sampling location was in a 77 1/2-inch ID vertical
section of stainless steel duct. A schematic of this duct is shown in Figure
4-8.
Two 4-inch holes cut through the duct wall were used as sampling ports.
These ports were positioned 90 degrees apart in a horizontal plane and were
located more than 12 feet (2 duct diameters) upstream from the top of the
stack and 20 feet 6 inches (3.4 duct diameters) downstream from the scrubber
unit. Since this sampling location did not meet the "eight and two dia-
meters" criteria of EPA Method 1, 20 sampling points were used on each trav-
erse axis, for a total of 40 sampling points. Figure 4-8 shows a cross-
sectional view of this duct at the sampling location, and shows the exact
distance of each point from the duct wall.
4.3 Prill Cooler - AN Sampling
4.3.1 Scrubber Inlet
The scrubber inlet sampling location was in a 47 1/2-inch ID horizontal
section of stainless steel duct. A schematic of this sampling location is
shown in Figure 4-9.
Two 4-inch holes cut through the duct wall were used as sampling ports.
These ports were positioned 90 degrees apart in a vertical plane, and were
located 9 inches (0.2 duct diameters) upstream from a right angle bend and 63
inches (1.3 duct diameters) downstream from a duct reduction leading from the
-90-
-------
T
18'
o : »
20 '-6"
PEABOOY
LOW DENSITY
SCRUBBER
FROM PREDRYER
AND DRYER
NOT TO SCALE
TRAVERSE POINT LOCATIONS
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
TRAVERSE POINT
LOCATION FROM
OUTSIDE OF DUCT
(INCHES)
1.0
3.0
5.2
7.5
10.0
12.9
15.8
19.9
23.7
30.1
47.4
53.8
58.1
61.7
64.7
67.5
70.0
72.3
74.5
76.5
FIGURE 4-8: PREDRYER/DRYER SCRUBBER OUTLET SAMPLING LOCATION AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
1430-E10
-91-
-------
„ TO PRILL
COOLER T
SCRUBBER
FLOOR
PRILL COOLER
NOT TO SCALE
TRAVERSE POINT LOCATIONS
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
TRAVERSE POINT
LOCATION FROM
OUTSIDE OF DUCT
(INCHES)
1.0
1.5
2.6
3.8
5.0
6.3
7.7
9.2
10.9
12.9
15.3
18.9
28.6
32.2
34.6
36.6
38.3
39.9
41.2
42.5
43.8
44.9
46.0
46.5
FIGURE 4-9: PRILL COOLER SCRUBBER INLET SAMPLING LOCATION
AT COLUMBIA NITROGEN CORPORATION,
AUGUSTA, GEORGIA
1430-E11
-92-
-------
cooler unit. Since this sampling location did not meet the "eight and two
diameters" criteria of EPA Method 1, 24 sampling points were used on each
traverse axis, for a total of 48 sampling points. Figure 4-9 shows a cross-
sectional view of the duct at the sampling location and shows the exact
distance of each sampling point from the outside duct wall.
4.3.2 Bypass
The bypass sampling location was in a 48-inch ID vertical section of
stainless duct. A schematic of this sampling location is shown in Figure
4-10.
Two 4-inch holes cut through the duct wall were used as sampling ports.
These ports were positioned 90 degrees apart in a horizontal plane, and were
located 8 feet 6 inches (2.1 duct diameters) upstream from the top of the
stack and 33 feet 4 inches (8.3 duct diameters) downstream from a duct reduc-
tion leading from the cooler unit. This sampling location did meet the
"eight and two diameters" criteria of EPA Method 1, and 6 sampling points
were used on each traverse axis for a total of 12 sampling points. Figure
4-10 shows a cross-sectional view of this duct at the sampling location, and
shows the exact distance of each sampling point from the outside wall of the
duct.
4.4 Particle Size Test Locations
The particle size tests were performed at the same locations as the
ammonium nitrate emission tests. Each test run was performed with an Ander-
son High Capacity Stack Sampler (HCSS) at a single average flow point in each
duct. The average flow points were determined by preliminary velocity trav-
erses. The exact sampling points that were used at each location are de-
scribed in Table 4-1.
-93-
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•48"
T
8'-6
i'
>,
33'-4"
PORT 1
(NORTH)
PRILL COOLER
PORT 2
(EAST)
NOT TO SCALE
TRAVERSE POINT LOCATIONS
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
TRAVERSE POINT
LOCATION FROM
OUTSIDE OF DUCT
(INCHES)
2.1
7.0
14.2
33.8
41.0
45.9
FIGURE 4-10:
PRILL COOLER BYPASS SAMPLING LOCATION AT
COLUMBIA NITROGEN CORPORATION,
AUGUSTA, GEORGIA
1430-E12
-94-
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TABLE 4-1
SAMPLING POINTS USED FOR PARTICLE SIZE TESTS
AT COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Unit
Prill Tower
Predryer Inlet
Dryer Inlet
Cooler Inlet
Cooler Bypass
Test/
Location
Inlet A
Inlet B
Inlet C
Bypass A
Bypass B
Bypass C
1
2
3
1
2
3
All 3 runs
All 3 runs
Port
East
South
North
West
West
North
North
North
North
North
North
North
West
North
Sampling
Point
4
4
5
6
5
3
16
12
9
15
11
8
11
8*
Reference
Figure
4-3
4-4
4-6
4-7
4-9
4-10
* A 12-point traverse was used for these particle size tests. Point 8 was
located 36 inches from the inside edge of the port.
-95-
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4.5 Visible Emissions Observation Locations
The prill tower scrubber outlet and bypass plumes were observed from
three locations atop the prill tower, shown in Figure 4-2. The predryer/
dryer scrubber outlet plume was observed from two ground-level locations,
shown in Figure 4-1. The prill cooler scrubber outlet and bypass plumes were
observed from three locations atop the AN building near the outlet and bypass
stacks. These locations are shown in Figure 4-11.
The coater baghouse plume was observed from two locations atop the AN
building near the baghouse outlet. These locations are shown in Figure 4-11.
The bagging operation baghouse plume was observed from one ground-level loca-
tion, shown in Figure 4-1.
All observation locations were chosen to conform to the guidelines of EPA
Method 9. Each observer location is described in Table 4-2.
4.6 Scrubber Liquor Sampling Locations
Scrubber liquor samples were collected from a tap on the recirculation
stream pump at the prill tower (Brinks) scrubber, and from the sprayer feed
line at the predryer/dryer (low density) scrubber. These sampling locations
are shown in Figure 4-12 and 4-13, respectively.
4.7 Scrubber Pressure Drop Measurement Location
Pressure drop measurements were made across the prill tower scrubber with
a vertical U-tube water manometer. One side of the manometer was connected
to a pressure tap approximately one foot above the sampling ports in each
inlet duct. The other side of the manometer was open to the atmosphere.
-96-
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-4
ROAD
AMMON
IUM NITRATE BUILD
PRILL COOLER
BYPASS
NG
o
PC-3
A
PRILL COOLER
SCRUBBER OUTLET
O
COATER
BAGHOUSE
OUTLET
D
xi
x
X
X
X
x
x
X
x
CAT
WALK
0
PC-3
ACB-2
O O
PC-1
CB-1
o
CONTROL
ROOM
A VISIBLE EMISSION OBSERVER LOCATIONS
(refer to Table 4-2 for codes)
NOT TO SCALE
FIGURE 4-11: OVERHEAD VIEW OF PRILL COOLER OUTLET, BYPASS STACKS AND
COATER BAGHOUSE OUTLET AT COLUMBIA NITROGEN CORPORATION,
AUGUSTA, GEORGIA
1430-E13
-------
TABLE 4-2
VISIBLE EMISSONS OBSERVATION LOCATIONS AT
COLUMBIA NITROGEN CORPORATION, AUGUSTA, GEORGIA
Observer Direction from
Location Discharge Point
Distance from Height Above
Discharge point Ground
(feet) (feet)
* PT = Prill tower
PD = Prill dryer
PC = Prill cooler
Discharge
Description*
PT-1
PT-2
PT-3
PD-1
PD-2
PC-1
PC-2
PC-3
CB-1
CB-2
BB
SSW
SE
E
NW
WNW
SE
S
NE
E
N
ENE
SE
SE
15
35
30
50
25
125
125
35
45
15
20
40
100
250
250
280
250
250
0
0
115
115
135
115
115
0
PT bypass B
PT bypass C
PT scrubber outlet
PT scrubber outlet
PT bypass A
PD scrubber outlet
PD scrubber outlet
PC scrubber outlet
PC bypass
PC bypass
coater baghouse
coater baghouse
bagging baghouse
-98-
-------
FROM
MAKE UP
TO DRAIN
A
BRINKS
SCRUBBER
* SAMPLING LOCATION (RECIRCULATION STREAM TO BRINKS SCRUBBER)
FIGURE 4-12:
PRILL TOWER SCRUBBER LIQUOR FLOW DIAGRAM AND
SAMPLING LOCATION AT COLUMBIA NITROGEN CORPORATION,
AUGUSTA, GEORGIA
H30-E14
-99-
-------
T
SURGE TANK
(SUMP)
# SAMPLING LOCATION
FIGURE 4-13: PREDRYER - DRYER SCRUBBER LIQUOR FLOW DIAGRAM AND
SAMPLING LOCATION AT COLUMBIA NITROGEN CORPORATION,
AUGUSTA, GEORGIA
1430-E15
-100-
-------
4.8 Ambient Air Measurement Locations
Ambient air temperature and relative humidity measurements were taken at
the top of the prill tower during the prill tower AN emissions tests, at
ground-level at the base of the predryer/dryer scrubber during the predryer/
dryer emissions tests, and at ground-level at the prill cooler air intakes
during the cooler emissions tests. These locations are shown in Figure 4-2
(prill tower) and Figure 4-1 (dryer and cooler).
-101-
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5.0 SAMPLING AND ANALYSIS METHODS
This section presents general descriptions of sampling and analysis pro-
cedures employed during the emissions testing program conducted at the Colum-
bia Nitrogen Corporation ammonium nitrate manufacturing facility in Augusta,
Georgia during August 10-16, 1980. Details of sampling and analysis proce-
dures are contained in Appendices L and M.
5.1 EPA Reference Methods Used in This Program
The following EPA Reference Methods were used during this emission test-
ing program. These methods are taken from "Standards of Performance for New
Stationary Sources", Appendix A, Federal Register, Volume 42, (No. 160),
Thursday, August 18, 1977, pp. 41755 ff.
o Method 1 - Sample and Velocity Traverses for Stationary Sources
This method specifies the number and location of sampling points
within a duct, taking into account duct size and shape and local flow
disturbances.
o Method 2 - Determination of Stack Gas Velocity and Volumetric Flowrate
This method specifies the measurement of gas velocity and flowrate
using a pitot tube, manometer, and temperature sensor. The physical
dimensions of the pitot tube and its spatial relationship to the
temperature sensor and any sample probe are also specified.
o Method 4 - Determination of Moisture Content in Stack Gases
This method describes the extraction of a gas sample from a stack and
the removal and measurement of the moisture in that sample by conden-
sation impingers. The assembly and operation of the required sam-
pling train is specified.
o Method 9 - Visual Determination of the Opacity of Emissions from
Stationary Sources
This method describes how trained observers are to determine the
opacity of emissions. The duration and frequency of observations,
orientation of the observer with respect to the source, sun and back-
ground, methods of data recording and calculation, and qualifications
of observers are specified.
-102-
-------
The emissions tests and sample analyses were performed using EPA Refer-
ence Method 18, Determination of Particulate Emissions from Ammonium Nitrate
Plants. This method incorporates modifications to EPA Reference Method 5,
Determination of Particulate Emissions from Stationary Sources, that reflect
the characteristics of ammonium nitrate (AN) and AN sources. With Method 5
as a reference, Method 18 specifies the isokinetic sampling of AN particulate
from a gas stream utilizing techniques introduced in Methods 1, 2, and 4.
Sample collection and recovery, sampling train cleaning and calibration, and
gas stream flowrate calculations procedures are .specified. No filter is used
in the sampling train. Analysis of impinger samples for AN is performed with
the specific ion electrode (SIE) method. Method 18 is described in its
entirety in Appendix L.
5.2 Ammonium Nitrate Sampling and Analysis
5.2.1 Sampling Methods
5.2.1.1 Prill Tower Sampling Methods
Ammonium nitrate in the prill tower scrubber inlets, bypasses, and outlet
gas streams was sampled at points located in accordance with EPA Method 1.
Duct gas velocities were measured using S-type pitot tubes constructed and
calibrated in accordance with EPA Method 2.
The sampling train used on this program is shown in Figure 5-1 and is a
modification to the particulate sampling train specified in EPA Method 18.
The modifications used were: two acid impingers (instead of one) and use of
a Teflon line. No filter is used in the sampling train.
The sampling train shown in Figure 5-1 consists of a nozzle, probe, Tef-
lon line, six impingers, vacuum pump, dry gas meter, and an orifice flow
meter. The nozzle is stainless steel and of buttonhook shape. The nozzle was
-103-
-------
STACK WALL
THERMOMETER
o
£••
LEGEND
1 - NOZZLE 7
2 - PROBE 8
3 - TEFLON LINE 9
4 - ICE BATH 10
5 - FLEXIBLE LINE 11
6 - VACUUM GAGE 12
NEEDLE VALVE
PUMP
DRY GAS METER
ORIFICE
PITOT TUBE & INCLINED MANOMETER
POTENTIOMETER
FIGURE 5-1: MODIFIED EPA PARTICULATE SAMPLING TRAIN
AUGUST 18,1977, FEDERAL REGISTER
-------
connected to a 5/8-inch stainless steel glass-lined probe wrapped with nich-
rome heating wire and jacketed. Following the probe, the gas stream passed
through a 3/8-inch I.D. Teflon line into an ice bath/impinger system. The
impinger system consisted of six impingers in series. The first, third,
fifth, and sixth impingers were the Greenburg-Smith design, modified by
replacing the tip with a 1/2-inch glass tube extended to within 1/2-inch of
the impinger bottom. The second and fourth impingers were of regular Green-
burg-Smith design including tips with orifice plates located within 1/2-inch
of the impinger bottom. The first two impingers contained deionized, dis-
tilled water (100 mis each) . The next two impingers contained IN H SO
(100 mis each) . The fifth impinger was empty, and the sixth contained 200
grams of indicating silica gel. Leaving the last impinger, the sample stream
flowed through flexible tubing, a vacuum gauge, needle valve, pump, and a dry
gas meter. A calibrated orifice and inclined manometer completed the train.
The stack velocity pressure was measured with a pitot tube and inclined mano-
meter. Stack temperature was monitored with a thermocouple attached to the
probe and connected to a potentiometer. A nomograph was used to determine
the orifice pressure drop required for any pitot velocity pressure and stack
temperature in order to maintain isokinetic sampling conditions.
The probe temperature was maintained at about 10 F above the stack gas
temperature (but not higher than 180 F) in order to prevent condensation
within the probe.
Test data recorded at each sampling point included test time, sampling
duration at each traverse point, pitot pressure, stack temperature, dry gas
meter volume and inlet-outlet temperature, probe temperature and orifice
pressure drop.
-105-
-------
No sampling problems were encountered during the emissions tests at the
prill tower.
5.2.1.2 Prill Dryer Sampling Methods
The same AN sampling methods as described above for the prill towei: emis-
sions tests were used at the dryer and predryer scrubber inlet gas streams
and at the scrubber outlet gas stream.
Some difficulties were encountered at the dryer and predryer inlets
because of the heavy particulate loading at these locations. At the start of
the first test run the nozzles and pitot tubes immediately plugged with
particulate. Under the direction of the Technical Manager, larger diameter
nozzles were attached to the probe (3/16-inch diameters replaced with 1/4-
inch diameters) and sampling was resumed. Sampling time at each traverse
point was reduced from three minutes to one minute. Plugged pitot tubes were
reopened by squirting distilled water into the tubes and blowing them out
with air.
Nozzle plugging reoccurred only during the third test run at the dryer
inlet, and then only twice during the run. The first time a 10 ml volume of
distilled water was poured into the probe to dissolve the plug; this water
volume was discounted from impinger water gain measured during sample recov-
ery. The second time plugging occurred, the plug was removed with a wire
probe.
During one of the nozzle plugging occurrences some of the acid impinger
contents backed up into the second water impinger. As a result, the TRC
chemist analyzed the probe wash and water impinger contents separately for
this particular run (as discussed in Section 5.2.3 below).
-106-
-------
At the conclusion of the first dryer inlet test run the test crew discov-
ered one of the sampling train impingers had broken (the final leak check
indicated the train was open). This test run was therefore repeated.
Because of the larger diameter nozzles used at the inlet sampling loca-
tions, the sampling train pumps were not always able to produce orifice pres-
sure drops sufficient to maintain isokinetic sampling conditions. The per-
cent isokinetics for all three dryer inlet test runs and one of the predryer
inlet runs were less than 90 percent isokinetic. As discussed in Section
2.2, the particulate mass flowrates for these four runs were calculated by
two methods: the concentration method (by which calculations are normally
done) and the area ratio method. With the former method, the concentra-
tion of particulate entering the nozzle is calculated and then multiplied by
the volumetric flowrate to obtain the mass flow rate:
(m/V) x Q = MFR (pounds per hour)
where m = amount of particulate sampled (pounds)
V = volume of sampled gas (dry standard cubic feet)
Q = volumetric flowrate (dry standard cubic feet per hour)
If the nozzle sampling velocity is less than the stack gas velocity (subiso-
kinetic sampling conditions), then the calculated mass flowrate (MFR) will be
greater than the true MFR. This is because the heavier particles will leave
their streamlines (gas streamlines going around the nozzle) and will enter
the nozzle, as they would under, isokinetic conditions. Since the volume of
gas sampled is less than what would be sampled under isokinetic conditions,
the concentration m/V will be greater than that under isokinetic conditions.
d-'Brenchley, D.F., et al., Industrial Source Sampling, Ann Arbor Science
Publishers, Inc., 1973, p. 173 ff.
-107-
-------
Kith the area ratio method, the mass of participate collected is divided
by the sampling time and then multiplied by the ratio of the stack area to
the nozzle area to obtain the mass flowrate:
(m/t) x (As/An) = MFR (pounds per hour)
where m = amount of particulate sampled (pounds)
t = sampling time (hours)
AS = area of stack (square feet)
AJJ = area of nozzle (square feet)
Again, if the nozzle sampling velocity is less than the stack gas velocity,
then the MFR calculated by this method will be somewhat less than the true
MFR. The lighter particles follow their streamlines around the nozzle and
are not sampled; the amount of particulate sampled in time t is therefore
less than what should be sampled. The volume of sampled gas is not a factor
in this calculation. For a given test run, the average of the two calculated
MFR's was calculated as an estimate of the true MFR.
As shown in the particle size data in Section 2.4, approximately <)0 per-
cent of the particles in the dryer and predryer scrubber inlets are approxi-
mately 10 microns and larger in diameter. Therefore, if 10 micron pairticles
are considered large, the mass of particulate sampled will be within 10 per-
cent of what would be sampled at isokinesis. The data in Tables 2-13a and
2-13b show that for each subisokinetic test run, the concentrations method
MFR is approximately 10% greater than the average MFR and the area; ratio
method MFR is approximately 10% less than the average MFR.
5.2.1.3 Prill Cooler Sampling Methods
The same AN sampling methods as described above for the prill tower and
predryer/dryer emissions tests were used at the prill cooler scrubber inlet
and bypass gas streams.
-108-
-------
During the second test run, the bucket elevator conveying the AN prills
from the prill tower to the dryers broke down and a four hour delay was esti-
mated before the elevator would be repaired. At the time (late afternoon)
only three traverse points remained to complete the run at the inlet; one
complete traverse remained to complete the run at the bypass. Under the
direction of the Technical Manager, the inlet run was considered complete.
The bypass sampling train was sealed and this run was completed the following
morning.
Since the particulate loading was high at these locations, the 1/4-inch
nozzles were used. Some nozzle and pitot plugging occurred nevertheless. As
described in Section 5.2.1.2 above, pitot plugs were washed and blown out and
nozzle plugs were dissolved with measured amounts of distilled water.
During each test run at the bypass, each axis was traversed twice because'
of the relatively few sampling points and the lighter grain loading in this
duct. In this way sampling at the bypass was also kept concurrent with sam-
pling at the inlet.
5.2.2 Sample Recovery and Preparation
At the completion of each test run at all sampling locations (prill
tower, dryer, and cooler), the train was leak checked. Then the nozzle,
probe, and flexible Teflon line were washed with deionized, distilled water
(three times). The volume of the contents of each impinger was measured, and
samples were put in glass containers with Teflon-lined caps as follows:
Jar #1 contents of the first two impingers, and the deionized, distilled
water wash of their connecting glassware and the nozzle, probe,
and Teflon line.
Jar #2 contents of the third, fourth, and fifth impingers and the IN
H2S04 r^-nse °f tne impingers and their connecting glassware.
Jar #3 silica gel from the sixth impinger.
-109-
-------
At the field laboratory the volumes of the contents of Jars 1 and 2 were
measured, and the silica gel was weighed for moisture gain. The water impin-
ger samples (Jar 1) were split into two portions: to one portion 1 ml boric
acid solution was added per 100 ml of sample; the other portion remained un-
treated. The acid impinger samples remained untreated as well.
5.2.3 Sample Analysis
Ammonium nitrate analyses were performed in the field laboratory within
48 hours of sample collection. The boric acid treated portions of the. water
impinger samples were analyzed for nitrate (NO ) with an Orion model 93-07
specific ion electrode (SIE) and an Orion model 407 A/F specific ion meter.
Because high background ion concentrations interfere with the nitrate SIE
analysis and because normally only a very small fraction of AN is not cap-
tured in the water impingers, only the water impinger samples were analyzed
for nitrate. AN is calculated from nitrate by multiplying the measured
nitrate mass by the stoichiometric factor 1.29.
As noted in Section 5.2.1.2 above, the acid impinger contents backed up
into the water impingers during the third test run at the dryer inlet. The
pH of the water impinger contents was less than 2, so in order to minimize
the extent of any acid interference, the probe washings were not combined
with the water impinger contents in this case, and the probe washings were
analyzed seperately from the water impinger contents. The high nitrate con-
centration in the water impinger contents required that this sample be dilut-
ed 1250 times before analysis. The resulting sample pH was near 7, so no
interference is expected to have occurred.
-110-
-------
5.3 Ammonia Sampling and Analysis
5.3.1 Sampling, Sample Recovery and Preparation
The same samples collected and recovered as described in Sections 5.2.1
and 5.2.2 were analyzed for ammonia as well as for ammonium nitrate.
5.3.2 Sample Analysis
The untreated portions of the water impinger samples and the acid impin-
ger samples were analyzed for ammonia at the field laboratory within 48 hours
of sample collection. These analyses were performed with an Orion model 95-
10 specific ion electrode and an Orion model 407 A/F specific ion meter. The
SIE method is extremely specific for ammonia and is subject to few interfer-
ences.
In general, very little ammonia was detected in the acid impinger sam-
ples. For the prill tower emissions tests, the bypass and inlet acid impin-
ger ammonia contents were at the threshold of detection; the outlet acid
impinger ammonia contents averaged 39 percent of the total outlet ammonia
catch. For the predryer/dryer emissions tests, the predryer inlet acid
impinger ammonia contents averaged 1 percent of the total predryer inlet
ammonia catch; the dryer inlet acid impinger ammonia contents were at the
threshold of detection; the outlet acid impinger ammonia contents averaged 29
percent of the total outlet ammonia catch. For the prill cooler emissions
tests, the inlet and bypass acid impinger ammonia contents were at the
threshold of detection.
The relatively high acid impinger ammonia catches at the prill tower and
predryer/dryer outlets probably reflects the presence of excess ammonia
(gaseous ammonia) at these locations. Gaseous ammonia will be caught more
readily in an acid solution than in a neutral solution like water. The
-111-
-------
ammonia analysis results show that while the absolute amount of ammonia
caught was lowest at the outlet locations, the percent excess ammonia (excess
ammonia/total ammonia) was highest at the outlets.
5.4 Undissolved Solids Analysis
Analysis of the outlet and bypass samples for undissolved solids was
requested by the Technical Manager subsequent to the completion of the field
program. These analyses were performed at the TPC laboratory 18 to 22 days
after sample collection. The remaining volume of the untreated water impin-
ger sample portion was measured and then suction-filtered through a pre-
weighed glass fiber filter to remove the undissolved solids. The filters
were then desiccated and weighed to a constant weight.
The minimum detectable weight estimated by the TRC chemist was 1.0 mg,
and since only one third of the total water impinger sample volume was fil-
tered the limit of detection for these analyses was estimated to be 3.0 mg.
This relatively high limit of detection was required because several filter
analyses yielded negative weights. Further details of these analyses are
contained in Appendix M.
The bypass sample from the first prill tower test run contained an orange
colored particulate which may have precipitated during the time between
sample collection and these analyses. The nature of this material is not
known.
5.5 Particle Size Distribution Tests
Particle size distributions in the scrubber inlets and bypasses at the
prill tower, predryer, dryer, and cooler were measured with an Anderson High
Capacity Stack Sampler (HCSS). Particulate catches were washed out of the
sampler with distilled water and analyzed for nitrate by SIE.
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This section describes the sampling and analytical procedures used by MRI
in performing the particle size tests. Further details are contained in
Appendix E.
5.5.1 Sampling and Analytical Equipment Descriptions
The HCSS consists of two single jet impaction chambers followed by a
third stage cyclone and a backup filter thimble. A schematic of the HCSS is
shown in Figure 5-2. For the CNC tests the thimble was replaced by an impin-
ger train.
The HCSS is specifically designed for heavy grain-loading applications
where standard impactors cannot be used because of overloading or short sam-
pling times. The HCSS should only be used in stack situations where at least
40 mg of particulates can be collected in Stages 1 and 2.
The sampled gas stream enters the system through a nozzle which is appro-
priately sized to maintain isokinetic sampling. The gas then passes through
the Stage 1 acceleration jet. Particles with sufficient inertia are impacted
out against the bottom of the Stage 1 impaction chamber. Smaller particles
flow with the gas stream and exit the impaction chamber through three vent
tubes.
Stage 2 of the HCSS is simply a scaled version of Stage 1 in which the
jet nozzle diameter and the distance from jet exit to impaction surface have
been designed for the proper Stage 2 cutpoint.
Stage 3 of the HCSS is a small cyclone of the Southern Research Institute
(SoRI) design. A high efficiency glass fiber filter thimble can be used to
remove all particles greater than 0.1 micron which remain in the gas stream
downstream of the cyclone. The thimble was removed for these tests and an
impinger train used to collect the particulate which passed through the HCSS.
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FLOW
ACCELERATION
JET
rO
VENT
TUBE
LtOcm
SCALE
ISOK1NET1C PROBE
FIRST IMPACT10N STAGE
SECOND IMPACTION STAGE
CYCLONE STAGE
GLASS FIBER
THIMBLE FILTER
(removed for the CNC tests)
Figure 5-2: Schematic of the Anderson Model HCSS high grain-loading iapactor.
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Only straight nozzles should be used with the HCSS because gooseneck
nozzles have inherent outpoints lower than the cutpoint of Stage 1. Since
the HCSS only provides four data points, it is important that the first point
not be distorted by the wall loss material which would be separated out by
the gooseneck nozzle.
Separation between Stage 2 and the cyclone stage is provided so that
Stages 1 and 2 can be oriented to face directly into the gas stream without
changing the orientation of the cyclone and backup filter. Figure 5-3 is a
schematic of typical sampling positions for a stack with vertical upward flow.
The complete sampling train consisted of the HCSS, an impinger train, and
an EPA Method 5 console as shown in Figure 5-4. The Method 5 modifications
included removal of the pitot tube and filter assembly and placement of the
HCSS at the end of the probe. A Teflon tube and/or a stainless steel pipe
was used to connect the impactor to the impinger train. The first two impin-
gers each contained 100 ml distilled water. The third impinger contained 100
ml IN H.SO,, and the fourth contained 200 g of silica gel.
2 4
The analytical equipment consisted of an electrometer (pH meter with
millivolt scale), a specific ion electrode, and a reference electrode. This
instrumentation was calibrated and used to measure the nitrate ion concentra-
tion in the HCSS washes and the impinger catches.
5.5.2 Equipment Calibration
The components of the sampling train which were calibrated included the
console and the nozzle dimensions for the HCSS. Each console was calibrated
prior to shipment to the field using the techniques described in Method 5,
with the exception that the probe temperature was determined with a thermo-
couple rather than a calibration curve. A post-test calibration was also
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Figure 5-r3: HCSS orientation schematic.
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Anderson
Impactor
i
Teflon and/or
Stainless
.Steel Probe
IMPINGER TRAIN OPTIONAL.MAY BE REPLACED
BY AN EQUIVALENT CONDENSER
CHECK
VALVE
VACUUM
LINE
V fc-_.
VACUUM
GAUGE
THERMOMETERS
MAIN VALVE
V
AIRTIGHT
PUMP
DRY GAS METER
Figure 5-4: Schematic of HCSS sampling train.
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performed on the consoles. The nozzle dimensions were determined according
to the methods described in Method 5.
The ion electrode instrument was calibrated according to the description
provided in EPA Method 18. Standard solutions of nitrate ion were prepared
by dilution of stock solutions of known concentration. These standard solu-
tions were individually measured with the electrometer, and a calibration
curve was prepared prior to each set of laboratory analyses. A calibration
check was performed at the end of each set of analyses.
5.5.3 Determination of Sampling Points
The stack velocity at each sample port as measured by TRC was used when
available to calculate an average stack velocity. When data were not avail-
able from TRC, or there was reason to suspect that stack conditions had
changed, MRI measured the stack velocity using EPA Method 2 procedures. MRI
then selected a point as near as possible to the average velocity and temper-
ature of that duct and sampled using isokinetic techniques.
Standard EPA methodologies as described in the Federal Register, Vol. 42,
No. 160, Part II - Thursday, August 18, 1977, were used wherever applicable
for Methods 1 and 2. The molecular weight of the stack gas was assumed to be
28.84, and the percent moisture was assumed to be 2.
The procedure of sampling at only one point can lead to substantial error
if stratification of the particulate has occurred in the stack. Conditions
which can lead to stratification include long horizontal ducts where heavier
particles tend to collect at the bottom of the duct, bends in the duct which
tend to concentrate the heavier particles near the outer radius, stack velo-
city stratification where the larger particles collect in the lower velocity
areas, and changes in stack cross-section area. Since a constant sampling
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rate must be maintained to preserve the impactor outpoints, sampling at loca-
tions where the stack velocity varies may require multiple runs.
All sampling locations were evaluated for possible particulate stratifi-
cation. For those locations where stratification was almost certain to
exist, a different sampling point were used for each test run. Under the
direction of the Technical Manager, these procesures were followed at the
dryer and predryer scrubber inlets.
5.5.4 Determination of Sampling Rate and Nozzle Size
The HCSS collected particles at three distinct cut sizes which varied
according to the sampling rate. A sampling rate was selected at each point
which gave particle cutpoints of 10 to 12 microns for Stage III. Nozzle
sizes which allowed for isokinetic sampling at specified sample rate and
particle size were then selected. The nozzle size was determined using the
procedure provided in the Anderson HCSS Operating Manual.
5.5.5 HCSS Impactor Test Procedures
The following sequence of events was used at each test location:
1. An impinger train was assembled in the field laboratory. The first,
third, and fourth impingers were of the Greenburg-Smith design, modi-
fied by replacing the tip with 1.3-cm (1/2-in) ID glass tube extend-
ing to about 1.3 cm (1.2 in) from the bottom of the flask. The
second impinger was of the Greenburg-Smith design with the standard
tip. The first two each contained 100 ml of distilled water; the
third, 100 ml of IN I^SO^j; and the fourth, 200 g of silica gel.
2. The sampler was cleaned and assembled as described in the Anderson
HCSS Operating Manual.
3. The HCSS impactor was preheated in an oven in the field laboratory to
a temperature higher than the gas temperature of the source to be
tested. The impactor was wrapped in insulation for transport from
the lab to the test site. The insultation was removed just prior to
insertion into the sampling port. In this way sampling could begin
immediately, with no need to wait to condition the sampler to stack
temperature.
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4. Gas stream parameters for velocity, temperature, moisture, and static
pressure were obtained from TRC, if available; otherwise, they were
determined by MRI.
5. The sampling apparatus was assembled and leak-checked at the test
site following the leak check procedures in the Anderson HCSS Operat-
ing Manual.
6. The sample was collected isokinetically over a predetermined time
period (15 minutes to 3 hours) . Data were recordered every 3 to 5
minutes during each test.
7. Upon completion of the test, the impactor was removed from the sample
port while continuing to draw sample. This avoided loss of sample
due to possible negative stack pressure sucking the sample back out
of the nozzole.
8. The probes and nozzles were then capped, and the impingers, probes
and sample trains returned to the field lab for sample recovery.
Only minor problems were encountered in the actual testing. An over-
heated console pump caused interruptions in run 1 at the prill cooler un-
controlled outlet. This resulted in a low isokinetic value in this test. A
fan was furnished by CNC which alleviated the problem. Also at this loca-
tion, the impactor support was not used because of the small size of the
port. A stainless steel pipe was used in line with the Teflon probe to help
support the impactor. The stainless steel pipe was cleaned along with the
V
Teflon probe.
5.5.6 Sample Recovery
The sample recovery procedures used for each test run are outlined
below. Four sample containers were used for each run. A schematic of the
recovery fractions is shown in Figure 5-5.
Sample Container No. 1
1. Remove nozzle from impactor. Wash inside nozzle with distilled,
deionized water (DDW), and brush with nylon bristle brush. Wash and brush
three times, then give final rinse with DDW.
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ACCELERATION
JET
rO
L5
LKDcm
SCALE
VENT.
TUBE
ISOK1NET1C PROBE
FRACTION No.
FIRST IMPACT1CN STAGE
SECOND IMPACT10N STAGE
CYCUDNE STAGE
Figure 5-5: Schematic of the Anderson Model HCSS sample fractions.
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2. Remove impactor Stage 1 cap. Wash and brush inside of cap and jet
nozzle as above.
3. Remove impactor Stage 2 cap. Set aside Stage 2. Wash and brush
interior surfaces of Stage 1 collection chamber as above; do not wash the
interior surfaces of the three exit tubes.
Sample Container No. 2
1. Wash and brush inside of the three exit tubes of Stage 1 and the jet
nozzle and inside cap of Stage 2 with DDW and nylon brush. Wash and brush
three times, then give final rinse with DDW*
2. Wash and brush Stage 2 collection chamber as described in Stage 1
above, but do not wash the interior surfaces of the three exit tubes.
Sample Container No. 3
Wash and brush inside of the three exit tubes of Stage 2 and the exit chamber
and the 1/2-inch NPT fitting with DDW and nylon brush as described above.
Sample Container No. 4
Solutions from impingers 1 and 2 were each used to rinse the Teflon and
stainless steel sample lines connecting the impactor and the impingers. The
line was rinsed three times with each portion and placed in a sample contain-
er. This was done to minimize sample volume. The contents of impingers 3
and 4 were discarded.
Each sample fraction was rinsed into a clean polypropylene bottle ancl boric
acid preservation was added to each sample. Samples were then shipped to the
MRI laboratory.
5.5.7 Field Sample Analysis
An Orion nitrate specific ion electrode and a Corning model 12 potentio-
meter were calibrated using standard nitrate solutions. The electrode was
then placed in each field sample and a millivolt reading was recorded as soon
as the meter stabilized. Three aliquots from each sample were measured and
an average nitrate concentration calculated. Where necessary, samples were
diluted to bring concentrations into the working range of the electrode.
Because of potentiometer malfunctions during the initial analysis of
audit samples, the field samples were not analyzed at CNC. All samples were
returned to the MRI laboratory in Kansas City and analyzed within foui: weeks
of sample collection.
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5.5.8 Analysis of Audit Samples
The audit samples provided by EPA were to be analyzed prior to analysis
of the stack samples to establish quality assurance control. Some difficulty
was encountered in achieving satisfactory results in the field due to a mal-
function in the ion electrode potentiometer. The general problem was mani-
fested by a lack of reproducibility for the calibration curve and the audit
sample results. The audit samples were returned to the MRI laboratory in
Kansas City. The problem was corrected later by the MRI electronics shop,
where the potentiometer was serviced and a new electrode purchased, and all
samples were rerun at MRI.
All audit sample data are contained in Appendix E. Five audit samples
were provided. Each was measured after a preliminary dilution to ascertain a
concentration range. Additional dilutions were made as necessary to bring
the concentrations within the optimum analyzer range.
5.6 Visible Emissions Observations
The visible emissions observations were conducted by two certified vis-
ible emissions observers in accordance with EPA Method 9. Observations of
the prill tower bypass and scrubber outlet plumes were taken from three loca-
tions on the prill tower as shown in Figure 4-2. During each of the three
emission test runs, one observer monitored the outlet plume and the other
observer concurrently monitored the plume from the bypass being tested for AN
emissions. Observations of a given plume lasted two hours during an emission
test run, and within the two-hour period readings were taken and recorded at
15-second intervals. Six-minute averages were calculated from the 15-second
observations. Clear or partly cloudy skies and gray structures on the prill
tower were used as backgrounds.
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Observations of the predryer/dryer scrubber outlet plume were conducted
as described for the prill tower observations. The outlet plume was monitor-
ed for two hours during each of the three emission test runs performed at
this location. Observations were taken from the ground-level locations as
shown in Figure 4-1. Partly cloudy skies and the gray prill tower were used
as backgrounds.
Observations of the prill cooler bypass and scrubber outlet plumes were
conducted as described for the prill tower observations. The outlet plume
was monitored from a roof one story below and to the east of the outlet
stack, as shown in Figure 4-11. The gray AN building elevator shaft struc-
ture was used as a background. The outlet plume was monitored for four one-
hour periods. Only one period was concurrent with any of the three cooler
inlet and bypass emission test runs. The bypass plume was monitored from the
roof of the AN building (through which the bypass stack projects) and from
the roof one story below and to the east. These locations are shown in
Figure 4-11. The AN building elevator shaft and clear skies were used as
backgrounds. The bypass plume was monitored for three one-hour periods, two
of which were concurrent with the cooler inlet and bypass emission test runs.
The coater and bagging baghouse outlet plumes were monitored in the same
manner as described above. The coater baghouse plume was monitored from two
locations on the same roof from which the cooler scrubber outlet plume was
observed, as shown in Figure 4-11. Observations were taken over three one-
hour periods, using clear sky as a background. The bagging baghouse plume
was monitored from one ground-level location shown in Figure 4-1. Observa-
tions were taken over two one-hour and two 1/2-hour periods, using clear sky
as a background.
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5.7 Scrubber Liquor Sampling and Analysis
Five or six 100-ml liquor samples were collected from the prill tower
scrubber and the predryer/dryer scrubber during each emission test run at
these locations. Samples were collected in glass jars with Teflon-lined
caps. The temperature of each liquor sample was measured immediately follow-
ing its collection. Once the sample reached room temperature, the pH was
measured. The samples collected during a test run were then combined to form
one composite sample per run.
At the field laboratory, the composite samples were filtered using a
tared glass fiber filter in order to remove undissolved material. The
nitrate and ammonia analyses were performed within 24 hours of sample collec-
tion using the methods discussed in Sections 5.2 and 5.3. The solids analy-
ses were performed by desiccating and weighing each filter to a constant
weight at the TRC laboratory within 10 days of sample collection.
5.8 Scrubber Pressure Drop Measurements
Pressure drops across the prill tower scrubber were measured with a
vertical U-tube water manometer. One side of the manometer was connected to
a pressure tap in the scrubber inlet duct approximately 12 inches above the
emission test sampling ports. The other side of the manometer was open to
the atmosphere. During each emission test run at a given inlet, pressure
drop measurements were taken every 30 minutes at that inlet, except during
run 2. Due to an oversight by the field team leader, pressure drop measure-
ments during run 2 were continued at inlet B instead of inlet A where the
emission test was being performed. During emission test run 3 at inlet C,
pressure drops were measured at inlet A as well as at inlet C.
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5.9 Ambient Air Measurements
Ambient air temperature and relative humidity were measured every 30
minutes during each emission test run at the prill tower, predryer/dryer, and
cooler. Measurements were taken at the top of the prill tower, at ground
level next to the predryer/dryer scrubber, and at ground level near the air
intakes to the cooler. Wet bulb and dry bulb temperature measurements were
made with a sling psychrometer. Psychrometric tables were then used to com-
pute relative humidity from these measurements.
5.10 Volumetric Flowrates through the Prill Tower
During each emission test run at the prill tower, velocity traverses were
performed at each scrubber inlet and bypass not being tested for emissions.
Two perpendicular traverses were performed at each location at the beginning
and end of each emission test. Velocity head and stack gas temperature were
measured at each sampling point in accordance with EPA Method 2.
Duct static pressure, percent moisture, and stack gas molecular weight
values obtained from the scrubber inlet and bypass emission test runs were
applied on a run-by-run basis to the inlets and bypasses undergoing velocity
traverses in order to compute volumetric flowrates. Velocity head and tem-
perature data are contained in Appendix J.
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