United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 78-NHF-5
May 1979
Air
Ammonium Nitrate
Emission Test Report
N-ReN Corporation
Pryor, Oklahoma
-------
Environmental Consultants
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
EMISSION MEASUREMENT BRANCH
MAIL DROP 13
RESEARCH TRIANGLE PARK, NORTH CAROLINA 27711
FINAL REPORT
EMISSION TEST PROGRAM: AMMONIUM NITRATE MANUFACTURING PLANT
Conducted at
N-ReN CORPORATION
CHEROKEE DIVISION
P.O. BOX 429
PRYOR, OKLAHOMA 74361
CONTRACT NUMBER 68-02-2819
TASK ASSIGNMENT 8
PROJECT NUMBER 78-NHF-5
YORK PROJECT NUMBER 1-9517-08
APRIL 4, 1980
York Research Corporation
One Research Drive. Stamford. Connecticut 06906 • Telephone: C203J 325-1371 «TWX: 710-474-3947
-------
PREFACE
The work reported herein was conducted by personnel from the
York Research Corporation (YRC), the GCA/Technology Division
(GCA), and the United States Environmental Protection Agency
(USEPA).
The scope of the work, issued under EPA Contract No. 68-02-2819,
Work Assignment No. 8, was under the supervision of YRC Project
Director, Mr. James W. Davison. Mr. Roger A. Kniskern, of YRC,
served as Project Manager and was responsible for summarizing
the test and analytical data contained in this report. Analyses
of the samples were performed at the YRC laboratory in Stamford,
Connecticut under the direction of Ms. Kay Wahl.
Mr. Mark L. Bornstein and Mr. Stephen K. Harvey of GCA were
responsible for monitoring the process operations during the
testing program. GCA personnel provided the Process Description
and Operations Section and Appendix 6.9 of this report.
Personnel from N-ReN Corporation in Pryor, Oklahoma, whose assis-
tance and guidance contributed greatly to the success of the test
program, included Mr. J. C. Canon, Plant Manager, and Mr. John
Garrison, Technical Service Manager.
Mr. Eric A. Noble, of the Office of Air Quality Planning and
Standards, Industrial Studies Branch, USEPA,served as Test Pro-
cess Project Engineer and was responsible for coordinating the
process operations monitoring.
Mr. Clyde E. Riley, of the Office of Air Quality Planning and
Standards, Emission Measurement Branch, USEPA, served as Technical
Manager and was responsible for coordinating the emission test
program.
-------
Project No. 1-9517-08
Prepared by:
y
A. Kniskern
Senior Project Manager
Reviewed by:
Anthony J. Buonicore, P.E.
General Manager
Air Pollution Services Division
Approved by:
Jamete W. Davison
Vice^ President
"Technical Operations
-------
TABLE OF CONTENTS
Page
List of Figures iv
List of Tables vi
1.0 INTRODUCTION 1
2.0 SUMMARY AND DISCUSSION OF TEST RESULTS 13
2.1 Introduction 13
2.2 Ammonium Nitrate Results 13
2.3 Ammonia Results 28
2.4 Visible Emissions Observation Results 39
2.5 Particle Size Distribution Results 39
2.6 Gas Composition Results 39
2.7 Scrubber Solution Results 49
2.8 Pressure Drop Measurement Results 49
2.9 Temperature and Relative Humidity 49
2.10 Process Samples Results 58
3.0 PROCESS DESCRIPTION AND OPERATION 59
3.1 Process Description 59
3.2 Emission Control Equipment 62
3.3 Process and Control Equipment Monitoring 63
3.4 Process and Control Equipment Operation 67
4.0 LOCATION OF SAMPLING POINTS 71
4.1 Introduction 71
4.2 Cooler Inlet 71
4.3 Evaporator - Pan Granulator 72
4.4 Precooler - Chain Mill 80
5.0 SAMPLING AND ANALYTICAL PROCEDURES 87
5.1 Introduction 87
5.2 Preliminary Measurements 87
5.3 Auxiliary Test Data 87
5.4 Ammonium Nitrate 88
5.5 Ammonia 96
5.6 Gas Composition 98
5.7 Particle Size Distribution 98
5.8 Visible Emissions 101
5.9 Scrubber Solution Samples 102
5.10 Bulk Density and Particle Size of Product 102
-------
6.0 APPENDICES
6.1 Complete Computer Data Printouts
6.1.1 Cooler Test
6.1.2 Evaporator-Pan Granulator Test
6.1.3 Precooler - Chain Mill Test
6.2 Calculation Formulae
6.3 Particle Size Distribution Results
6.3.1 Computer Printouts
6.3.2 Particle Size Distribution
6.3.3 Field Data Sheets
6.3.4 Laboratory Results
6.4 Field Data Sheets
6.4.1 Cooler Test
6.4.2 Evaporator-Pan Granulator Test
6.4.3 Precooler - Chain Mill Test
6.5 Visible Emissions Observations Field Data Sheets
6.5.1 Combined Evaporator -Pan Granulator
Outlet Stack (venturi scrubber outlet)
6.5.2 Combined Precooler - Chain Mill Outlet
Stack (Buffalo Forge scrubber outlet)
6.6 Process Samples Data
6.6.1 Bulk Density and Sieve Analysis Data
6.6.2 Process Samples Laboratory Analysis
6.7 Calibration Data
6.7.1 Visible Emissions Certification
6.7.2 Orifice and Meter Calibration
6.7.3 Pitot Tube Calibration Data
6.7.4 Nozzle Measurements
6.8 Sampling Logs
6.8.1 Field Sampling Logs
6.8.2 Project Manager's Field Log
6.8.3 Field Laboratory Log
11
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6.9 Process Operations Log
6.9.1 Method of Calculating Production Rates
6.9.2 Process Operating Parameters
6.9.3 Copies of Correspondence Associated
with Process Monitoring Operations
6.10 Laboratory Data
6.10,. 1 Discussion of Analytical Methods
6.10.2 Summary of Laboratory Data
6.10.3 Laboratory Notebook
6.11 Scrubber Solution Analysis Data
6.11.1 Discussion of Collection, Preparation
and Analysis
6.11,2 Lab Analysis Results
6.11.3 Copy of Lab Notebook
6.11.4 Field Measurement Data
6.11,5 Laboratory Log
6.12 Ambient Air, Relative Humidity, and Pressure
Drop Measurement Data
6.12.1 Ambient Air and Relative Humidity Field
Data
6.12.2 Pressure Drop Field Data
6.13 Detailed Sampling and Analytical Procedures
6.13.1 Introduction
6.13.2 Sampling, Recovery, Preparation, and
Analytical Procedures
6.13.3 EPA Sampling and Analytical Methods
6.14 Cleanup Evaluation Results
6.14.1 Introduction and Summary of Results
6.14.2 Laboratory Log and Notebook
6.15 Project Participants
6.16 Work Assignment
6.16.1 Copy of Work Assignment
6.16.2 Technical Directives
111
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LIST OF FIGURES
Section 1.0
Figure 1 -
Process Flow Diagram, N-ReN Corporation, Pryor,
Oklahoma.
Section 2.0
Figure 2 -
Figure 3 -
Figure 4 -
Figure 5 -
Section 3.0
Figure 6 -
Venturi Scrubber Stack - Visible Emission Observations
Plot.
Buffalo Forge Scrubber Stack - Visible Emission
Observations Plot.
Composite Particle Size Distribution - Cooler Inlet.
Composite Particle Size Distribution - Precooler
Inlet.
Process Flow Diagram, N-ReN Corporation, Pryor,
Oklahoma.
Section 4.0
Figure 7 -
Figure 8 -
Figure 9 -
Figure 10 -
Figure 11 -
Figure 12 -
Figure 13 -
Figure 14 -
Figure 15 -
Figure 16 -
Section 5.0
Cooler. Inlet Port and Sampling Point Locations.
Evaporator - Pan Granulator Port Locations.
Evaporator Inlet Sampling Point Locations.
Evaporator - Pan Granulator Combined Inlet Sampling
Point Locations.
Evaporator - Pan Granulator Combined Outlet Sampling
Point Locations.
Relative Positions of Observer for Visible Emission
Measurements.
Precooler - Chain Mill Port Locations.
Precooler Inlet Sampling Point Locations.
Chain Mill Inlet Sampling Point Locations.
Precooler - Chain Mill Combined Outlet Sampling
Point Locations.
Figure 17 - Ammonium Nitrate Sampling Train.
Figure 18 - Modified Ammonium Nitrate Sampling Train for Evaporator
Pan Granulator Locations.
IV
-------
LIST OF FIGURES (Cont'd)
Figure 19 - In-stack Orifice and Nozzle Assembly.
Figure 20 - Andersen Stack Sampler.
Figure 21 - Andersen Sampling Train.
Figure 22 - Schematic of Scrubber Solution Flow and Sampling
Locations.
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LIST OF TABLES
Section 1.0
Table 1 -
Table 2 -
Table 3 -
Table 4 -
Table 5 -
Table 6 -
Table 7 -
Table 8 -
Section 2.0
Table 9 -
Daily Summary Log For Cooler Sampling Conducted
on November 3, 1978 at N-ReN Corporation in Pryor,
Oklahoma.
Daily Summary Log For Cooler Sampling Conducted
on November 4, 1978 at N-ReN Corporation in Pryor,
Oklahoma.
Daily Summary Log For Cooler Sampling Conducted
on November 5, 1978 at N-ReN Corporation in Pryor,
Oklahoma.
Daily Summary Log For Precooler Sampling Conducted
on November 6, 1978 at N-ReN Corporation in Pryor,
Oklahoma.
Daily Summary Log For Evaporator, Pan Granulator and
Precooler Sampling Conducted on November 7, 1978 at
N-ReN Corporation in Pryor, Oklahoma.
Daily Summary Log For Evaporator and Pan Granulator
Sampling Conducted on November 8, 1978 at N-ReN
Corporation in Pryor, Oklahoma.
Daily Summary Log For Precooler and Chain Mill Sampling
Conducted on November 9, 1978 at N-ReN Corporation in
Pryor, Oklahoma.
Daily Summary Log For Precooler and Chain Mill Sampling
Conducted on November 10, 1978 at N-ReN Corporation in
Pryor, Oklahoma.
Particulate and Ammonium Nitrate Concentration and
Emission Data Summary of Gases Entering and Exiting
the Scrubber of the Evaporator and Pan Granulator
(Venturi Scrubber), English Units.
Table 9-A - Particulate and Ammonium Nitrate Concentration.and
Emission Data Summary of Gases Entering and Exiting
the Scrubber of the Evaporator and Pan Granulator
(Venturi Scrubber), Metric Units.
Table 10 -
Table 11 -
Table 12 -
Table 13 -
Table 14 -
Summary of Uncontrolled Emissions From The Evaporator.
Summary of Uncontrolled Emissions for the Combined
Evaporator and Pan Granulator Stream.
Summary of Uncontrolled Emissions From the Pan Granulator,
Summary of Controlled Emissions From The Evaporator
and Pan Granulator Scrubber Outlet.
Particulate and Ammonium Nitrate Concentration and
Emission Data Summary - Gases Entering and Exiting
the Scrubber of the Precooler and Chain Mill (Buffalo
Forge Scrubber), English Units.
vi
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LIST OF TABLES (Cont'd)
Table 14-A -
Table 15 -
Table 16 -
Table 17 -
Table 18 -
Table 19 -
Table 20 -
Table 21 -
Table 22 -
Table 23 -
Table 24 -
Table 25 -
Table 26 -
Table 27 -
Table 28 -
Table 29 -
Table 30 -
Table 31 -
Particulate and Ammonium Nitrate Concentration and
Emission Data Summary - Gases Entering and Exiting
the Scrubber of the Precooler and Chain Mill (Buffalo
Forge Scrubber), Metric Units.
Summary of Uncontrolled Emissions From the Precooler.
Summary of Uncontrolled Emissions From the Chain Mill.
Summary of Controlled Emissions From the Precooler
and Chain Mill Scrubber Outlet.
Summary of Emission Test Results for the Cooler
Scrubber Inlet (English and Metric Units).
Summary of Emissions Test Results for the Cooler
Scrubber Inlet.
Summary of Ammonia and Ammonium Nitrate Uncontrolled
Emissions at the Evaporator - Calculated from Collected
Ammonia.
Summary of Ammonia and Ammonium Nitrate Uncontrolled
Emissions at the Combined Evaporator-Pan Granulator
Outlet - Calculated from Collected Ammonia.
Summary of Ammonia and Ammonium Nitrate Uncontrolled
Emissions at the Pan Granulator Inlet to the Scrubber -
Calculated from Collected Ammonia.
Summary of Ammonia and Ammonium Nitrate Controlled
Emissions at the Evaporator and Pan Granulator
Scrubber Outlet - Calculated from Collected Ammonia.
Summary of Ammonia and Ammonium Nitrate Uncontrolled
Emissions - Calculated from Collected Ammonia at the
Precooler.
Summary of Ammonia and Ammonium Nitrate Uncontrolled
Emissions - Calculated from Collected Ammonia at the
Chain Mill.
Summary of Ammonia and Ammonium Nitrate Controlled
Emissions at the Precooler and Chain Mill Scrubber
Outlet - Calculated from Collected Ammonia.
Summary of Ammonia and Ammonium Nitrate Emissions
at the Cooler Scrubber Inlet - Calculated from
Collected Ammonia.
Summary of Visible Emissions Observations - Venturi
Scrubber Stack.
Summary of Visible Emissions Observations - Buffalo
Forge Scrubber Stack.
Summary of Particle Size Distribution Tests Conducted
on the Cooler Scrubber Inlet at N-ReN Corporation,
Pryor, Oklahoma.
Summary of Particle Size Distribution Tests Conducted
on the Precooler Scrubber Inlet at N-ReN Corporation,
Pryor, Oklahoma.
VII
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LIST OF TABLES (Cont'd)
Table 32 - Summary of Gas Composition Data.
Table 33 - Summary of Scrubber Solution Analysis - Venturi
Scrubber.
Table 34 - Summary of Scrubber Solution Analysis - Buffalo
Forge Scrubber.
Table 35 - Comparison of Venturi and Buffalo Forge Scrubber
Liquors Average Net Gains for Ammonium Nitrate and
Ammonia.
Table 36 - Summary of Scrubber Pressure Drop Measurements -
Venturi Scrubber.
Table 37 - Summary of Scrubber Pressure Drop Measurements -
Buffalo Forge Scrubber.
Table 38 - Temperature and Relative Humidity at the Test Site,
Section 3.0
Table 39 -
Table 40 -
Table 41 -
Relative Averages and Ranges for Process Equipment
Operating Parameters (Cooler Test - Summary Data).
Relative Averages and Ranges for Process and Control
Equipment Operating Parameters (Pan Granulator -
Evaporator Test - Summary Data).
Relative Averages and Ranges for Process and Control
Equipment Operating Parameters (Precooler Test -
Summary Data).
vin
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1.0 INTRODUCTION
Section 111 of the Clean Air Act of 1970 charges the Administra-
tor of the United States Environmental Protection Agency (USEPA)
with the responsibility of establishing federal standards of
performance for new stationary sources which may significantly
contribute to air pollution. When promulgated, these standards
of performance for new stationary sources (SPNSS) will reflect
the degree of emission limitation achievable through application
of the best demonstrated emission control technology. To assemble
this background information, the USEPA utilizes emission data ob-
tained from controlled sources involved in the particular industry
under consideration.
Based on the above criteria, the USEPA's Office of Air Quality
Planning and Standards (OAQPS) selected the N-ReN Ammonium Nitrate
manufacturing plant in Pryor, Oklahoma as a site to conduct an
emission test program. York Research Corporation (YRC), under
contract 68-02-2819, was requested by the United States Environ-
mental Protection Agency (USEPA) to conduct the emission test
program at the N-ReN Corporation. The test program was designed
to provide a portion of the emission data base required for es-
tablishing the SPNSS for the processes associated with the pro-
,duction of ammonium nitrate. This plant is considered to employ
process and emission control technology representative of ammonium
nitrate pan granulation facilities. The tests performed at the
plant were designed to characterize and quantify uncontrolled and
controlled emissions from the cooling process of the- solids, as
well as to determine the collection efficiency of the control
equipment for the evaporator, pan granulator and precooler emissions
i
The N-ReN manufacturing plant in Pryor produces granulated ammonium
nitrate for use as a fertilizer. This particular plant is the only
one of its kind in the United States utilizing a pan granulation
process.
-------
Hot nitric acid and ammonia are sprayed into a. neutralizer tank
where they react exothermically, producing ammonium nitrate.
The heat released in the reaction concentrates the ammonium
nitrate and produces steam. The reaction proceeds as follows:
NH3 + HN03 >• NH4N03 + heat
The resulting 85% ammonium nitrate solution is concentrated to
99.5% in a falling film evaporator. The hot ammonium nitrate
solution (or melt) is sprayed into the pan granulator, where
the ammonium nitrate is cooled and granules of specific particle
size are formed. The granular product is transferred to a rotary
drum precooler. From the precooler, the product is conveyed to a
cooler and then to a coater, where it is coated with a clay mix-
ture. At this point, the finished product is delivered to the
warehouse for storage.
At several locations throughout the process the product is
screened,with the oversized and undersized material being re-
processed. Figure 1 presents the process flow diagram for ammon-
ium nitrate production at the N-ReN plant. The product, air,
and scrubber liquor streams, as well as the sampling point loca-
tions, are indicated on the diagram.
Emissions from the evaporator and pan granulator units are con-
trolled by a venturi scrubber. Emissions from the precooler and
chain mill area are vented to a Buffalo Forge scrubber before
being released to the atmosphere. Wet cyclones are used to con-
trol emissions from the product cooler. Details of the process
and the emission control equipment utilized at N-ReN Corporation
are provided in Section 3 of this report.
Emission sampling was conducted from November 3 to November 10,
1978 at the following process locations:
• Evaporator Scrubber Inlet
• Combined Evaporator-Pan Granulator Scrubber Inlet
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TO
ATMOIPHKNC
TO
ATMOSPHCM
AN
TANK
NIUTNALIICft
•CHUMCH LIOUOII
OViRfLOW
KEY:
PRODUCT VTHfAM
AIM I Tit I AM
SCMUBMN LIQOUN STMf AM
•AMPLIN* POINT
TO MAHIHOUSf
Figure 1
Process Flow Diagram
N-ReN Corporation, Pryor, Oklahoma
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• Combined Evaporator-Pan Granulator Scrubber Outlet
• Precooler Scrubber Inlet
• Chain Mill Scrubber Inlet
• Combined Precooler-Chain Mil.l Scrubber Outlet
• Cooler Scrubber Inlet
Concurrent tests performed at the inlet and outlet locations
provided velocity, moisture, gas composition, ammonium nitrate
and ammonia emissions data. Samples were collected and analyzed
for insoluble particulate, ammonium nitrate, and ammonia in
accordance with the prescribed EPA methods.
The cooler and precooler scrubber inlet locations were tested
for determination of particle size distribution. These tests
were performed using the prescribed procedures, as instructed
by the manufacturer, which are applicable to cascade impactors.
Pressure drop measurements across the venturi and Buffalo Forge
scrubbers were recorded every 15 minutes during the testing
periods. The static pressure was measured in lieu of pressure
drop at the cooler inlet to the wet cyclones emission control
system. Wet-bulb/dry-bulb and ambient air temperatures measure-
ments were also recorded every 10-15 minutes during the test
runs conducted on the evaporator-pan granulator, precooler and
cooler. Visible emissions observations were conducted on the
venturi and Buffalo Forge scrubber stacks during the testing
program.
Samples of inlet- and outlet scrubber solutions were collected
every 30 minutes during the ammonium nitrate and ammonia testing.
The pH and temperature were recorded immediately after collection,
These samples were analyzed for nitrate concentration, ammonia
concentration and percent solids in YRC laboratory in Stamford,
Connecticut.
Process materials were collected at various times during the
emission tests. These samples included:
-------
• Pan Granulator Product
• 85% Ammonium Nitrate (AN) Solution
• Precooler Product
• Cooler Inlet and Outlet Product
• AN Melt and Clay
YRC personnel were responsible for collecting and measuring
the above parameters, while GCA personnel were responsible
for monitoring and recording the necessary process parameters
(e.g., production rate). Tables 1 through 8 present "daily
summary logs" for all sampling performed at N-ReN Corporation
from November 3 to November 10, 1978. The production rate is
included in these tables and is discussed in detail in Section
3 and Appendix 6.9.
The following sections of this report include:
• summary and discussion of test results
• process description and operation
• location of sampling points
• sampling and analytical procedures.
In addition, Appendix 6.14 contains the summary and results of
cleanup evaluations performed on the sampling apparatus and
reagents used for sample recovery during the test program.
Detailed descriptions of sampling methods and procedures, field
and laboratory data, and calculations are presented in various
appendices.
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TABLE 1
DAILY SUMMARY LOG FOR COOLER SAMPLING CONDUCTED
ON NOVEMBER 3, 1978 AT N-ReN CORPORATION IN PRYOR, OKLAHOMA
Clock
Time
1026
1046
1056
1111
1126
1200
1205
1220
1235
1250
1300
1450
1455
1505
1515
1525
1535
1545
1550
1557
1600
1610
1620
1630
1640
1650
1655
1657
Production
Rate
(Ton /Hour)
14.4
>
1
14
14
4
'
14
t
'
4
7
i
r
7
Ammonium Nitrate
Particulatea
Cooler inlet
Started Run 1
1
Switched Ports
Continued
)
f
Completed Run 1
Started Run 2
i
Switche
t
d Ports
Continued
>
r
Completed Run 2
Static
Pressure
(in. H20)
-1.4
-1.4
-1.6
-1.3
-1.5
-1.9
-1.8
-1.6
-1.3
-1.8
-1.7
-1.6
-1.9
-1.6
-1.8
-1.9
-1.9
-1.8
-1.3
-1.7
Ambient
Temperature
(°F)
87
87
86
86
84
84
84
84
84
83
82
Relative
Humidity
(%)
34
34
33
33
32
34
34
34
38
37
36
Particulate samples also analyzed for ammonia.
-------
TftHI.E 2
DAILY SUMMARY I .or: TOR C'OOI.F.R SAMPl.lNf: OINIMICTKII
ON NOVEMBF.R 4, 1978 AT N-ReN CORPORATION IN PHYOR, OKLAHOMA
Clock
Time
0845
0900
0915
0930
0945
0958
1000
1015
uno
1045
1050
i:no
1410
1410
1445
15 00
11330
1!>3G
1540
15b5
IfilO
IC25
1(. Hi
10 "if.
Production
Rate
(tons/hour)
14
1
.1
1
14 1
14
i
\
.7
i
f
14 7
Ammonium Nitrate
Particulate
Cooler Inlet
Started Run 3
1
Switched Ports
Continued
1
1
Completed Run 3
Started Run 4
Switched Ports
Continued
1
t
Completed Run 4
Particle
Size
Inlet
Started Run 1
Completed
Run 1
Static
Pressure
Un.l!20)
-2.0
-2.0
-1.9
-1.6
-1.8
-1.8
-1.8
-1.6
-2.0
-1.7
-1.8
-1.5
-1.7
-1.7
-1.8
-1.5
Ambient
Temperature
63
67
70
72
75
76
78
78
84
84
84
84
84
84
83
82
Relative
Humidity
69
58
46
49
50
41
39
39
41
41
41
41
41
31
32
39
Process Material Samples
Cooler
Inlet
Grab
Outlet
Grab
Other °
Melt
Crab
Clay
Grab
('articulate samples also analyzed for ammonia .
Process samples retained by N-ReN.
-------
TABLE 3
DAILY SUMMARY LOG FOR COOLER SAMPLING CONDUCTED
ON NOVEMBER 5, 1978 AT N-ReN CORPORATION IN PRYOR, OKLAHOMA
Clock
Time
Production
Rate
(tons/hour)
Particle Size
Cooler Inlet
0850
1050
1130
1330
Not Measured
Not Measured
Started Run 2
Completed Run 2
Started. Run 3. . .
Completed Run 3
TABLE 4
DAILY SUMMARY LOG FOR COOLER SAMPLING CONDUCTED ... . ..
ON NOVEMBER 6, 1978 AT N-ReN CORPORATION IN PRYOR, OKLAHOMA
Clock
Time
0911
0951
1035
1050
1135
1150
Production
Rate
(tons/hour)
Not Measured
Not Measured
Not Measured
Particle Size
Cooler Inlet
Started Run 1
Completed Run 1"
Started Run 2
Completed Run 2
Started Run 3
Completed Run 3
-------
TAIU.K r>
DAILY SHMMAKY U»; TOR KVAI'ORA'H Hi , PAN < IRANIILATOK, AND PRKCY1OI.KR SAMPI.INC
(IN NOVEMBER 'I, ll.»7R AT tl-rtRN CORPORATION IN PRYOR, OKLAHOMA
Clock
TJme
0947
1047
1050
1110
1116
1122
1125
1310
1313
1322
1325
1330
1334
1340
1343
1353
1355
1358
1400
1401
1-107
1410
1425
1552
1555
1600
1601
1603
1607
1610
1613
1623
1637
1645
1650
1655
1700
Production 1
Rate 1
(tons/hour)!
14.7
i
1
Ammonium Nitrate ^articulate
Evaporator
Inletc
Started
Run 1
Stopped
Con1
Con'
i
Swlt
t
>ed
t
f
ched
Ports
Con1
t
Sampling
1
' 1 '
14 7 I Comf
I Run
1
luted
1
Pan Granulator
Inlet
Started
Run 1
i
f
Switched
Ports
Con't
Sampling
\
Completed
Run 1
Combined13
Outlet
Started
Run 1
f
Stopped
Con1!;
i
Switched
Ports
Con't
Stopped
Con't
i
i
Completed
Run 1
Snnihhpr f?riliit- inncs
Tnlof
tit
8.7
Temp(°F)
90
OirMPfr
pH
7.5
Temi)(°F)
124
Pressure
Drop
Un.II20)
27.1
27.3
27.4
27.4
27.4
26.9
26.7
26.8
Ambient
Temp
<°F)
71
73
82
80
80
78
78
81
Relative
Humidity
(%)
31
24
20
24
22
27
25
25
Visible Emissions
Combined
Stack
Started
Test 1
1
Stopped
Con't
Tea 1
' r
Completed
Test 1
Precooler
Outlet Stack
Started
Stopped
Particulate samples also analyzed for ammonia.
Includes controlled emissions from evaporator and pan granulator.
C
Gas composition sample collected at 1500 and analyzed for CO , 0
Note - Collected sample from 85% AN tank at 1245 (retained by N-ReN)
-------
i-tm f:%'Af IFATIu* MID I-AH ctitAHMi-A i "H SAMi'i.ii*; <(*j|x
n, i'»;n HT N-m:r. (.-'wnpivrioM in rtiwiu. «-*-|.AH"»m
Tl««
09(18
0910
0912
091)
0915
0920
092)
09)0
0915
0945
0950
0955
0958
1000
1005
1006
1008
101)
1015
1024
10 10
10)6
1045
105)
1054
1100
III]
1115
1 .1110
Din
H2)
1 127
1310
II 45
1)55
1406
1410
1415
1416
M21
1421
14)1
14)7
1445
1504
1509
1515
15)4
I51O
lf.115
Production
(tona/liour)
14.7
I
14.7
15
2
15.2
IWmnnlin Nitrate Participate"
Inlet
Started
Run 2
'
Switched
Ports
Coii't
'
Coat
pletod
Run 2
SI nit p.!
Run )
1
Switched
Ports
Con ' t
Co*
,1 feted
Hun )
Inlet0
Started
Run
2
Switched
Port s
Con 'I
1
On
>leted
Run 2
Started
Run 1
1
Switched
Port-.s
Con ' t
Completed
Run )
Crohl i.ed1'
Outlet
Started
Hun 2
Switched
Ports
Con't
Completed
llun 2
Started
Run 3
Switched
I'oets
Con • r.
'
Cooi|
lete.l
Run 1
Scrul>ber Solutions
Inlet
8.85
8.85
8.78
0.82
6.67
8.61
0.55
8.60
T.,,pi°F>
61
64
6)
64
72
7)
76
79
Outlet
pll
7..)5
7.42
7.37
7.35
6.75
6.85
6.9U
6.95
\
re»p< conposlct for Runs 1, 2, and 3.
-------
TAB [.I! 7
DAILY SUMMARY IOC TOR PRECOOLER AND CHAIN MI I.I.
SAMPLING ON NOVEMBER 9, 1978 at N-ReN CORPORATION IN PRYOU, OKLAHOMA
Clock
Time
1 1 3d
134')
I'l'iii
14 III)
Mil
1421
14.'!'',
M i<>
1447
14 ',1
14V.
M'.V
I'.n:'
l',i)4
IMi.
r>::4
i'.:">
r. tu
i '>•!:•
K.illl
11,11::
it. as
11.10
n.vi
Product ion
Rate
(tons/hour)
14.9
4
t
\\.-)
Ammonium Nitrate Particulate
Precooler
Inlet
Started
Run 1
Kxper iencec
number
of probe
nozzle
plllCJijilKJS
^ /
i;tO| ,e,l
Run 1
(on 1 y
completed
1 .ixit;)
Cliain Mill
Inlet
Started
Run 1
,..
-on '
r
L-lu.-d Ports
t
1
Swi tclied
Ports
Con
i
•t
1
Sw itched
Ports
.
'
Con
•t
i
Completed
Run
1
Combined'1
Outlet
Started
Run 1
i
i
Switched
Ports
Con't
Stopped
for
Inlet
Con't
1
r
Comi leted
Run 1
Sc rubier So In t ions
i
pi!
7.05
6.80
6.98
6.95
nlet
Temp(°F)
no
138
136
136
Outlet
pll
5.71
5.58
5.65
5.65
Perap("F)
99
101
99
99
Pressure
Drop
(in.U20)
3.3
3.5
3.2
3.0
3.0
2.9
3.0
2.9
3.4
3.4
3.9
Ambient
Temp.
70
70
71
74
75
75
72
73
73
73
Relative
Humidity
3O
30
28 "
24
20
23
28
27
27
24
Visible Emissions
Precooler-Chain Mill
Combined Outlet
Started Test
i
Complete
d Test
Process Materials Samples
851
Solution
Crab
Precooler
Product
Collected
Composite
Sample
Cat t i CM I a I «: sump) uis al so anal yzed for airunon La .
|i,,:lii'K:s control lutl oinlsnionu t'roin prucnolur an«1 chain mill.
I • i < K:I •:;:; sam| • I *: s r u t a i i ujf I by N -I :oN .
-------
TAIU.Ii II
DAILY SUMMAIty [/Xl FOI< IWCOOLRK AND CHAIN Ml 1.1.
SAMPLINU ON NOVKM1IUK 1U, 1978 at N-)
oted
Run 3
Chain Hill
Inlet
Started
Run 2
^
Swit
p
:ched
Ports
aed
Con
'
Com[
t
r
>leted
Run 2
Started
Run 3
i
Swit
/
cited
Port a
Con.'t
i
•
Completed
liun 3
Combined
Outlet
Started
liun
)
2
f
Switched
Ports
Con't
I
Stopped
Con't
i
i
Completed
Run 2
Started
Dun 3
i
Swlt
r
died
Ports
Con • t
'
Comp
'
loted
l
-------
2,0 SUMMARY AND DISCUSSION OF TEST RESULTS
2.1 Introduction
The results of the emission test program conducted at the
N-ReN Corporation in Pryor, Oklahoma are presented in
Tables 9 through 38 and Figures 2 through 5. These results
are discussed briefly in nine separate categories. Detailed
. discussions are presented in Section 5.0, "Sampling and
Analytical Procedures", and in various related appendices.
Samples were collected concurrently at the evaporator in-
let, the combined evaporator-pan granulator inlet, and the
combined evaporator-pan granulator outlet. These sampling
locations are incorporated with the venturi scrubber. Con-
current sampling was also conducted at the precooler inlet,
the chain mill inlet, and the combined precooler-chain mill
outlet. These sampling locations are associated with the
Buffalo Forge scrubber. The inlet to the scrubber which
vents the cooler operation was also sampled. Major problems
encountered in the sampling program and deviations from
normal sampling procedures are discussed in Section 5.0,
"Sampling and Analytical Procedures", and in Appendix 6.13.
2.2 Ammonium Nitrate Results
The ammonium nitrate emission data represent the recovery
of the untreated water sample, and the train filter for
each test run. Most of the ammonium nitrate catch was
found in the untreated water sample and only minor amounts
were found on some of the filters.
The ammonium nitrate particulate is expressed as both measured
nitrate and measured ammonia in the following tables. The
ammonium nitrate concentration was calculated from the amount
of ammonia recovered during each test. A sample calculation
for the determination of ammonium nitrate from ammonia is
13
-------
provided in Appendix 6.13. The rationale for incorporating a
stoichiometrically valid expression for ammonium nitrate par-
ticulate lies in its usefulness as an alternative for evalu-
ating emissions.
A. Evaporator-Pan Granulator
Table 9 summarizes the collection efficiencies of the venturi
scrubber as calculated from insoluble particulate, ammonium
nitrate particulate and total particulate, in English units.
Table 9-A presents this data in Metric Units. The factors
used to convert data from English to Metric units appear in
Appendix 6.2.
Cyclonic flow patterns were suspected at the combined evaporator-
pan granulator inlet location, resulting in measured volumetric
flow rates ten to fiften percent lower than actual volumetric
flow rates. Since emissions calculations are based on volu-
metric flow rates, these are also believed to be low by ten
to fifteen percent. Consequently, the efficiency calculations
would be expected to be less than the actual efficiency. This
would mean that a calculated average collection efficiency of
97.9% would actually be about 98.5%.
It should also be noted that the percent moisture by volume
data presented in Tables 9 and 9-A have been adjusted in
accordance with saturation moisture for the average stack
temperature. A detailed explanation of this adjustment is
forthcoming.
Summaries of uncontrolled emissions from the evaporator and
combined evaporator-pan granulator streams appear in Tables
10 and 11, respectively. Problems were encountered during
the first run at the evaporator inlet, resulting in insoluble
and total particulate concentrations which were not represent-
ative of the actual operating conditions. A vacuum, follow-
ing a testing delay, caused the 1.ON H^SO, solution in the
14
-------
TABLE 9
PARTICUIATE AND ANMONIUM NITRATE CONCENTRATION AND EMISSION
DATA SUMMARY OF GASES ENTERING AND EXITING THE SCRUBBER
OF TIIE EVAPORATOR AND PAN GRANULATOR (VEMIURI SCRUBBER)
(ENGLISH UNITS)
Location
Date
Voluire of Gas Saitpled (DSCF)a
Percent Maisture by volume
Average Stack Tenperature ( F) .
Stack Volunetric Flow Rate (DSCFM)
Percent Isokijietic
Prod' iction Rate (Tons/Hour)
Insoluble Particulates —
Filter Catch and Collection
Water Filtrate
mg
gr/DSCF
Ib/hr
Jh/ton
CoUection Efficiency, Percent
Aninoniinn Nitrate Part.iculate —
qr/IJKCF
ib/lir
Ib/ton
CoUection Efficiency, Percent
Total Participate —
Insoluble & Aiinnnium Nitrate
ing
qr/USCT
.lb/hr
lb/tim
Collection Efficiency, Percent
Run 1
Inlet Outlet
11/7/78
44.24 77.63
23.2 19.5
186 140
7936C 9089
78 101
14.7
115.77 5.86
0.0403 0.0012
2.74d 0.09
0.186 0.006
96.7
3104.40 50.08
1.0807 0.0100
73.51d 0.78
5.001 0.053
98.9
3220.17 55.94
1.1210 0.0111
76.25d 0.87
5.187 0.059
98.9
Run 2
Inlet Outlet
11/8/78
59.83 75.94
27.9 19.5
192 140
7355C 8773
114 103
14.7
28.66 3.51
0.0074 0.0007
0.46a 0.05
0.031 0.004
89.1
1621.12 43.12
0.4173 0.0088
26.31d 0.66
1.790 0.045
97.5
1649.78 46.63
0.4247 0.0095
26.77d 0.71
1.821 0.048
97.3
Run 3
Inlet Outlet
11/8/78
54.80 78.74
26.8 19.0
194 138
7619C 9214
101 101
15.2
38.58 16.21
0.0108 0.0032
0.71d 0.25
0.047 0.017
64.8
1200.16 20.90
0.3373 0.0041
22.02** 0.32
1.449 0.021
98.5
1238.74 37.11
0,3481 0.0073
22.73d 0.57
1.496 0.038
97.5
Average
Inlet Outlet
52.96 77.44
26.0 19.3
191 139
7637° 9025
98 102
14.9
61.00 8.53
0.0195 0.0017
1.30d 0.13
0.088 0.009
83.5
1975.23 38.03
0.6118 0.0076
40.61d 0.59
2.747 0.040
98.3
2036.23 46.56
0.6313 0.0093
41.92d 0.72
2.835 0.048
97.9
a Dry Standard Cubic Feet at 68°F, 29.92 in. Hg
Dry Standard Cubic Feet Per Minute at 68°F, 29.92 in. Hg.
Cyclonic flow patterns suspected; volumetric flows believed to be approximately 10-15 percent low.
Pound per hour results are based on volumetric flows and are therefore suspected to be 10-15 percent low.
-------
TABU: 9 A
PARflCUIATE AND AMMONIUM NITRATE CONCENTRATION AND EMISSION
DATA SUMMARY — GASES ENTERING AND EXITING THE SCRUBBER OF
TliE EVAPORATOR AND PAN GRANULATOR (VENTURI SCRUBBER)
(METRIC UNITS)
Location
Date
Voluma of Gas Sampled (DNm )a
Percent Moisture by Volume
Average Stack Temperature ( C) , . .
Stack Volumetric Flow Rate (DNm /tain-)
Percent Isokinetic
Production Rate (Mg/hr)
Insoluble Particulates —
Filter Catch and Collection Water Filtrate
ing ,
y/UNni
Kg/lir
Kg/Mg
Collection Efficiency, Percent
Ammonium Nitrate Particulate —
mg ,
tj/UNm
K\: and 760 mm. llg.
Cyclonic flow patterns suspected; Volumetric flows believed to be approximately 10-15 percent low.
Kilogram per hour results are based on volumetric flows and are therefore suspected to be 10-15 percent low.
-------
TAB1£ 10
SUMMARY OF UNCONTROLLED EMISSIONS FROM "HIE EVAPORATOR
IX-.tC
Voluiie of Gas Sampled (DSCF)a
Percent Moisture by Volume
Average Stack Hanperature ( F) .
Stack Volumetric Flow Rate (DSCFM)
Percent Jsokinetic
Production Kate (Tons/Hour)
Insoluble Particulatt. —
Filter Catch and Collection
Water Filtrate
1IUJ
yr/nKCF
ib/lir
Ib/ton
Aiini'miiin Nitrate Particulate —
Nitrate and Anmonium Nitrate
Measured as Annonici
in«l
Mr/I >S(,T'
Ib/hr
Ib/tDii
'l\>l;il ParticulaU. —
Insoluble t. Aniiuniuw Nitrate
HIM
-------
TABLE 11
SUWARY OF UNCONTIOUED EMISSIONS FOR TIE COMBINED EVAPORATOR
AND PAN GRANULATOR STREAM
Date
Volume of Gas Sampled (DSCF)3
Percent Moisture by Volume Q
Average Stack Temperature ( F) .
Stack Volumetric Flow Rate (DSCFM)D
Percent Isokinetic
Production Rate (Tons/Hour)
Insoluble Particulates —
Filter Catch and Collection
Water Filtrate
mg
cjr/DSCF
Ib/hr"
lb/ton
Amnonium Nitrate Particulate —
Nitrate and Airmonium Nitrate
iitjasured as Amnania
nuj
-------
impingers to back up into the filter holder and subsequently
wet the filter. This is the probable cause of this filter
being considerably heavier than the other filters (see
Appendix 6.10) . During this run, it was also noted that
crystallization occurred in the impingers at the combined
evaporator-pan granulator inlet and outlet locations. These
crystals dissolved when the impingers were warmed to room
temperature. Additional reagent was added to the inlet
impinger trains during the second and third runs to prevent
crystallization.
While sampling at the evaporator inlet, the operator had
problems maintaining a constant orifice pressure differential,
resulting in high isokinetic sampling ratios for the second
and third runs (see Table 10).
While sampling at the combined evaporator-pan granulator inlet,
the velocity pitot tubes became clogged several times, requir-
ing the use of velocity pressure data obtained from the initial
velocity traverse for determination of orifice pressure drops.
The fluctuating moisture content of the flue gas, in addition
to the other problems encountered, caused the isokinetic sampl-
ing ratio to vary during the sampling run (see Table 11).
Table 12 summarizes the uncontrolled emissions from the pan
granulator inlet. The results were determined from the dif-
ferences between data obtained from sampling at the combined
evaporator-pan granulator inlet and the evaporator inlet.
Therefore, these results reflect the sampling conditions and
experimental anomalies at both of these locations.
Controlled emissions from the combined evaporator-pan gran-
ulator inlet are presented in Table 13. The moisture measure-
ments exceeded the saturation point at the stack temperature
for each run. The percent moisture by volume values
19
-------
TABLE 12
SIM1AKY OF UXXNTROLUD EMISSIONS FROM TIE PAN GRANUIATOR '
Date
Stack VoluriEtric Flow Rate (DSCFM)b
Production Rate (Tons/Hour)
Insoluble Particulate —
Filter Catch and Collection
Water Filtrate
gr/DSCF
Ib/hr
Ib/ton
Armenian Nitrate Particulate —
Nitrate and Armnnium Nitrate
measured as Armenia
gr/DSCF
Ib/hr
Ib/ton
Total Particulatc —
Insoluble & Amnonium Nitrate
gr/DSCF
Ib/hr
Ib/ton
Percent particulate catch
Run 1
11/7/78
6533C
14.7
Evaporator filter
contaminated by IN H so.
from inpingers
Measured as
Nitrate Armenia
1,2934 1.5641
72.45. 87.61
4.929 5.960
Evaporator filter
contaminated by IN H2sc>4
from inpingers
Run 2
11/8/78
6034°
14.7
0.0085
0.44
0.030
Measured as
Nitrate Armenia
0.4904 0.5932
25.37 30.69
1.726 2.088
0.4989 0.6017
25.80 31.13
1.756 2.118
1.7 1.4
Run 3
11/8/78
6571C
15.2
0.0122
0.69
0.045
Measured as
Nitrate Armenia
0.3752 0.5694
21.14 32.08
1.391 2.111
0.3874 0.5816
21.83 32.77
1.436 2.156
3.1 2.1
Average
6379
14.9
(no average presented)
Measured as
Nitrate Armenia
0.7197 0.9089
39.65 50.13
2.682 3.386
(no average presented)
Data determined by difference of evaporator and ccmbined evaporator-pan granulator data
b Dry Standard Cubic Feet Per Minute at 68°F.. 29.92 in. Hg.
c Cyclonic flow suspected at the combined inlet.
-------
TABU: 13
SUMMARY OK CONTROM.UO EMISSIONS PROM EVAPORATOR AND
I'AN GKAHUI.ATOR SCRUBBER OIITIJ5T
Volume of Gas Sampled (DSCF)'
Pel cent Moisture by Volume
Avei aije Stack Temperature ( F) .
IILack Volumetric Flow Rate (DSCFM)
Pressure! Drop Across Scrubber (in.tl^O)
Percent Isoklnetic
Percent Opacity Average
Product ion Rate (tons/dour)
Insoluble ['articulate — Filter
C.ilf.-li cinrl Col lee 1 ion Mater Filtrate
HIM
• ir/DSCF
Ib/hr
Ib/ton
d
AniiiHiiijuin Nilirate ('articulate — -
Nilr, ili- and Ammonium Nitrate
measured a:> Ammonia
n,.|
a rent lies is adjusted for excessive moisture. Measured moisture exceeds state of saturation at measured temperature.
r:
-------
have been adjusted for this excessive moisture. A psy-
chrometric chart was employed for these adjustments and
is presented in Appendix 6.13. The stack volumetric flow
rates and isokinetic ratios have also been adjusted to
conform with the percent moisture by volume at saturation.
Data for the average percent opacity readings and the
pressure differentials across the scrubber are also pre-
sented in Table 13. It should be noted that the pressure
differential decreased slightly as the production rate
increased during the third run.
B. Precooler - Chain Mill
Table 14 presents a comprehensive emission data summary
for gases entering and exiting the Buffalo Forge scrubber.
The inlet data represent the sum of the individual volumetric
flow rates for corresponding test runs conducted at the pre-
cooler and chain mill inlets. The collection efficiencies
of the Buffalo Forge scrubber are noticeably higher than
those of the venturi scrubber, with an average total par-
ticulate removal of 99.4%. This would be expected due to
an increase in the retention time of the flue gas, enabling
more time for gas-liquid contact and subsequent mass transfer.
Summaries of uncontrolled emissions from the precooler and
chain mill are presented in Tables 15 and 16, respectively.
The results of the first run at the precooler inlet are
based on a 24 point traverse (out of 48 total traverse points)
conducted on the horizontal sampling port. Appendix 6.13
provides a detailed explanation of this test run.
Table 17 summarizes the controlled emissions from the Buffalo
Forge scrubber outlet. Average percent opacity readings
and pressure differential measurements across the scrubber
are also included.
22
-------
TABLE 14
PARTICULATE AND AMMONIUM NITRATE CONCENTRATION
AND EMISSION DATA SUMMARY -
GASES ENTERING AND EXITING THE SCP.UBBER OF THE
PRECOOLER AND CHAIN MILL (BUFFALO FORGE SCRUBBER)
(ENGLISH UNITS)
Location
Date
Volume of Gas Sampled (DSCF)a
Percent Moisture by Volume
Average Stack Temperature (°F)
Stack Volumetric Flow Rate (OSCFM)
Percent Isoklnetlc
Production Hate (Tons/Hour)
Insoluble Particulate —
Filter Catch and Collection
Water Filtrate
gr/DSCF
Ib/hr
llj/ton
Collection Efficiency,
Pei cent
Ammonium Nitrate Particulate
gr/DSCF
lb/l>r
Ib/ton
Collection Efficiency (Percent)
Total Particulate —
Insoluble K Ammonium Nitrate
gr/DSCF
Ih/hr
Ib/ton
Collection Efficiency (Percent)
Run 1
Ihletc Outlet
11/9/78
89 . 15
3.4
112
23264 25866
102
14.9
0.0006
16.15 0.13
1.084 0.009
99.2
2.0474 0.0108
408.39 2.39
27.409 0.160
99.4
2.1284 0.0114
424.54 2.52
28.493 0.169
99.4
Run 2
Inletc Outlet
11/10/78
89.54
4.0
112
26106 25843
102
14.7
0.0019
21.19 0.41
1.441 0.028
98.1
2.5086 0.0201
561.50 4.46
38.197 0.303
99.2
2.6032 0.0220
502.69 4.87
39.639 0.331
99.2
Run 3
Inlet0 Outlet
11/10/78
93.19
4.9
113
30069 27062
102
14.6
0.0006
27.94 0.13
1.914 0.009
99.5
2.5254 0.0145
651.07 3.37
44.594 0.231
99.5
2.6337 . 0.0151
679.01 3.50
46.508 0.240
99.5
Average
Inlet Outlet
90.63
4.1
112
26480 26257
102
14.7
0.0010
21.76 0.23
1.480 0.015
98.9
2.3605 0.0151
540.32 3.41
36.733 0.231
99.4
2.4551 0.0161
562.08 3.64
38.213 0.246
99.4
UJ
aDry Standard Cubic Feet at 68°F, 29.92 in. Hg.
bDry Standard Cubic Feet Per Minute at 68°F., 29.92 in. Hg.
clnlet data calculated by adding standard volumetric flow rates of corresponding test runs of the precooler and chain mill inlets.
-------
TABt.E 14 -A
PARTICULATE AND AMMONIUM NITRATE CONCENTRATION
AND EMISSION DATA SUMMARY —
f.ASRS ENTERING AND EXITING THE SCRUBBER OF THE
PRECOOLER AND CHAIN MILL (BUFFAI/D FORGE SCRUBBER)
(METRIC UNITS)
Location
Date
Volume of Gas Sampled (DNm )a
Percent Moisture by Volume
Averaye Stack Temperature ( C)
Stack Volumetric Flow Rate (DNm /min.)
Percent Isokinetic
Production Rate (Mg/hr.)
Insoluble Particulates —
Filter Catch and Collection
Water Filtrate
q/DNm
Ky/lir.
Kg/My .
Collection Efficiency (Percent)
Ammonium Nitrate Particulate
y/DNm
K.|/hr.
Kg/My .
Collection Efficiency (Percent)
Total Particulate —
Insoluble and Ammonium Nitrate
tj/DNin3
Kc|/l,r.
Ky/Mg .
Collection Efficiency (Percent)
Run 1
Inlet1- Outlet
11-9-78
2.53
3.4
44.3
659 733
102
13.5
0.0014
7.326 0.059
0.542 0.005
99.2
4.6845 0.0247
185.246 1.084
3.705 0.080
99.4
4.8698 0.0261
192.571 1.143
14.247 0.085
99.4
Run 2
Inlet0 Outlet
11-10-78
2.54
4.0
44.2
739 732
102
13.3
0.0043
9.612 0.186
0.721 0.014
98.1
5.7397 0.0460
254.696 2.023
19.099 0.152
99.2
5.9561 0.0503
264.308 2.209
19.820 0.166
99.2
Run 3
Inlet0 Outlet
11-10-78
2.64
4.9
45.2
852 766
102
13.2
0.0014
12.674 0.059
0.957 0.005
99.5
5.7781 0.0332
295.325 1.529
22.297 0.116
99.5
6.0259 0.0345
307.999 1.588
23.254 0.120
99.5
Average
Inlet Outlet
2.57
4.1
44.5
750 744
102
13.3
0.0023
9.870 0.104
0.740 0.008
98.9
5.4008 0.0345
245.089 1.547
18.367 0.116
99.4
5.6173 0.0368
254.959 1.651
19.107 0.123
99.4
Dry Normalized Cubic Meters at 20 C. and 760 mm. llg.
Ury Normalized Cubic Meters Per Minute, at 20 C. and 760 mm. llg.
clnlet data calculated by adding standard volumetric flow rates of corresponding test runs of the precooler and chain mill inlets.
-------
TABLE 15
SUMMAKY OF UNCONTROLLED EMISSIONS FROM TUB PRECOOLER
DATE
Volume of (Jau Sampled (DSCF)
Percent Moisture by Volume
Average Stack Temperature ( F) .
Stack Volumetric Flow Kate (DSCFM)
Percent Isokinetic
Production Kate — (tons/hour)
Insoluble I'articiilate — Filter Catch
anil Collection Water filtrate
mg
SCF
Ih/hr
Ib/ton
Auimoniiiin Nirratc Participate —
Nil: rate ami Ammonium Nitrate
luea.surud as Ammonia
IIUJ
i|r/DSCF
ll>/hr
Ib/Lon
'l'ol:al Part iculate — Insoluble
and Ammonium Nitrate
UK.)
.(I'/USCF
ll./hr
1 IV Lou
Percent p.'irl: icu late catcli
Run 1°
11-9-78
40.97
2.0
200
21593°
100
14.9
222.23
0.0835
15.46
1.038
MEASURED
as Nitrate as Ammonia
5669.40 5570
2.1355 2.0979
395.36 388.39
26.534 26.067
5892 5792
2.2192 2.1817
410.9 403.9
27.57 27.11
3.8 3.B
Run 2
11-10-78
82 .09
2.0
181
24707
101
14.7
522.14
0.0980
20.74
1.411
MEASURED
as Nitrate as Ammonia
13902.80 13082
2.6136 2.4593
553.65 520.97
37.663 35.440
14425 " 13604
2.7117 2.5574
574.4 541.8
39.08 36.85
3.6 3.8
Run 3
11-10-78
92.69
2.0
182
28666
98
14.6
669.56
0.1112
27.33
1.072
MEASURED
as Nitrate as Ammonia
15622.00 11019
2.6009 1.8346
639.26 450.92
43.785 30.885
16292 11689
2.7121 1.9458
666.6 478.3
45.66 32.76
4.1 5.7
Averacje
71.92
2.0
188
24989
100
14.7
471.31
0.0976
21.18
1.440
MEASURED
as Nitrate as Amonnia
11731.40 9890
2.4500 2.1.306
529.42 453.43
35.994 30.797
12203 10362
2.5477 2.2283
550.6 474.6
37.44 32.24
3.8 4,4
Ul
ai'jry Standard Cubic Feet at 68°F. , 29.92 in. Hg.
bl)ry Standard Cubic Feet Per Minute at 68°F. , 29.92 in. llg.
Only 1 axis traversed during run.
Average ambient air moisture used for test data.
^Volumetric flow data suspected to be low due to only 1 traverse being performed during run.
-------
TABLE 16
SUMMARY OF UNCONTROLLED EMISSIONS FROM THE CHAIN MILL
Date
Volume of Gas Sampled (DSCF)a
Percent Moisture by Volume
Average Stack Temperature (°F)
Stack Volumetric Flow Rate (DSCFM)b
Percent Isokinetic
Production Rate (Tons/Hour)
Insoluble Particulate —
Filter Catch and Collection
Water Filtrate
incj
cjr/DSCF
Ib/hr
Ib/ton
Ammonium Nitrate Particulate
Nitrate and Ammonium Nitrate
measured as Ammonia
mg
rjr/DSCF
Ib/hr
Ib/ton
Total ['articulate —
Insoluble and Ammonia Nitrate
luq
yr/DSCF
Ib/hr
Ib/ton
Percent particulate catch
RUN 1
11-9-78
97.62
0.8
83
1671
101
14.9
-
306.62
0.0484
0.69
0.046
MEASURED
as Nitrate as Ammonia
6200.00 5980
0.9801 0.9452
14.04 13.54
0.942 0.909
6507 G287
1.0285 0,9936
14.73 14.23
0.988 0.955
4.7 4.9
RUN 2
11-10/78
82.55
1.6
81
1399
101
14.7
202.50
0.0378
0.45
0.031
MEASURED
as Nitrate as Ammonia
4096.40 4562
0.7658 0.8528
9.19 10.23
0.625 0.696
4299 4765
0.8036 08906
9.64 10.68
0.656 0.727
4.7 4.3
RUN 3
11-10-78
85.37
4.4
93
1403
105
14.6
281.49
0.0508
0.61
0.042
MEASURED
as Nitrate as Ammonia
6156.80 6263
1.1130 1.1321
13.39 13.62
0.917 0.933
6438 6544
1.1638 1.1829
14.00 14.23
0.959 0.975
4.4 4.3
AVERAGE
88.51
2.2
85
1491
102
14.7
263.54
0.0456
0.59
0.040
MEASURED
as Nitrate as Ammonia
5484.40 5602
0.9530 0.9767
12.21 12.46
0.828 0.846
5748 5865
0.9986 1.0224
12.79 13.05
0.868 0.886
4.6 4.5
Dry Standard Cubic Feet at 68°F., 29.92 in. Hg.
Dry Standard Cubic Feet Per Minute at 68°F., 29.92 in. Hg.
-------
TABLE 17
SUMMARY OF CONTROLLED EMISSIONS PROM THE PRECOOLER
AND CHAIN MILL SCRUBBER OUTLET
Date
Volume of Gas Sampled (DSCF)a
Percent Moisture by Volume
Average Stack Temperature ( F) .
Stack Volumetric Flow Rate (DSCFM)
Pressure Drop Across Scrubber (in.H-O)
Percent Isokinetic
Percent Opacity Average
Production Rate (Tons/hour)
Insoluble Particulate - Filter Catch
and Collection Water Filtrate
ing
gr/DSCF
Ib/hour
Ib/ton
. Ammonium Nitrate Particulate - Nitrate
and Ammonium Nitrate Measured
as Ammonia
nuj
yr/DSCF
Ib/hour
Jb/ton
Total Particulate - Insoluble and
Ammonium Nitrate
nig
gr/DSCF
lb/liour
Ib/ton
Percent Particulate Catch
Run 1
11-9-78
89.15
3.4
112
25866
3.2
102
9.8
14.9
3.51
0.0006
0.13
0.009
Measured as
Nitrate Ammonia
62.40 164.85
0.0108 0.0285
2.40 6.33
0.161 0.425
65.91 168.36
0.0114 0.0291
2.53 6.46
0.170 0.434
5.3 2.1
Run 2
11-10-78
89.54
4.0
112
25843
6.9
102
14.7
10.78
0.0019
0.41
0.028
Measured as
Nitrate Ammonia
117.12 1309.88
0.0202 0.2258
4.47 50.02
0.304 3.403
127.90 1320.66
0.0221 0.2277
4.88 50.43
0.332 3.431
8.4 <1
Run 3
11-10-78
93.19
4.9
113
27062
6.8
102
14.6
3.46
0.0006
0.13
0.009
Measured as
Nitrate Ammonia
87.79 1758.92
0.0145 0.2913
3.37 67.58
0.231 4.629
91.25 1762.38
0.0151 0.2919
3.50 67.71
0.240 4.638
3.8 <1
Average
90.63
4.1
112
26257
5.6
102
14.7
5.92
0.0010
0.23
0.015
Measured as
Nitrate Ammonia
89.10 1077.88
0.0152 0.1819
3.41 41.31
0.232 2.819
95.02 1083.80
0.0162 0.1829
3.64 41.53
0.247 2.834
5.8 1.0
3 Dry Standard Cubic Feet at 68°F, 29.92 in. Hg.
b Dry Standard Cubic Feet Per Minute at 68°F, 29.92 in. Hg.
-------
C. Cooler
The emission test results for the cooler scrubber inlet
appear in Tables 18 and 19. Four tests were conducted
at this location. The first test was repeated due to an
unacceptable final leak check on the sampling apparatus
and several process disturbances. The static pressure
at the inlet to the scrubber was measured rather than
scrubber pressure drop because there was no pressure tap.
2.3 Ammonia Results
Tables 20 through 27 present the results of total ammonia,
ammonium nitrate (as calculated from moles of ammonia), and
excess ammonia (ammonia not combined with ammonium nitrate)
for each test location. The excess ammonia was determined
from the difference between ammonium nitrate (as calculated
from moles of ammonia) and measured nitrate particulate.
A sample calculation for excess ammonia is provided in
Appendix 6.13.
The ammonia emission data represent the catch of the treated
water sample, the 1.0 N H-SO. sample and the train filter.
At each test location, the highest concentration of ammonia
was found in the treated water sample. The average percentage
of ammonia in the treated water samples at each location is
as follows:
• Evaporator Inlet 72.3%
• Combined Evaporator-Pan Granulator Inlet 72.9%
• Combined Evaporator-Pan Granulator Outlet 33.5%
• Precooler Inlet 99.8%
• Chain Mill Inlet 99.5%
• Combined Precooler-Chain Mill Outlet 66.8%
• Cooler Inlet 97.9%
The ammonia collection efficiency of the Buffalo Forge Scrubber
is presented in Table 26. The efficiency was calculated by
adding the total ammonia recovered from corresponding test
28
-------
TAMI.E in
SUMMARY OF EMISSION TEST RESULTS FOR THE
COOLER SCRUBBER INLET
(English and Metric Units)
lla to
Volume of Clas Sampled
PC r c:en t Mo i a 1. u re by
Vn 1 nine
Av/eraqe Stack Temp.
Sl:..u:k Volumetric Flow
Kate
Percent Isokinctic
Production Rate
Insoluble Particulate-
F.i 1 tor Catch and
Collection Water
Fi 1 tratc
Aimiuiii i inn Ni I ti y Normal i zed Cubii- Motors at 20 'c, 760 nun II.).
' l:iy SI .nularil Cul.ir Fool, at (.u"f, 29.92 in. ll<|. por minute
Dry Normalized Cubic Meters at 20 C, 760 mm IKj.per minute
-------
TABUS 19
SUMMARY OP EMISSIONS TEST RESULTS FOK THE COOLER
SCRUBBER INLET
IRun 1
11-5-78
Volume of Gas Sampled (DSCP)a 106.36
Percent Moisture by Volume 1.4
Average stack Temperature ( F) . 167
Stack Volumetric Plow Rate (DSCFM) 12536
Percent Isokinetic 96
Average Static Pressure (in.l^O) -1.5
Production Rate (tons/hour) 14.4
Insoluble Particulate — Filter
Catch and Collection Water Filtrate
aig 25.24
ur/DSCF 0.0037
Ib/lir 0.39
Ib/ton 0.027
Auiinoniuni llittatt! Particulate —
Nitrate and Ammonium Nitrate MEASURED
measured an Ammonia as Nitrate aa Ammonia
mcj 561.60 480.65
gr/HSCF 0.0815 0.0698
Ib/hr 8.74 7.50
lb/l:nn 0.607 0.521
Total Part iculate — Insoluble
and Ammonium Nitrate
iiuj 586.84 506. 09
gr/IJSCF 0.0852 0.0735
Ib/lir 9.13 7.89
Ib/ton 0.634 0.548
Percent {'articulate catch ... ,. „
a Dry Standard Cubic Feet at 68°F., 29.92 in. llg.
Run 2
n-i-fa
105.19
1.3
173
12396
96
-1.6
14.7
14.04
0.0021
0.22
0.015
MEASURED
as Nitrate as Ammonia
315.60* 295.91
0.0463 0.0434
4.91 4.61
0.334 0.313
329.64 309.95
0.0484 0.0455
5.13 4.83
0.349 0.328
4.2 4.5
Run 3
11-4-78
109.83
1.3
168
12249
101
-1.8
14.1
24.75
0.0035
0.36
0.026
MEASURED
as Nitrate as Ammonia
638.40 600.52
0.0897 0.0844
9.40 8.86
0.666 0.628
663.15 625.27
0.0932 0.0879
9.76 9.22
0.692 0.654
3.7 4.0
Run 4
ii-4^n
111.01
1.2
174
12348
101
-1.7
14.7
18.97
0.0026
0.28
0.019
MEASURED
As Nitrate as Ammonia
360.00 348.71
0.0500 0.0485
5.29 5.13
0.360 0.349
378.97 367.68
0.0526 0.0511
5.57 5.41
O.379 0.368
5.0 5.2
Average
108.10
1.3
171
12382
99
-1.7
14.5
20.75
0.003O
0.31
0.022
MEASURED c
as Nitrate as Ammonia
468.90 431.50
0.0669 0.0615
7.09 6.53
0.492 0.453
489.65 452.25
0.0699 0.0645
7.40 6.84
0.514 0.475
4.3 4.7
LO
O
Dry Standard Cubic Feet Per Minute at 68°F., 29.92 in. llg.
Used Cor Concentration and Emission Factors.
-------
TABLE 20
SUMMARY OF AMMONIA AND AMMONIUM NITRATE UNCONTROLLED EMISSIONS
AT THE EVAPORATOR-CALCULATED FROM COLLECTED AMMONIA
Date
Volume of Gas Sampled (DSCF)a
Stack Volumetric Flow Rate (DSCFM)b
Production Rate (Tons/hour)
Total Ammonia
mg
gr/DSCF
Ib/hr
Ib/ton
Ammonium Nitrate Calculated
From Moles of Ammonia
nig
gr/DSCF
Ib/hr
Ib/ton
Excess Ammonia (ammonia not
combined with ammonium nitrate)
mg
gr/DSCF
Ib/hr
Ib/ton
Run 1
11/7/78
26.41
1403
14.7
333.42
0.1948
2.34
0.159
1569
0.9168
11.03
0.750
301.4
0.1761
2.12
0.144
Run 2
11/8/78
29.34
1321
14.7
383.53
0.2017
2.28
0.155
1805
0.9494
10.75
0.731
350.0
0.1841
2.09
0.142
Run 3
11/8/78
21.31
1048
15.2
290.93
0.2107
1.89
0.124
1369
0.9914
8.91
0.586
262.2
0.1899
1.71
0.112
Average
25.69
1257
14.9
335.96
0.2024
2.17
0.146
1581
0.9525
10.23
0.689
304.5
0.1834
1.97
0.133
U)
Dry Standard Cubic Feet at 68 F, 29.92 in. Hg.
b Dry Standard Cubic Feet Per Minute at 68°F, 29.92 in. Hg.
-------
TAHI.fc: 21
UllMMAIiY OF AMMONIA AND AMMONIUM NITRATE UNCONTROLLED EMISSIONS
AT THE COMU1NEU EVAPORATOR-PAN CKANULATOR INLET - CAI.CUI.AreD FROM COLLECTI3D AMMONIA
Dale
Volume of Gas Sampled (DSCF)a
Stack Volumetric Plow Rate (DSCFM)b
Production Rate (Tons/Hour)
Total Ammonia
IK]
• |i- /DSCF
Ib /hr
Id /ton
Ammonium Nitrate Calculated
F 1:0111 Moles ot: Ammonia
IIK|
<|i /IWCF
11. /hr
Ih /ton
Kxciiss Ammonia (Ammonia Not
Combi noil With Ammonium Nitrate
m
-------
TABLE 22
SUMMARY OF AMMONIA AND AMMONIUM NITRATE UNCONTROLLED EMISSIONS
AT THE PAN GRANULATOR INLET TO THE SCRUBBER-CALCULATED FROM COI.LECTED AMMONIA3
Date
Stack Volumetric Flow Rate (DSCFM)
Production Rate (Tons/Hour)
Tota 1 Ammon iurn
gr/DSCF
Ib/hr
Ib/ton
Ammonium Nitrate Calculated
From Moles of Ammonia
gr/DSCF
Ib/hr
Ib/ton
Excess Ammonia (ammonia not
combined with ammonium nitrate)
gr/DSCF
Ib/hr
Ib/ton
Run 1
11-7-78
6533C
14.7
0.3324
18.62
1.267
1.5641
87.61
5.960
0.0568
3.18
0.216
Run 2
11-8-78
6034C
14.7
0.1262
6.53
0.444
0.5932
30.69
2.088
0.0215
1.11
0.076
Run 3
11-8-78
6571C
15.2
0.1211
6.82
0.449
0.5694
32.08
2.111
0.0410
2.31
0.152
Average
6379
14.9
0.1932
10.66
O.720
0.9089
50.13
3.386
0.0398
2.20
0.148
LO
U)
Data determined by difference of evaporator and combined evaporator-pan granulator data.
Dry Standard Cubic Feet Per Minute at 68°p, 29.92 in. Hg.
Cyclonic flow suspected at the combined inlet.
-------
TABLE 23
SUMMARY OF AMMONIA AMD AMMONIUM NITRATE CONTROLLED EMISSIONS
AT THE EVAPORATOR AND PAN GRANULATOR SCRUBBER
OUTLET-CALCULATED PROM COLLECTED AMMONIA
DATE
Volume of Gas Sampled (DSCF)
Stack Volumetric Plow Rate (DSCFM)
Production Rate (Tons/Hour)
Total Ammonia
my
gr/DSCF
Ib/hr
Ib/ton
Ammonium Nitrate Calculated
from Moles of Ammonia
cncj
yr/IJSCF
Ib/hr
Ib/ton
Excess Ammonia (ammonia not combined
wi tli ammonium nitrate)
my
yr/DSCf
]b/lir
Ib/ton
Run 1
11-7-78
77.63
9089C
14.7
t
1136.16
0.2259
17.60
1.197
5347
1.0629
B2.83
5.635
1126.0
0.2238
17.44
1 . 186
Run 2
11-8-78
75.94
8773C
14.7
793.78
0.1613
12.13
0.825
3735
0.7591
57.10
3.884
784.8
0.1595
12.00
0.816
Run 3
11-8-78
78.74
9214°
15.2
590.81
0.1158
9.15
0.602
2780
0.5449
43.05
2.832
586.3
0.1149
9.08
0.597
Average
77.44
9025
14.9
R40.25
0.1677
12 . 96
0.875
3954
0.7890
60.99
4.117
832.4
0.1661
12. B4
0.866
to
3 Dry Standard Cubic' Feed at 68°F., 29.92 in. llg.
Dry Standard Cubic Feed Per Minute at 68°F., 29.92 in. Hcj.
Volumetric flows adjusted for excessive moisture. All subsequent calculations adjusted accordingly.
-------
TABLE 24
SUMMARY OF AMMONIA AND AMMONIUM NITRATE UNCONTROLLED
EMISSIONS-CALCULATED FROM COLLECTED AMMONIA AT THE PRECOOLER
DATE
Volume of Gas Sampled (DSCF)a .
Stack Volumetric Flow Rate (DSCFM)
Production Rate (Tons/Hour)
Total Ammonia
mg
gr/DSCF
Ib/hr
Ib/ton
Ammonium Nitrate Calculated
from Moles of Ammonia
ing
cjr/DSCF
Ib/hr
Jb/ton
Excess Ammonia (ammonia not
combined with ammonium nitrate)
UK]
cjr/DSCF
Ib/hr
Ib/ton
Run I
11-9-78
40.97
21593d
14.9
1188.53
0.4458
82.53
5.539
5570
2.0979
388.39
26.067
Oe
-
-
—
Run 2
11-10-78
82.09
24707
14.7
2779.97
0.5226
110.71
7.531
130B2
2.4593
520.97
35.440
Oe
-
_
—
Run 3
11-10-78
92.69
28666
14.6
2341.63
0.3899
95.82
6.563
11019
1.8346
450.92
30.885
Oe
-
_
—
Average
71.92
24989
14.7
2101.71
0.4528
96.35
6.544
9890
2.1306
453.43
30.797
Oe
-
_
—
uv
3 Dry Standard Cubic Feet at 68°F., 29.92 in. Hg.
b Dry Standard Cubic Feet Per Minute at 68°F., 29.92 in. Hg.
£
Only 1 axis traversed during run.
Volumetric flow data suspected to be low due to 1 axis-traverse being conducted during run.
6
Negative values calculated.
-------
TABLE 25
SUMMARY OF AMMONIA AND AMMONIUM NITRATE UNCONTROLLED
EMISSIONS-CALCULATED FROM COLLECTED AMMONIA AT THE CHAIN MILL
Date
Volume ol: Gas Sampled (DSCF)a
Stack Volumetric flow Rate (DSCFM)
Production Rate (Tons/Hour)
TolaJ Ammonia
IIKJ
gr/DSCF
Ib/hr
Ib/Lon
Ammonium Nitrate Calculated
From Moles of Ammonia
MU)
ijr/DSCF
ib/lu-
Ih/Lon
Excess Ammonia (Ammonia not
combined with ammonium
nit rate)
Illlj
(jr/DSCF
Ib/hr
Ib/ton
Run 1
11/9/78
97.62
1671
14.9
1270.61
0.2009
2.88
0.193
5980
0.9452
13.54
0.909
Oc
-
-
"
Run 2
11/10/78
82.55
1399
14.7
969.43
0.1812
2.17
0.148
4562
0.8528
10.23
0.696
98.6
0.0184
0.22
0.015
Run 3
11/10/78
85.37
1403
14.6
1330.86
0.2406
2.89
0.198
6263
1.1321
13.62
0.933
22.7
0.0041
0.05
0.003
Averaqe
88.51
1491
14.7 .
1190.30
0.2076
2.65
0.180
5602
0.9767
12.46
0.846
40.4
0.0075
0.09
0.006
OJ
JDry Standard Cubic Feet at 68°F., 29.92'in. Hg.
'iJry Standard Cubic Feet Per Minute at 68°F., 29.92 in. Hg.
"Negative Value Calculated.
-------
TABLE 26
SUMMARY OF AMMONIA AND AMMONIUM NITRATE CONTROLLED
EMISSIONS AT THE PRECOOLER AND CHAIN MILL SCRUBBER OUTLET
-CALCULATED FROM COLLECTED AMMONIA
Date
Volume of Gas Sampled (DSCF)a
Stack Volumetric Flow Rate (DSCFM)
Production Rate (Tons/hour)
Total Ammonia
my
gr/DSCF
Ib/hour
Ib/ton
Ammonium Nitrate Calculated From
Moles of Ammonia
nig
gr/DSCF
Jb/hour
Ib/ton
Excess Ammonia (Ammonia not combined
with ammonium nitrate)
m
-J
a Dry Standard Cubic Feet at 68°F, 29.92 in.llg.
b Dry Standard Cubic Feet Per Minute at 68°F, 29.92 in.llg.
-------
TABLE 27
SUMMARY OF AMMONIA AND AMMONIUM NITRATE EMISSIONS AT COOI.ER SCRUBBER INLET
-CAICUTATEI) FROM COLLECTED AMMONIA
Date
Volume of Gas Sampled- (DSCF) a
Percent Moisture by Volume
Average Stack Temperature — (°F) .
Stack Volumetric Flow Rate— (DSCFM)
Percent Isokinetic
Production Rate-- (tons/hour)
Total Ammonia
mg
gr/DSCF
Ib/hr
Ib/ton
Ammonia Nitrate Calculated
From Moles of Ammonia
my
(jr/OSCF
Ib/hr
Ib/ton
Excess Ammonia- (ammonia not
combined with ammonium nitrate)
ni'l
• ir/USCF
Ib/hr
Ib/l.on
Run 1
31/3/78
106.36
1.4
167
12536
96
14.4
102.18
0.0148
1.59
0.111
480.85
0.0698
7.50
0.521
Oc
_
_
—
Run 2
11/3/78
105.19
1.3
173
12396
96
14.7
62.88
0.0092
0.98
0.067
295.91
0.0434
4.61
0.313
oc
_
_
—
Run 3
11/4/78
109.83
1.3
168
12249
101
14.1
127.61
0.0179
1.88
0.134
600.52
0.0844
8.86
0.628
0C
__
—
—
Run 4
11/4/78
111.01
1.2
174
12348
101
14.7
74.10
0.0103
1.09
0.074
348.71
0.0485
5.13
0.349
Oc
_
_
—
Average
108.10
1.3
171
12382
99
14.5
9.1.69
0.0131
1.39
0.097
431.50
0.0615
6.54
0.453
Oc
_
_
—
U)
00
Dry Standard Cubic Feet at 68°F., 29.92 in. llg.
Dry Standard Cubic Feet Per Minute at 68°F., 29.92 in. Kg.
Negative values calculated.
-------
runs conducted on the precooler and chain mill inlets
and comparing this value with the total ammonia obtained
at the outlet.
2.4 Visible Emissions Observation Results
Visible emissions observations were conducted on the venturi
scrubber and Buffalo Forge scrubber outlet stacks. Summaries
of these observations are presented in Tables 28 and 29 and
Figures 2 and 3. The emissions measurements were recorded
of the plume between the stack and the detached steam
plume on the evaporator and pan granulator stack. The
length of the steam plume was estimated and recorded during
each observation period. The observations were made for
the duration of the particulate testing at the outlet loca-
tions. The average percent opacity measurement seldom ex-
ceeded 10% for either stack.
2.5 Particle Size Distribution Results
Tables 30 and 31 and Figures 4 and 5 display the results of
the particle size distribution tests conducted on the pre-
cooler and cooler scrubber inlets. A cyclone pre-separator
was used for each test, with the exception of the first test
conducted at the cooler inlet. Test 3 at the cooler inlet
shows only two points because negative weights had been
calculated for six of the nine substrates (see Figure 4).
2.6 Gas Composition Results
The results of the gas composition analyses are shown in
Table 32. Orsat Analyses were performed on the flue gases
at the evaporator and combined evaporator-pan granulator
inlets. Since there was no combustion involved in the pro-
cess, all of the other sampling locations were assumed to
be venting air, whose standard composition is 0% CO-, 20.9%
02, and 79.1% N2.
39
-------
TABLE 28
SUMMARY OF VISIBLE EMISSIONS OBSERVATIONS
VENTURI SCRUBBER STACK
TEST NO.
GENERAL DATA
Date
Time
Steam Dispersion
Distance (Ft)
SIX MINUTE INTERVAL
11/7
1110-1310
80
11/7
1600-1700
68
11/8
0915-1115
100
11/8
1345-1530
47
AVERAGE OPACITY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
(%)
5
5
7
7.5
5
5
5
6
5
6
5
7
5
5
5
' 5
5
5
5
6
10
9.5
11
11
8
10
11.5
10.4
11.5
10
—
—
-
—
—
-
—
—
—
—
8
11
9
10
10
10
9
10
10
10
10
10
10
10
10
10
10
-1£
10
.. 10 ....
.
10
10
10
10
10
10
10
10
10
9
8
10
10
9
10
10
10
10*
-
—
......-_
* 3 Minute Interval
40
-------
TABLE 29
SUMMARY OF VISIBLE EMISSIONS OBSERVATIONS
BUFFALO FORGE SCRUBBER STACK
TEST NO.
GENERAL DATA
Date
Time
SIX MINUTE INTERVAL
AVERAGE OPACITY (%)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
38
29
30
1
11/10
0947-1047
10
9
10
11
10
10
10
10
10
9
—
—
-
-
—
—
—
-
—
-
—
-
-
-
—
-
—
—
—
—
2
11/10
1130-1430
11
11
10
10
10
10
10
11
10
10
11
10
10
11
10
10
11
10
10
10
10
10
10
10
10.
10
10
10
10
10
3
11/10
1430-1630
10
10
11
11
10
10
10
10
10
10
9
11
10
8
9
7.5
8.5
7
6.5
7
-
-
-
-
-
-
—
-
-
41
-------
OPACITY
11/7
1110
10 11 12
1310
1600
1700
0915
O
O
1115
1345
1530
Figure 2
Venturi Scrubber Stack
Visible Emission Observations Plot
42
-------
OPACITY
11/10
0947
1047
1130
1430
s
1630
CO
9 10 11 12
$**&•?
£'.*%',?:•'•:
f.^;-;~r"
Figure 3
Buffalo Forge Scrubber Stack
Visible Emission Observations Plot
43
-------
TABLE 30
SUMMARY OF PARTICLE P\7.f. DISTR MUITTON TESTS CONDUCTED ON THE
COOLER SCRlinBKR INLET AT N-ReN CORPORATION
PP.YOR, OKLAHOMA
Test Test Test Participate Particle
Mumber Date Time Concentration Size Ranye
(gr/DSCF) (microns)
1 11/4/78 1310 - 1410 0.10320 >9.94
9.94 - 6.19
6.19 - 4.19
4.19 - 2.84
2. 84 - 1.81
1.81 - 0.89
0.89 - 0.54
0.54 - 0.32
<0.32
2 11/5/78 0850 - 1050 0.03725 >9.96
9.96 - 6.20
6.20 - 4.19
4.19 - 2.85
2.85 - 1.82
1.82 - 0.90
0.90 - 0.54
0.54 - 0.33
<0. 33
3 11/5/78 1130 - 1330 0.03354 >10.40
10.40 - 6.48
6.48 - 4.38
4. 38 - 2.98
2.98 - 1.90
1.90 - 0.94
0.94 - 0.57
0.57 - 0.35
<0.35
Mass in
Size Range
<%)
76.96
15.71
4.87
1.17
0.27
0.30
0.44
0.14
0.13
96.75
1.14
0.63
0.24
0.12
0.70
0.27
0.00
0.16
98.58
0.00
0.00
0.00
0.00
0.70
0.72
0.00
0.00
-------
PARTICLE SIZE DISTRIBUTION
•»» 99.9 99J
99 98 35 90 80 70 rj M JO 30
10
2 1 03 03 0.1 OOS O01
IOOO
^^JHyBi^^i^^^^^^MMM^^^MMU**«MM*H*telN*MB**«MB«Mfc«*MMM^M»^W*«
10 20 30 *0 30 60 70 30 30 99 9fl
0.01 OOS 0.1 0.2 03 1 2
9.1
O.I
CUMULATIVE PER CENT 3Y WEIGHT LESS THAN(Op)
Figure 4
Composite Particle Size nistribution-Cooler Inlet
45
-------
TABLE 31
SUMMARY OF PARTICLE sr/.p: 01KTIUUMT1 ON TKSTS CONHUCTPin
ON THE PRECOOLER SCRUBBER INLET AT N-ReN CORPORATION
PRYOR, OKLAHOMA
CTl
Test Test Test Particulate Particle
Number Date Time Concentration Size Range
(gr/DSCF) (microns)
1 11/6/78 0911 - 0951 1.53400 >9 .
9.32
5.80
3.92
2.66
1.69
0.83
0.49
<0.
2 11/6/78 1035 - 1050 2.86298 >9.
9.32
5.80
3.92
2.66
1.69
0.83
0.49
<0.
3 11/6/78 1135 - 1150 2.94889 9.
9.32
5.80
3.92
2.66
1.69
0.83
0.49
32
- 5.80
- 3.92
- 2.66
- 1.69
- 0.83
- 0.49
- 0.27
27
32
-5.80
- 3.92
-2.66
- 1.69
- 0.83
-0.49
- 0.26
26
32
-5.80
- 3.92
- 2.66
- 1.69
- 0.83
- 0.49
- 0.27
<0.27
Mass In
Size Range
(%)
99.34
0.12
0.07
0.01
0.01
0.05
0.18
0.17
0.05
99.47
0.31
0.07
0.00
0.00
0.04
0.10
0.00
0.00
99.47
0.31
0.07
.0.00
0.01
0.04
0.08
0.02
0.00
-------
PARTICLE SIZE DISTRIBUTION
9»39U »9» 98 90 « 70 « 50 JO 30 ffl -.0 5 210302 0100S 001
IOOO
ai
CUMULATIVE PER CENT 8V WEIGHT LESS THAN(DP)
Figure 5
Composite Particle -Size Distribution-Precooler Inlet
o.i
47
-------
TABLE 32
SUMMARY OF GAS COMPOSITION DATA
Gas Composition
Location
Cooler Inlet
Evaporator Inlet
Evaporator-Pan
Granulator Inlet
Evaporator-Pan
Granulator Outlet
Precooler Inlet
Chain Mill Inlet
Precooler-Chain Mill
Outlet
Date
11/3 -
11/7 -
11/7 -
11/7 -
11/9 -
11/9 -
11/9 -
11/4
11/8
11/8
11/8
11/10
11/10
11/10
(Average-Dry Percent Basis)
% CO? % O9 % N? **
0
0*
0*
0
0
0
0
20.
18.
20.
20.
20.
20.
20.
9
4*
9*
9
9
9
9
79.
81.
79.
79.
79.
79.
79.
1
6
i
1
1
1
1
1
oo
* These values are results from Orsat Analyses, These analyses were not nerformed at
the other locations. The standard gas composition of air is 0% CO2, 20.9% O2/ 0% CO
and 79.1% N~.
**
By difference
-------
2.7 Scrubber Solution Results
Scrubber solution analyses for the venturi scrubber and the
Buffalo Forge scrubber are summarized in Tables 33 and 34,
respectively. The temperature and pH measurements were
made in the field immediately after collection of the
samples. The treated and untreated samples were analyzed
for ammonium nitrate and ammonia at YRC laboratory in
Stamford, Connecticut. (See Appendix 6.11).
The higher removal efficiency of the Buffalo Forge scrubber
for ammonium nitrate and ammonia is evident in Table 35 by
the greater average net gain of these chemicals in both the
treated and untreated samples. It should be noted that the
inlet sampling location of the Buffalo Forge scrubber is
also the outlet sampling location of the venturi scrubber.
Consequently, the data for location "SW 2" in Tables 33 and
34 are similar.
2.8 Pressure Drop Measurement Results
Pressure drop measurements are presented for the venturi
scrubber and the Buffalo Forge scrubber in Tables 36 and 37,
respectively. The average Ap for the three tests at the
venturi scrubber was calculated as 27.0 inches of H_0. All
readings are within 5.2% of this average.
At the Buffalo Forge scrubber, the average Ap for tests 1
through 3 was .calculated as 5.6 inches of H_0. However,
the Ap's measured for the first test are significantly less
(by a factor >2) than those of tests 2 or 3. This may be
explained by either a fluctuation in the scrubber solution
level or the concentration and temperature of the scrubber
solution.
2.9 Temperature and Relative Humidity
Table 38 provides a summary of temperature (wet bulb and
dry bulb) and relative humidity data recorded at the test
site.
49
-------
TABLE 33
SUMMARY OF SCRUBBEK SOLUTION ANALYSIS - VKNTUIU SCRUBBER
Test 8
Location
Date
Time
Temperature (°F)
pl.h
Treated Sample
Ammonium Nitrate (g/1)
Ammonia (cj/1)
% Solids (mg/1)
Untreated Sample
Ammonium Nitrate (q/1)
Ammonia (rj/1)
* Solids (mq/1)
1
SW 1 SW 2
11/7 11/7
1400 1400
90.0 124.0
8.7 7.5
.
72.0 136.0
17.5 23.0
7.149 9.871
56.0 92.8
15.4 19.4
5.053 10.068
2
SW 1 SW 2
11/8 11/8
0915-1130 0915-1130
63.0 123.5
8.83 7.37
60.8 128.0
15.4 20.0
6.907 11.699
72.0 122.4
15.1 20.0
5.648 11.067
3
SW 1 SW 2
11/8 11/8
1330-1515 1330-1515
75.0 127.5
8.61 6.88
68.8 115.2
15.7 19.4
7.488 9.884
64.0 128.0
14.2 19.4
6.177 10.836
AVERAGE
SW 1 SW 2
-
76 125
8.71 7.25
67.2 126.4
16.2 20.8
7.181 10.485
64.0 114.4
14.9 19.6
5.626 10.657
Ul
o
SW 1 - Inlet; SW 2 = Outlet
Temperature and pll recorded in field immediately after collection.
Results were reported as moles NO.,/1 (see Appendix 6.11)
Results wnro reported as |iq Nil (see Appendix 6.11)
-------
TABLE 34
SUMMARY OF SCRUBBER SOLUTION ANALYSIS - BUFFALO FORGE SCKUBBF.R
Test; II
Local, i on
Hate
Time
Temperature ( F)
Pi."
Treated Sample
f^
Ammonium Nitrate (g/1)
Ammonia (g/1)
% Solids (mq/.l)
Untreated Sample
f*
Ammonium N.i trate (g/1)
Ammonia (q/1)
% Solids (mg/1)
1
SW 2 SW .1
1.1/9 11/9
1400-1625 1400-1625
135.0 99.5
6.95 5.65
96.0 624.0
15.7 125.8
8.319 62.3.34
89.6 672.0
17.5 127.4
7.743 62.005
2
SW 2 SW 3
1.1/10 11/10
0845-1100 0845-1100
128.0 100.0
7.30 5.90
100.0 624.0
19.4 124.8
9.9.38 65.233
96.0 704.0
18.8 125.8
10.139 65.410
3
SW 2 SW 3
11/10 11/10
1345-1530 1345-1530
138.5 105.5
6.49 5.49
72.0 624.0
15.7 121.0
8.187 64.643
84.0 672.0
15.7 122.1
8.303 65.455
Average
SW 2 SW 3
_ _
-
133. R 104.3
6.91 5. 68
89.3 624.0
16.9 124.2
8.815 64.070
89.9 682.7
17.3 125.1
8.728 64.290
Ul
SW 2 = Inlet; SW 3 = Outlet
Temperature and pll recorded in field immediately after collection.
Results were reported as moles NO-j/1 (see Appendix 6.11)
Results were reported as |ig Nil., (see Appendix 6.11)
-------
TABLE 35
COMPARISON OF VENTURI AND BUFFALO FORGE SCRUBBER LIQUORS
AVERAGE NET GAINS FOR AMMONIUM NITRATE AND AMMONIA
Sample
Average Net Gain of Sample -A
(g/D
Treated
Ammonium Nitrate
Ammonia
% Solids
Untreated
Ammonium Nitrate
Ammonia
% Solids
Venturi
Scrubber
59.2
4.6
3.384
50.4
14.1
55.255
Buffalo Forge
Scrubber
534.7
107.3
5..031
592.8
107.8
55.562
52
-------
TABLE 36
SUMMARY OF SCRUBBER PRESSURE DROP MEASUREMENTS
VENTURI SCRUBBER
DATE TEST NO.. CLOCK. TIME
11/7/78 ' 1 1115
1125
1325
1340
1355
1410
1425
1555
1610
1625
1635
Average
11/8/78 2 0910
0920
0935
0945
1000
1015
1023
1030
1045
1100
Average
11/8/79 3 1325
1340
1355
1410
1425
1440
1500
1510
Average
Ap, in. H-0
_
27.1
27.3
27.4
27.4
27.4
26.9
26.5
26.8
26.9
26.9
27.1
26.9
27.0
27.1
27.0
26.7
27.0
-
27.2
27.0
28.4
27.1
26.8
26.5
26.5
26.7
26.8
-
27.0
26.8
26.7
AVERAGE Ap= 27.0 in.
53
-------
TABLE 37
SUMMARY OF SCRUBBER PRESSURE DROP MEASUREMENTS
BUFFALO FORGE SCRUBBER
DATE TEST NO. CLOCK TIME
11/9/78 1 1353
1413
1437
1449
1505
1517
1521
•1602
1610
1622
1634
Average
11/10/78 2 0841
0857
0913
0921
0933
0941
1013
1021
1029
1037
1105
Average
11/10/78 3 1452
1508
1520
1532
1552
1614
1638
Average
Ap, in. H20
3.3
3.5
3.2
3.0
3.0
2.9
3.0
2.9
3.4
3.4
3.9
3.2
7.7
6.8
6.9
6.9
6.8
6.8
6.7
6.7
6.7
6.9
7.1
6.9
7.0
6.5
6.5
6.6
7.0
6.9
7.0
6.8
AVERAGE A = 5.6 in.
54
-------
TABLE 38
TEMPERATURE AND RELATIVE HUMIDITY DATA
N-ReN CORPORATION
PRYOR, OKLAHOMA
Date
11/3/78
11/4/78
.
Time
1505
1515
1525
1545
1602
1612
1622
1642
1657
0850
0905
0920
0935
1002
1017
1032
1047
1435
1450
1505
1541
1556
1611
1626
1641
Test
Number
21
3
4
Test
Location
Cooler
.
Cooler
Temperature ,°F
Wet Bulb
67
67
66
64
67
65
65
65
64
57
58
58
j 60
61
j
1
Cooler
61
62
62
65
65
65
65
65
64
63
63
Dry Bulb
87
87
86
84
84
84
84
83
82
63
67
70
72
75
76
78
78
84
84
84
84
84
84
83
82
Relative
Humidity ,%
35
35
34
33
4.1
35
35
37
37
70
58
48
50
44
42
40
40
35
35
35
35
35
33
32
34
" First test conducted at cooler inlet was invalid due to a leak in
the sampling train.
55
-------
TABLE 38 (cont.)
TEMPERATURE AND RELATIVE HUMIDITY DATA
N-ReN CORPORATION
PRYOR, OKLAHOMA
Date
11/7/78
11/8/78
11/9/78
Time
1334
1343
1352
1401
1607
1618
1628
1643
0913.
0931
0949
0958
1014'
1023
1035
1050
1327
1336
1400
1418
1433
1439
1454
1503
1410
1422
1437
1449
1504
Test
Number
1
2
3
1
Test
Location
Evaporator-
Temperature,0?
Wet Bulb Dry Bulb
54
Pan Granulator 53
Evaporator^-
58
58
57
58
57
59
57
Pan Granulator
Precooler
56
57
58
58
58
57
57
60
60
60
62
62
61
60
60
53
53
53
54
54
71
73
82
80
80
78
78
81
71
72
74
74
76
76
76
76
87
87
82
86
85
86
84
84
70
71
75
72
73
Relative
Humidity ,%
31
23
21
24
21
28
25
25
41
35
34
37
32
32
29
29
18
18
26
24
26
22
22
22
30
28
19
29
26
56
-------
TABLE 38 (cont.)
TEMPERATURE AND RELATIVE HUMIDITY DATA
N-ReN CORPORATION
PRYOR, OKLAHOMA
Date
11/10/78
Time
1513
0843
0858
0913
0925
0943
0955
1007
1025
1043
1101
1338
1356
1414
1432
1450
1505
1517
1535
1553
1609
Test
Number
2
3
Test
Location
Precooler
Temperature ,°F
Wet Bulb
53
55
55
55
Precooler
56
57
58
58
58
59
59
62
62
64
65
63
64
62
62
62
62
Dry Bulb
73
63
64
64
65
66
67
67
68
69
70
74
73
75
75
78
76
74
74
74
74
Relative
Humidity ,%
23
60
56
56
57
58
58
58
55
55
52
51
54
55
59
43
52
51
51
51
51
N.B.: Temperature measurements were made by a member of the test
crew at the designated test site and recorded on the data
sheets (Appendix 6.4)
57
-------
The relative humidity values were extrapolated from
relative humidity tables (See Appendix 6.12).
2.10 Process Samples. Results
Composite samples of the various process materials were
collected from the process samples used for the bulk
density and sieve analyses. Bulk density and sieve analyses
are discussed in detail in Section 5.10. The samples were
given to Mr. John Garrison of N-ReN Corporation, to be
stored for future analyses. No data are presented on the
process samples because of N-ReN Corporation's request
for confidential treatment of this material.
58
-------
3.0 PROCESS DESCRIPTION AND OPERATION
3.1 Process Description
The N-ReN Corporation in Pryor, Oklahoma produces fertilizer
grade ammonium nitrate using a pan granulation process.
Installation of the pan granulator increased the capacity
of the plant from 300 TPD (tons per day), the limit of
the previous prill tower, to 400 TPD. Process equipment
employed at the plant include the following:
• two-stage neutralization unit
• ' pan granulator
• screens
• rotary drum precooler
• cooler
• rotary drum coater
Figure 6 presents a flow diagram of the process. The neutral-
ization step is carried out in two vessels in series. Over-
heads from both vessels are used to preheat the HNO., feed.
The overheads from the first-stage neutralizer pass through
an HV Brinks unit before being used for preheating. Over-
heads from the second neutralizer enter a Sly Scrubber after
serving as a preheat source.
The AN product stream exiting the neutralizers enters a tank
which also receives scrubber liquor recycle (85% AN tank).
It then flows to a Whitlock, air-swept, falling film evapor-
ator and is concentrated. Overheads from the evaporator
enter the same adjustable-throat venturi scrubber that con-
trols the pan granulator exhaust.
Concentrated AN solution leaves the evaporator and enters
a process tank, where an additive is introduced into the
melt. This additive surrounds the individual crystals
formed during the granulation process and allows crystal
expansion and contraction through various phase changes
59
-------
TO
ATMOSPHERE
TO
ATMOSPHERE
CTv
O
BUFFALO
FORCE
SCRUBBER
SCRUBBER LIQUOR
OVERFLOW
— PRODUCT STREAM
— AIR STREAM
-- SCRUBBER LIOOUR STREAM
SAMPLING POINT
TO WAREHOUSE
Figure 6
Process Flow Diagram
N-ReN Corporation, Pryor, Oklahoma
-------
while preventing granule disintegration.
Formation of solid AN takes place in a pan granulator.
The molten AN is sprayed onto a bed of seed material. Of
particular importance to the operation of the pan granu-
lator is the temperature of operation and rate of molten
AN cooling.
All of the product which leaves the pan. granulator is de-
livered to a rotary drum precooler. Inlet air to the pre-
cooler is cooled and exhausted through a Buffalo Forge
scrubber.
Product exiting the precooler is sent through an enclosed
lump breaker and delivered by a bucket elevator to the
Rotex recycle screen. A dust pick-up on the recycle bucket
elevator exhausts dust from the lump breaker and elevator
through the Buffalo Forge scrubber. Undersized granules
are recycled to the pan granulator. Those granules not
passing through the crusher screen are returned to the
crusher. The product size can be varied by simply changing
the screen sizes. The initial Rotex recycle screen, the
crusher screen, the crusher, and the transfer points are
all exhausted to the Buffalo Forge scrubber.
Properly sized product leaving the Rotex recycle screen is
conveyed by a belt and a vibrating conveyor to the rotary
drum product cooler. Inlet air to the product cooler is
cooled by chilling coils and then heated by steam coils.
Air exiting the product cooler is exhausted through wet
cyclones.
Product leaving the cooler is lifted by a bucket elevator
to the Sweco product screen. Undersized and oversized
material from this screen is recycled to the process tank
61
-------
upstream of the evaporators. Product AN granules leave
the Sweco product screen and enter the coater screw.
A coating clay and Petro-AG flows by gravity to the enclosed
coater screw. The mixture of AN granules with coating enters
an enclosed rotary drum coater. The granules are lifted by
an enclosed bucket elevator to a belt conveyor for transfer
to the bulk storage warehouse. A dust exhaust pick-up on
the bucket elevator maintains a negative pressure across
the coater screw, rotary drum coater, and bucket elevator.
This air pick-up is exhausted through a baghouse.
The AN granules are stored in piles in an enclosed heated
warehouse. The'final product is transferred by bulk trucks
or railcars. Product granules are removed from the bulk
storage piles by front-end loaders and dropped into a hopper
which feeds the bulk loading equipment. The hopper has a
dust pick-up that exhausts through a baghouse. There is no
dust control where the granules are dropped into the trucks
or railcars.
3.2 Emission Control Equipment
Emission control equipment at this facility consists of an
HV Brinks unit on the first-stage neutralizer, a Sly Scrubber
on the second-stage neutralizer, a variable-throat venturi
scrubber on the evaporator and pan granulator, a Buffalo
Forge scrubber on the precooler/crusher area and two wet
cyclones on the cooler.
The HV Brinks unit on the first-stage neutralizer is an in-
tegral part of the vessel. Mist removed by Teflon elements
is retuned directly to the neutralizer.
The off-gas stream from the second-stage neutralizer is passed
through a Sly Scrubber before it is vented to the atmosphere.
62
-------
The vent stack has a mist eliminator immediately at its exit
point.
'Both the evaporator and the pan granulator exhausts are
controlled by the adjustable-throat venturi scrubber. After
passing through the venturi, the air stream passes through
a cyclonic droplet separator. An induced draft fan exhausts
the air through the collection system.
The Buffalo Forge scrubber controls emissions from the pre-
cooler/crusher area. There is a mesh pad mist eliminator
at the scrubber outlet. An induced draft fan pulls the air
through the collection system and exhausts it through a
metal stack.
The exhaust air from the cooler passes through two wet cy-
clones in parallel, an induced draft fan, and out a metal
stack.
Makeup water is supplied to the scrubber liquor for the
wet cyclones. This liquor is used in the venturi scrubber.
The scrubber liquor leaving the venturi enters the Buffalo
Forge scrubber. A density meter controls the outlet scrubber
liquor from this unit. The liquor is then returned to the
process tank which is upstream of the evaporator.
3.3 Process and Control Equipment Monitoring
A. Cooler Tests
Production rates during the four cooler tests (designated
as tests 1, 2, 3, and 4) were calculated to be 14.4, 14.7,
14.1 and 14.7 tons per hour, respectively. Process summary
data are presented in Table 39. Recycle rates directly
affect the amount of material flowing through the cooler.
However, N-ReN has stated that this information is confi-
dential. By comparing the relative differences in recycle
63
-------
TABLE 39
RELATIVE AVERAGES AND RANGES FOR PROCESS EQUIPMENT OPERATING PARAMETERS
Cooler Test - Summary Data
Run No. 1, 11/3/78
Run No. 2, 11/3/78
Run No. 3, 11/4/78
No.
Column heading
Run No. 4. 11/4/78
. Standard .... . . Standard .... . . Standard .... , . Standard ... , ,
Average High Low Average D High Low Average High Low Average High Low
4 Instantaneous welgh-
belt weight 1,153 13.3 1.170 1,120 1,161 7.4 1,170 1,150 1,151 5.5 1.160 1.140 1.157 11.1 1,170 1,140
5 Gallons per minute of
AN solution to 85
percent tank 52 2.7
6 Level of 99 percent
tank 78 0
7 Level of 35 percent
tank 80
57 48 50.8 1.0
52 50 50.8 1.0
78 78
80 80
78
80
78 78
80 80
8 Relative turbidity
of melt Not operating
Not operating
75
80
A 0.35
52 50
75 75
48
75
80
80 80
t 0.7 i 0 i+O.77
9 Product temperature 3 readings taken during test 3 readings taken during test
into cooler, °F L 0, -2, -2 A-2, 0. -1
10 Product temperature
out of cooler, °F
11 Recycle rate of
granulator AH
1 reading £+8
130 120 132.8
0 48 48
0 75 75
0 80 80
fl+O.6 i 0
2 readings i+4, +5
128.6 3.2 130 120 132.9 1.9 135 131 124.4 3.3
i-f6.4 - i+20 4 0 A+9.0 - i«0 i 0 i+77 - i+90 At60 44-52
3.0 137 130
itSO i+40
-------
rates from one test to another, it is believed that there
was no significant difference during the four tests.
The temperature of the product leaving the cooler appears
to be dependent upon the temperature of the ambient air.
As the ambient air temperature increased, the product temp-
erature exiting the cooler also increased. The average
difference in product temperatures for tests 2, 3 and 4 were
within 8.5 F, or 6.4 percent. This small difference in
temperature is expected to have a negligible impact on
emission rates.
The temperatures of the product entering the cooler for these
same tests were within 10°F. The temperature of the product
entering the cooler also appears to be dependent upon ambient
air temperature. These small differences in temperature
should be considered a normal operating range.
B. Evaporator-Pan Granulator-Tests
Production rates during the three evaporator-pan granulator
tests (designated as tests 5, 6 and 7) were calculated to be
14.7, 14.7 and 15.2 tons per hour, respectively. Process .
summary data are presented in Table 40. The average temp-
erature of the recycle stream to the granulator was lower
in test 6 than in either of tests 5 or 7. The difference between
tests 5 and 6 was 3.5 F, and the difference between tests 6
and 7 was 6.1°F. The average temperatures of the product
leaving the granulator for the three tests were within 3 F
of each other. All other parameters monitored during these
three tests indicate that the process equipment, production
rate and control equipment were functioning in a reasonably
stable manner.
C. Precooler-Chain Mill Tests
The production rates during the three precooler-chain mill
tests (designated as tests 8 , 9 and 10) were determined to
65
-------
TABLE 40
RELATIVE AVERAGES AND RANGES FOR PROCESS AND CONTROL EQUIPMENT
OPERATING PARAMETERS
Pan Granulator/Evaporator Test - Summary Data
CTl
Run No. 5, 11/7/78
No.
4
5
6
7
e
9
10
11
12
13
IS
16
17
18
19
20
21
22
23
26
Colum heading
Instantaneous welghbelt weight
Gallons per minute of AN solution to
85 percent tank
Level of 99 percent tank
Level of 85 percent tank
Relative turbidity of melt
Melt temperature leaving evaporator, °F
Kelt temperature to granulator. °f
Temperature of recycle to granulator, °F
Temperature product leaving granulator, °F
Venturl fan amperage
Pressure of melt to spray nozzles
Recycle rate of granulator AN
Revolutions per minute of granulator
Angle of granulator
Concentration scrubber liquor Into
venturl percent
Concentration scrubber liquor exiting
venturl percent
Percent H2O In product leaving
granulator
Temperature scrubber liquor leaving
venturl, °F
Temperature scrubber liquor Into
venturl. °F
Temperature air exiting granulator, °F
Standard
Average n
1.157 7.5
50.9 2.3
75 0.4
80 0
MO. 6
4+0.8
A 0
A+4.4
A+9.7
91.5 1.2
i 0
A«l
High
1,175
54
75
80
A+0.90
A«
A+2
A+10
A+13
94
A4O.2
A+70
Low
1,150
46.5
74
80
A+O.15
i-3
A-3-
A 0
d«
90
i 0
i+40
2 readings during test
-
-
,2 readings during test 5
2 readings during
141 2.0
1 reading during
162 4.0
test 7,
145
test 82
169
-
, 5
10.6
139
156
Run No. 6, 11/8/78
Standard „. .
Average D High
1.161
50
74
80
A-0.3
A+l
A-1.3
A-W.9
if 7
91
1 0
i«07
No
-
2
2
144
1
160
8.5 1,175
0 50
0.4 75
0 80
A-0.25
A+l
t 0
A+4
AHO
0.4 92
a o
AH20
Low
1.145
50
74
80
A-0.40
A+l
A-3
A-3
At3
91
A-0.1
iV90
data taken during test
-
readings during test
readings during test
... *Note 1 ...
0.8 145
reading during test
2.4 162
-
5, 5
7. 7
.
143
62
156
Run No.
7, 11/8/78
Average Standard Hlgh
1,171
50.
75
80
c+0.03
A+1.25
A-0.5
At7
A+10
90
a+o.z
A+105
No
-
2
2
144
6.
9 0.
0
0
-
:
'
-
0.
-
-
2 1,180
6 52
75
80
i+O.35
A+2
A+l
A+9
A+ll
4 90
itO.4
A+120
Low
1,160
50
75
80
A-0.30
A+1
A-3
A+5
i+9
89
i 0
A*90
data taken during test
-
-
readings during test
readings
0.
2 readings
165
1.
during test
5 144
during teat
8 168
-
5. 5
7. ?
143
72, 74
163
* See Note 1 - Confidential Addendum. Contact Eric Noble, EPA - 919-541-5213
-------
be 14.9, 14.7 and 14.6 tons per hour, respectively. Process
summary data are presented in Table 41.
The temperature of the product entering the precooler in
the first test averaged 3.8°F higher than the second test
and 6.3 F higher than the third test. The recycle rate during
the first test was slightly lower than that during the second
or third precooler tests. This may explain why the tempera-
ture of the product leaving the granulator was higher during
this test.
3.4 Process and Control Equipment Operation
Process operating parameters were monitored during the par-
ticulate sampling runs to insure that measurements represent-
ative of the normal plant operation were obtained. Production
rate parameters were also monitored for determination of pro-
duction rates during emission sampling. Scrubber operating
parameters were monitored while tests on the control equipment
for the pan granulator and the precooler were being conducted.
The results of the monitoring of the process and control
equipment parameters are summarized in Tables 39 through 41.
The symbol "A" denotes the deviation of the recorded value
from the standard value. The standard value is defined as
the first reading recorded for that particular parameter
during a designated testing period. This method was employed
to insure that those parameters deemed confidential by N-ReN
Corporation would remain confidential. At the same time,
this would allow GCA personnel to determine if any of these
parameters directly affected the operation of the process.
Averages of values recorded during the emissions testing,
as well as maximum deviation from the overall average, are
also presented in these tables.
67
-------
TABLE 41
RELATIVE AVERAGES AND RANGES FOR PROCESS AND CONTROL EQUIPMENT
OPERATING PARAMETERS
Precooler Test - Summary Data
CO
No.
4
5
6
7
8
9
10
11
14
15
16
17
18
19
20
21
Column heading
Instantaneous welghbelt weight;
Gallons per alnute of AN solution to
85 percent tank
Level of 99 percent tank
Level of 85 percent tank
Relative turbidity of melt
Product temperature Into precooler, °F
Product temperature out of cooler, °F
Recycle rate of granulator AN
Concentration scrubber liquor
entering Buffalo Forge percent
Concentration scrubber liquor
exiting Buffalo Forge percent
Buffalo Forge scrubber level
Buffalo Forge fan amperage
Air temperature into precooler, °F
Temperature scrubber liquor into
Buffalo Forge, °F
Temperature scrubber liquor out of
Buffalo Forge, °F
Buffalo Forge scrubber liquor nozzle
pressure
Run Ho.
8, 11/9/78
Average Sta°d"d High
1,165 16.
37.1 6.
78 0.
76 0
4+0.08
4+13.9
1 reading
4+63.3
, 2 readings
2 readings
53 2.
118 0.
A-ll
149.5 3.
97 0.
75 0
4 1,180
9 46
4 79
76
4+0.4
4+15
during test
4+80
during test
during test
8 54.
6 119
4 0
4 153
8 98
75
Low
1,135
30
78
76
4-1.1
4 0
4 0
4+40
6. 10
56, 64
5 46.5
117
4-15
143
96
75
Run No.
9, 11/10/78
. Standard ... .
Average _ High
1.161
51
78
78
4-0.2
i+10.
1
4+73
1
1
25
119
A-1.6
144
98
80
11
.3 3
0
0
-
1
reading
-
reading
reading
.7 2
0
-
.7 3
.2 0
1
.9 1,180
.0 55
78
78
4+0.5
4+11
during test
4+110
during test
during test
.3 30.0
119
A 0
.7 150
.7 99
.1 81
Run Ho. 10, 11/10/78
Low
1,140
47
78
78
4-1.0
4+9
4-10
4+50
10.2
55.5
23.0
119
4-4
140
97
78
Average
1,158
45.1
78.5
78
4+0.7
4+7.6
Standard ^
12.7 1,175
5.5 54
1.1 80
0 78
4+1.8
4+14
No readings taken during
4+78
4+100
2 readings during test 11
2 readings during test 55
37.9
121
4+0.7
150.3
100.2
79.4
6.7 49.5
0.5 121
4+5
4.3 154
1.1 102
1.3 81
Low
1,140
40
76
78
4-0.8
4 0
test
4+50
. 11
. 54
31.5
120
4-3
143
99
78
-------
The production rates during the cooler and evaporator-
pan granulator tests can be calculated using the readings
recorded from the integrator on the weighbelt to the ware-
house. This integrator was calibrated by plant personnel
during the week of testing. Each unit reading on the
integrator corresponds to 0.02157 tons of product. The
procedure used to calculate hourly production rates is
presented below.
A = integrator weighbelt reading at end of test
B = integrator weighbelt reading at beginning
of test
A - B \x/ 0.02157 tons\ = tons production
Time between readings! [unit integrator] minute
of A and B in minutes/ treading
ml x / 6^
:fcons productioni x /60 minutes! = tons production
minuteI I hour I hour
An equation correlating the average instantaneous weighbelt
reading and the integrator reading on the weighbelt during
the cooler and evaporator-pan granulator tests was developed
for the precooler test. This was done because the integrator
on the weighbelt to the warehouse was not functioning during
the precooler tests.
A least squares analysis performed on seven sets of data
points resulted in the following equation, with a correlation
coefficient of 0.942: ,
f Average instantaneous
1= 0.048 x I weighbelt reading - 41.1
Production rate I tons j=
Ihoury
1 during test
Therefore, for each of the precooler tests, the production
rate can be calculated by applying the above equation to
the average instantaneous weighbelt reading.
69
-------
70
-------
4.0 LOCATION OF SAMPLING POINTS
4.1 Introduction
Testing was conducted on the cooler, evaporator, pan gran-
ulator, precooler, and chain mill operations at the N-ReN
Corporation in Pryor, Oklahoma. The locations of the ammon-
ium nitrate-ammonia (AN-A) test ports and sampling points
at each test site were determined in accordance with guide-
lines outlined in EPA Method 1 (Sample and Velocity Traverses
for Stationary Sources) .
Temperature and barometric pressure measurements were re-
corded during the sampling program. These measurements
were first recorded from instruments located in a warehouse
approximately a quarter mile from the test sites. This loca-
tion was changed, however, to the actual sampling site,
where the data would be representative of the testing envir
ronment.
This section presents detailed descriptions of the sampling
locations for AN-A, particle size distribution, gas compos-
ition, scrubber pressure drop and opacity observation meas-
urements .
4 . 2 Cooler Inlet
The AN-A sampling ports on the cooler scrubber inlet are
located in the duct which vents the exhaust gases from the
rotary drum cooler to the cyclone scrubber. The inner
duct diameter at this sampling location was measured as
29.88 inches. Two ports, located 99 inches (3.3 duct dia-
meters) downstream of a bend in the duct and 91 inches
(3.0 duct diameters) upstream of a bend in the duct, were
All test methods cited in this report are taken from,
"Standards of Performance for New Stationary Sources,
Appendix A," Federal Register, Volume 42, No. 160,
August 18, 1977.
71
-------
used for sampling. A total of 24 traverse points (12 in
each port), were sampled for 3 minutes each, resulting in
a total test time of 120 minutes (Figure 7).
Particle size distribution samples were obtained at Point A6.
Sampling was conducted for 1 hour for the first test and 2
hours for tests 2, 3, and 4. Static pressure measurements
were recorded every 15 minutes at the AN-A ports during the
tests.
4.3 Evaporator - Pan Granulator
The AN-A sampling ports for the evaporator-pan granulator
process are located in the duct which vents the exhaust from
the evaporator and pan granulator to the venturi scrubber,
and in the duct which vents the exhaust from the separator
to the stack (Figure 8). There were three sampling locations:
i) evaporator inlet, ii) combined evaporator-pan granulator
inlet, and iii) the combined evaporator-pan granulator outlet.
i) Evaporator Inlet
The vertical duct at the evaporator inlet AN-A sampling loca-
tion was determined to have an inner diameter of 21.75 inches.
Two ports, located 133 inches (6.1 duct diameters) downstream
of a bend in the duct and 109 inches (5.0 duct diameters) up-
stream of the inlet duct from the pan granulator, were sampled
at 16 traverse points, 8 in each port. Each point was sampled
for 6 minutes, resulting in a total test time of 96 minutes
(Figure 9) .
A grab sample of the flue gas was taken at point A4 in the
evaporator inlet and was analyzed for C0_, and 0_ with an
Orsat Analyzer. (Refer to Section 5.6, "Gas Composition", for
further details.
72
-------
B (TOP)
r~\
Cooler
Inlet
Ports
29.875
7
15
Rotary
Drum
Cooler
A O
>"-3|*— 91"
Cyclone
Scrubber
(Elevation View)
(Cross section of duct)
SAMPLING
POINT
1
2
3
4
5
6
7
8
9
10
11
12
DISTANCE FROM
STACK WALL (IN.)
1.00
2.00
3.53
5.29
7.47
10.64
19.24
22.41
24.59
26.35
27.88
28.88
* A6 - particle size sampling location
COOLER INLET PORT AND SAMPLING POINT LOCATIONS
FIGURE 7
-------
N
s
( ,
Cyclonic
Droplet
Separator
(n
w
B
rth
st)
30'
A—
From
Evaporator
rrrz
133"
(sou
Evaporator-
Pan Granulator
202- Combined
Outlet
Ports
log-
(north'
east)
Evaporator -
Pan Granulator
Combined Inlet
Ports
A (south)
21. 1
Evaporator
Inlet
Ports
B
(East)
Wenturi Adjustable-Throat
loo" Scrubber
To Fan
From
Pan Granulator
B (east)
EVAPORATOR - PAN GRANULATOR PORT LOCATIONS
FIGURE 8
-------
Port B
(east)
SAMPLING POINT
1
2
3
4
5
6
7
3
Port A
(south)
DISTANCE FROM STACK WALL (IN.)
1
2
00
28
4.22
7.03
14.72
17.53
19.47
20.75
* A4 - Gas Composition Sampling Point
EVAPORATOR INLET SAMPLING POINT LOCATIONS
FIGURE 9
75
-------
ii) Combined Evaporator-Pan Granulator Inlet
Two ports, located 36 inches (1.7 duct diameters) downstream
of the pan granulator inlet duct and 15 inches (0.9 duct dia-
meters) upstream of a bend in the duct, were sampled with a
total of 32 traverse points. Sixteen traverse points were
sampled in each port, across a measured inner duct diameter
of 21.75 inches. Each point was sampled for 3 minutes, re-
sulting in a total test time of 96 minutes (Figure 10).
A grab sample of the flue gas was obtained at point A-8,
and was analyzed for CO-, and 0- with an Orsat Analyzer.
iii) Combined Evaporator-Pan Granulator Outlet
The diameter of the vertical duct at the combined evaporator
pan granulator outlet was determined to be 30 inches. Two
ports, located 202 inches (6.7 duct diameters) downstream of
a bend in the duct and 100 inches (3.3 duct diameters) upstream
of a bend in the duct, were used for sampling. Twenty-four
traverse points, twelve in each port, were sampled for 5 minutes
each, resulting in a total test time of 120 minutes (Figure 11).
The pressure drop across the venturi scrubber was recorded by
the operator at this location. The inlet pressure was obtained
at the combined evaporator-pan granulator inlet port and the
outlet pressure was obtained at the combined evaporator-pan
granulator outlet port. (Refer to Section 5.3, "Auxiliary Test
Data") .
Visible emissions observations were recorded on the combined
evaporator-pan granulator controlled emissions. Figure 12
indicates the relative positions of the observation sites.
These locations were determined in accordance with EPA Method
9 (Visual Determination of the Opacity of Emissions from
Stationary Sources). The observer stood on a rooftop which
was east of the stack. He was positioned either southeast or
northeast of the stack, depending upon the location of the sun.
76
-------
Port B
(east)
SAMPLING POINT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Port A
(south)
DISTANCE FROM STACK WALL (IN.)
1,
1,
1,
00
07
85
2.72
3.68
4.79
6.16
8.16
13.59
15.59
16.69
18.07
19.03
19.90
20.63
20.75
* A8 - Gas Composition Sampling Point
Evaporator-Pan Granulator Combined Inlet Sampling Point Locations
Figure 10
77
-------
Port B
(northwest)
SAMPLING POINT
1
2
3
4
5
6
7
3
9
10
11
12
Port A
(northeast)
DISTANCE FROM STACK WALL (IM)
1.00
2..01
3.54
5.31
7.50
10.68
19.32
22.50
24.69
26.46
27.99
29.00
Evaporator-Pan Granulator Combined Outlet
Sampling Point Locations
FIGURE 11
78
-------
N
Evaporator - Pan
Granulator
Stack
Precooler-
Chain-Mill
Stack
Building-
Edge
D - position to observe Evaporaior
Pan-Granulator Stack
O- position to observe Precooler
Chain Mill Stack
At times, the observer
stood on the ground to
observe the Evaporator-
?an Granulator Stack
Storage
Warehouse
VIEW FROM TOP
y N
Roof
Top '" '/
"•7
>
1
*-l
\
V"""
0' ',
f
o'
§
\s
/
"^Ai
^s
>
V
o/
£?
f
4-
RorvF ijrrirtr/i \
Top
* -7
ground
level
>w
1
-*-/
>
0/
1
o1
V
—}
*8
\
_*»-
^
a'
«>
ground
level
Elevation View
Precooler - Chain Mill Stack
Elevation View
Evaporator-Pan Granulator Stack
RELATIVE POSITIONS OF OBSERVER FOR VISIBLE
EMISSION MEASUREMENTS
FIGURE 12
_7Q-
-------
At times, the observer evaluated the emissions from the
ground, at a position approximately northeast of the stack.
4.4 Precooler-Chain Mill
The AN-A sampling ports for the precooler-chain mill process
are located in the ductwork which vents the exhaust from the
rotary drum precooler and the chain mill to the Buffalo Forge
Scrubber, and the duct which vents the exhaust from the
scrubber to the atmosphere (Figure 13). Sampling was performed
at three locations: i) the precooler inlet, ii) the chain
mill inlet, and iii) the combined precooler-chain mill outlet.
i) Precooler Inlet
The inner duct diameter of the precooler inlet sampling loca-
tion was measured as 39.25 inches. Two ports, located 56.5
inches (1.4 duct diameters) downstream of a bend in the duct
and 84 inches (2.1 duct diameters) upstream of a bend in the
duct, were used for sampling (Figure 14). A total of 48
traverse points, 24 in each port, were sampled for 3 minutes
each, resulting in a total test time of 144 minutes. Par-
ticle size distribution samples were obtained at ooint A7.
ii) Chain Mill Inlet
The inner duct diameter at the chain mill inlet AN-A sampling
location was measured to be 11.75 inches. Two ports had been
installed 172.5 inches (14.7 duct diameters) downstream of a
bend in the duct and 109 inches (9.3 duct diameters) upstream
of a bend in the duct. Eight traverse points, 4 per port,
were sampled at this location. Each point was sampled twice
for 8 minutes, with a total test time of 128 minutes (Figure 15)
The operator at this location also recorded the pressure drop
across the Buffalo Forge scrubber. Figure 13 indicates the
80
-------
CO
PRECOOLER-
CHAIN MILL
COMBINED
OUTLET
PORTS
A (southwest)
B
231"
i to-/
-Y >
(southwest)
y
17.75
O
/
CHAIN MILL
INLET PORTS
A (top)
109"
FROM
CHAI
MILL.
CHAIN-fr» 11.75"
FAN
B (west)
BUFFALO FORGE SCRUOUER
Pressure drop
measured
here
a
PRECOOLER INLET
PORTS
A (east)
o-
25" O
ROTARY DRUM
PRECOOLER
B (bottom)
GROUND LEVEL
PRECOOLER - CHAIN MILL PORT LOCATIONS
FIGURE 13
-------
Port A
(east)
SAMPLING POINT
1
2
3
4
5
6
'7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Port B
(bottom)
DISTANCE. FROM STACK WALL (IN.)
,00
1
1.25
2
3
16
10
4.12
5.18
6.32
7.61
9.03
10.68
12.68
15.62
23.63
26.57
28.57
30.22
31.64
32.93
34.07
35.13
36.15
37.09
38.00
38.25
* A7 Particle Size Sampling Point Location
PRECOOLER INLET SAMPLING POINT LOCATIONS
FIGURE 14
82
-------
Port A
(top)
Port B
(west)-
SAiMPLING POINT
1
2
3
4
DISTANCE FROM STACK WALL_(.IN.)
1,
2,
3,
00
94
81
10.75
Chain Mill Inlet Sampling Point Locations
FIGURE 15
83
-------
positions where the inlet and outlet pressure measurements
were taken (refer to Section 5.3, "Auxiliary Test Data" for
further details).
iii) Combined Precooler Chain Mill Outlet
The inner duct diamter at the combined precooler-chain mill
outlet AN-A sampling location was measured to be 37.75 inches
Sampling was performed in two ports located 140 inches (3.7
duct diameters) downstream of the fan inlet and 231 inches
(6.1 duct diameters) upstream of the stack outlet. At this
location, 36 traverse points, 18 per port, were required.
Each point was sampled for 4 minutes, resulting in a total
ttst time of 144 minutes (Figure 16).
Visible emissions observations were recorded from the roof
of a building located to the southeast of the stack. The
observer stood either- due east or southeast of the stack to
measure the emissions. (Figure 12).
84
-------
Port A
(southwest)
SAMPLING POINT
1
2
3
4
5
6
7
3
9
10
11
12
13
14
15
16
17
18
Port B
(southeast)
DISTANCE FROM STACK WALL (IN.)
00
66
83
4.11
5.51
7.10
8.91
11.71
14.42
23.33
26.58
28.34
30.65
32.24
33.64
34.92
36.09
36.15
Precooler-Chain Mill Combined Outlet Sampling Point Locations
FIGURE 16
85
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86
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5.0 SAMPLING AND ANALYTICAL PROCEDURES
5.1 Introduction
This section describes the sampling and analytical procedures
used by YRC at N-ReN Corporation, Cherokee Division, Pryor,
Oklahoma during a test program conducted in November 1978.
Brief descriptions of modifications and standard procedures
are presented in this section, details are outlined in
Appendices 6.10 through 6.14.
5.2 Preliminary Measurements
A. Gas Velocity and Temperature
Velocity and temperature were measured at each test location
in accordance with guidelines outlined in EPA Method 2
(Determination of Stack Gas Velocity and Volumetric Flow
Rate). Using a pitot tube and thermocouple, measurements
were made and recorded at each traverse point.
B. Moisture Determination
The moisture content of the stack gas at each test location
was determined in accordance with guidelines outlined in
EPA Method 4 (Determination of Moisture Content in Stack
. Gases).
5.3 Auxiliary Test Data
A. Scrubber Pressure Drop Measurements
The pressure drop across the venturi scrubber was measured
and recorded every 15 minutes by the operator at the scrubber
outlet. The legs of a U-tube manometer were attached to
stainless steel tubes which were attached to taps at the
combined Evaporator-Pan Granulator Inlet and scrubber outlet.
The pressure drop across the Buffalo Forge scrubber was
measured and recorded every 15 minutes at the Chain Mill
Inlet. At this location the legs of a U-tube manometer
were attached to taps at the inlet and outlet of the scrubber,
87
-------
The. pressure drop across the Cyclone scrubber could not be
measured because a tap could not be installed at the scrubber
outlet. However, the static pressure was measured at the
cooler inlet every 15 minutes during sampling.
B. Ambient Air Temperature, Relative Humidity, and Barometric
Pressure Measurements
Ambient air temperatures, in degrees Fahrenheit, were measured
with a wet-bulb/dry-bulb thermometer. The dry bulb thermo-
meter was used to measure the ambient air temperature. Rela-
tive humidity values were obtained by using a table which
correlates wet-bulb and dry-bulb temperatures to percent rela-
tive humidity. Barometric pressure was measured on a barometer
in inches of mercury. These values were measured and
recorded every 10-15 minutes during sampling. However, only
those temperature measurements taken outside were considered
representative of the test site conditions (see Table 38) .
C. Process Samples
Grab samples of the product, melt, and clay were taken. The
samples and results of the analyses (see Section 5.10) were
left with N-ReN personnel because of confidentiality.
5. 4 Ammonium Nitrate
A. Sampling
The sampling apparatus at each location consisted of a probe,
teflon line, impingers, vacuum pump and dry gas meter
(Figure 17) .
The sampling probe was glass-lined with a ball joint at one
end and wrapped with heater tape. A button hook nozzle, of
appropriate diameter, was attached to the probe by means
of a stainless steel coupling. A pre- calibrated, S-type
pitot tube and thermocouple were rigidly attached to the
probe.
88
-------
The correct nozzle size was determined from the velocity
traverse and moisture test. The probe was connected to
the first impinger with a flexible teflon sampling line.
The first and second impingers each contained 100 ml of
distilled water. A tared fiber glass filter, heated to
100°F, was located between the second and third impingers.
The third and fourth impingers contained 100 ml of IN H_S04.
The fifth impinger was empty and the sixth contained 300
grams of indicating type silica gel. The first, second,
fourth and fifth impingers were of the modified type (see
Figure 17).
From the impinger train, sample gas flowed through a check
valve, flexible rubber vacuum tubing, a vacuum gauge, a
needle valve, a leakless vacuum pump and a dry gas meter.
A calibrated orifice at the end of the train was used to
measure instantaneous flow rates. An inclined, vertical
manometer graduated in hundredths of an inch of water from
0 to 1.0 inch and in tenths of an inch of water from 1 to
10 inches was used to measure orifice and velocity pressure
drops.
The stack condition at the Evaporator-Pan Granulator loca-
tions necessitated some modifications in the sampling trains,
Due to the extremely high. (>35%). moisture content of the gas
stream, an additional empty impinger was placed in the train
at the Evaporator Inlet and Pan Granulator Inlet. The
scrubber outlet train did not change. An in-stack orifice
was also placed after the nozzle at the Evaporator Inlet
and Pan Granulator Inlet sampling locations (see Figures
18 and 19). The orifice was precalibrated at several rep-
resentative flow rates. This in-stack orifice was used at
the Evaporator Inlet for Tests 1, 2 and 3, but was only
used for Test #1 at the Pan Granulator Inlet location.
It was removed at this location when plugging resulted
from the excessive moisture and ammonium nitrate loading.
For tests 2 and 3, the probe being used at the Pan-Granu-
lator Inlet was wrapped with an additional heater tape
89
-------
PYROMETER
Distilled
water
ORIFICE
empty
AMMONIUM NITRATE SAMPLING TRAIN
FIGURE 17
-------
In-stack orifice at
Evaporator-Inlet
only.
Otherwise, the orifice follows
the dry gas meter.
IMPINGER TRAIN
FILTER HOLDER
PYROMETER
Distilled
Water
empty
METER
empty
MODIFIED AMMONIUM NITRATE SAMPLING TRAIN FOR Evaporator--
Pan Granulator Inlet Sampling Locations
FIGURE 18
-------
ID
to
MANOMETER TAPS
ORIFICE
GASKET
NOZZLE
IN-STACK ORIFICE AND NOZZLE ASSEMBLY
FIGURE 19
.TIP
-------
and insulated with aluminum foil to minimize me effects
of the high moisture. The probe temperature at the inlet
and outlet sampling locations was maintained at approxi-
mately 10°F plus the stack temperature (TS+10°F), and did
not exceed 160°F throughout the test program.
During tests 2 and 3 at the Pan Granulator Inlet, 100 ml of
distilled water was added to the empty impinger before the
filter and 100 ml of IN H2S04 was added to the IN H2S04
impinger number five. This was done to prevent crystals
from forming in the impingers.
During each test run the following readings were taken
and recorded at each traverse point:
• Point designation
• Clock time
• Dry gas meter reading (cf)
• Velocity head (Ap in inches of water)
• Desired orifice pressure drop (AH in inches of water)
• Actual orifice pressure drop (AH in inches of water)
Dry gas temperatures at meter
Vacuum gauge reading (in. Hg)
Dry gas temperatures at meter inlet and outlet (°F)
• Dry gas temperature at the exit of last impinger (°F)
• Stack temperature (°F)
The relationship of the Ap reading with the AH reading is a
function of the following variables:
• Orifice calibration factor
• Gas meter temperature
• Moisture content of flue gas
• Ratio of flue gas pressure to barometric pressure
• Stack temperature
• Sampling nozzle diameter
The operator was able to sample isokinetically using a
nomograph showing a direct relationship between Ap and AH.
At the Pan Granulator Inlet the pitot tubes became clogged
during tests 1 and 2, and the operator had to assume Ap
values from velocity traverse data until the lines were
cleared.
-------
Sometime during test #1 at the cooler inlet, the glass probe
lining cracked. This was evident when the post-test leak
check failed to meet the requirements of the method (0.02
cfm). This test was voided and another was run in its place.
B. Sample Recovery
At the completion of each test the train was separated
between the probe and teflon sample line. The probe and
impinger train, with the teflon line attached, were carried
to an onsite warehouse that YRC used as a field laboratory.
The samples were placed in glass sample jars with teflon
lined caps. The jars were labeled with date, test location,
test number, contents, and sample number which was logged
into a laboratory notebook.
The total volume of deionized, distilled water in the first
set of impingers was measured and recorded. Deionized,
distilled water was used to wash the front half (i.e.,
all glass before the filter) of the train and the teflon
sample line. The probe and nozzle were rinsed with deionized,
distilled water and brushed three times. The brush was also
rinsed.
The total volume of IN H2S04 in the last set of impingers
was measured and recorded. The back half (i.e., all glass
after the filter except for the silica gel impinger) of
the train was rinsed with IN H_S04.
The silica gel was weighed on a platform balance and the
weight was recorded. The silica gel was returned to its
original container.
The filter from the train was returned to its original
container.
94
-------
Each test had a total of 6 samples:
1 - Untreated portion of the distilled water sample
2 - Treated portion of the distilled water sample
(pH <_ 6)
3 - Filter used to filter the distilled water sample
(funnel filter)
4 - Total IN H2S04 sample
5 - Silica gel
6 - Train filter
One problem occurred during recovery of the Pan Granulator
inlet and outlet samples. In test #1 at the inlet, crystals
formed in two of the front-half and two of the back-half
impingers. Fifty milliliters of the appropriate reagent
were added to each impinger. They also had to be warmed
to room temperature with a heater tape before the crystals
dissolved.
Prior to testing, a cleanup evaluation was performed of
the probe, teflon line, front half of the impinger train,
and back-half of the impinger train. Details of the analysis
are presented in Appendix 6.14.
C. Sample Preparation
The water portions were combined and filtered through a
tared, glass fiber filter using a vacuum. The filtrate
was divided and one half was treated with concentrated •
H-SO. until the pH was 6 or less.
All sample containers were sealed with tape. Liquid levels
were marked and the samples were transported to the YRC
laboratory in Stamford, Connecticut for analysis.
D. Sample Analysis
The total volume of the sample was measured. A 100 ml
aliquot was treated with ionic strength and pH adjusted
reagents. The nitrate molarity of the sample was then
determined using a standardized Specific Ion Electrode
95
-------
and Meter with several dilutions of stock ammonium nitrate
standard. The weight of the ammonium nitrate in the sample
was determined by the following equation.
Wn = 0.08 (Vt Ct - Vb Cb)
where: Wn = Weight of ammonium nitrate collected, grams
V = Total volume of sample, ml
C. = Nitrate molarity of sample, gm-moles/liter
V, = Total volume of blank, ml
C, = Nitrate molarity of blank, gm-moles/liter
0.08 = Grams of NH. N03 per milliequivalent (meg.)
where (V. C. - V, c. ) = meg. NH.NO-.
t t b b 4 J
Since all blanks contained no nitrate, the equation reduced
to the following:
Wn = 0.08 (Vt Cfc)
The train filters were macerated in 150 ml of deionized,
distilled water. The liquid sample was then analyzed for
nitrate molarity using the above procedure.
5.5 Ammonia
A. Sampling and Recovery
The sampling and sample recovery of ammonia samples were
identical to those used for ammonium nitrate. Aliquots
of the same sample were used for the ammonia analysis.
B. Sample Preparation
The water portions were combined and filtered through a
tared, glass fiber filter using a vacuum. The filtrate
was divided and one half was treated with concentrated
H_SO. until the pH was 6 or less.
All sample containers were sealed with tape. Liquid levels
were marked and the samples were transported to the YRC
laboratory in Stamford, Connecticut for analysis.
96
-------
C. Sample Analysis
Two analytical methods were employed for the determination
of ammonia:
Method 1 - Direct Nesslerization
The total volume of the sample was measured. A 20 ml
aliquot of sample was made alkaline and treated with
Nessler reagent and diluted to 25 ml. The resulting
characteristic color was measured colorimetrically at 405 nm
by comparison to a series of ammonia standards. The
results were reported as total micrograms of ammonia in
the sample. This method is used for determining low levels
of ammonia. The filter solution was analyzed for ammonia
using this method.
Method 2 - Specific Ion Electrode
The total volume of the sample was measured. A 50-100 ml
aliquot was withdrawn and made alkaline simultaneously with
a specific ion electrode in the sample.
The concentration of ammonia was then measured potentio-
metrically using an Ammonia Specific Ion Electrode versus
ammonia standards.
The weight of ammonia in grams was determined by the
following equation:
Wa = 0.0012 (Vt Ct - Vb Cb)
where: W = Weight of ammonia, grams
cl
0.0012 = Conversion of (N »NH,) -r 1000 milliliters
J liter
V. = Total volume of sample, milliliters
C. = Concentration of NH., in sample as N, gm-mole/liter
V, = Volume of blank, milliliters
D
C, = Concentration of NH-. in blank as N, gm-mole/liter
97
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5.6 Gas Composition
The gas composition was determined in accordance with
guidelines outlined in EPA Method 3 (Gas Analysis for
Carbon Dioxide, Oxygen, Excess Air and Dry Molecular Weight).
5. 7 Particle Size Distribution
A. Sampling
The particle size distribution samples were collected using
an Andersen Cascade Impactor. Andersen tests were run at
the Cooler Inlet and Precooler Inlet.
The impactor consists of multiple stages which collect
different particle sizes (Figure 20). Each stage consists
of an orifice of a specific diameter above a collection
plate. The orifice sizes of each stage are different and
are arranged in descending order, the largest being stage 1.
The sampling system was set up as shown in Figure 21. The
stack conditions were determined and the sample was extracted
isokinetically at a predetermined average flow point.
The gas sample flows through each orifice, and is deflected
off a tared, glass fiber substrate placed on the collection
plate. Particles of a specific size become impacted on the
substrate while the remaining particles entrained in the
gas stream proceed to the next collection stage. The range
of particle sizes retained on the substrate varies according
to the velocity of the gas (as determined by the sampling
rate and orifice diameter) along with the gas viscosity and
the particle density. Since the orifices are arranged in
descending diameters, the gas velocity increases and the
particle size collected on each stage decreases.
During the sampling,a cyclone preseparator was used to pre-
cut particles above 10 microns and avoid overloading the
collection substrate.
98
-------
ANDERSEN STACK SAMPLER
JET STAGE (9 TOTAL)
SPACERS
NOZZLE
GLASS FIBER
COLLECTION
SUBSTRATE
CYCLONE
PRESEPARATOR
INLET
BACKUP
FILTER
PLATED
HOLDER
CCRE
FIGURE 20
99
-------
ANDERSEN SAMPLING TRAIN
o
o
ANDERSEN
SAMPLER
IMPINGERS
POMP
GAS METER
ORIFICE
MANOMETER
FIGURE 21
\
ES-094
-------
B. Sample Recovery
The contents of the preseparator and a distilled water wash
were placed in a sample jar after each test. The level
was marked and the container was sealed with tape. The
glass fiber substrate filters were returned to their
original containers and sealed.
All samples were transported to the YRC laboratory in
Denver, Colorado for analysis.
C. Analysis
The glass substrate filters were desiccated and weighed to
a constant weight. The net weight gain was recorded to
the nearest 0.01 mg.
The distilled water rinse of the cyclone preseparator was
transferred to a tared, beaker. The water was evaporated by
heating. The beaker was desiccated and weighed to a constant
weight. The net weight gain was recorded to the nearest
0.01 mg.
5.8 Visible Emissions
A. Field Measurements
Visible emissions measurements were conducted at the Pan-
Granulator stack and the Precooler stack by a certified
visual emission evaluator in accordance with EPA Reference
Method 9. (Visual Determination of the Opacity of
Emissions from Stationary Sources). Readings were taken
at 15 second intervals.
The Pan Granulator outlet had a steam plume. The observa-
tions were made of the plume between the stack outlet and
the detached steam plume. The length of the steam plume
and visible emissions after dissipation of the steam plume
were observed. These observations were taken every 10 to
15 seconds.
101
-------
B. Summary of Data
The field measurements were averaged over six minute
intervals and are presented in Table 28 and Table 29.
5.9 Scrubber Solution Samples
A. Sampling
During testing at the Evaporator-Pan Granulator and Pre-
cooler-Chain Mill Duct locations, scrubber solution samples
were taken. Samples of the influent and effluent solution
were collected every 30 minutes during the respective tests.
There were 3 separate sampling locations (Figure 22). The
time of collection, temperature and pH of the sample were
recorded immediately after collection.
B. Analysis
At the end of each test the samples of one location were
combined. Approximately one half of the total sample was
then treated with concentrated H^SO. to a pH of 6 or less;
the remaining portion was untreated.
Each sample was analyzed in Stamford, CT for ammonium nitrate
and ammonia (see methods above, i.e., 5,4 Ammonium Nitrate
Analysis and 5.5 Ammonia Analysis). Each sample was also
analyzed for percent solids. An aliquot of sample was trans-
ferred to a tared beaker. The water was evaporated at 103 C.
The beaker was desiccated and weighed to a constant weight.
The percent solids was calculated.
5.10 Bulk Density and Particle Size of Product
A. Sampling
Product samples were taken from each test location. Samples
taken from conveyor belts were collected in 1 quart jars by
scooping the jar across the flow. Three scoops were made to
fill the jar. Samples from free flowing vents were taken by
placing a jar in the vent directly in the stream of product
flow.
102
-------
SCHEMATIC OF SCRUBBER SOLUTION FLOW
AND SAMPLING LOCATIONS
Evapora-
tor Pan
Granula-
tor
Locations
Venturi
Scrubber
SWJ2
Solution overflow from
cyclone scrubber
Precooler-
Chain Mill
Duct
Locations
Buffalo
Forge
Scrubber
85%
Tank
- flow of solution
)C - sattpling point
SWl - influent solution,
SW2 - effluent solution,
influent solution,
venturi scrubber
venturi scrubber and
Buffalo Forge scrubber
SW3 - effluent solution, Buffalo Forge scrubber
Figure 22
103
-------
B. Analysis
The analyses were performed in the N-ReN laboratory by
YRC and N-ReN personnel. The results are confidential.
Bulk Density:
The sample was passed through a riffle and a 300-350 ml
portion was obtained. The tare weight of a graduated
cylinder was determined. The sample was put into the
graduated cylinder and leveled with the top of the cylinder.
The cylinder and contents were reweighed. The bulk density
is determined by the following:
Bulk Density (lbs/ft3) = (Weight of Sample) (0.2497)
Particle Size:
The particle size of the product is estimated by means of
a sieve analysis. A sieve shaker, timer, balance, sample
splitter, (sieves 4, 6, 8, 10, 12, 14, 16, 20) and a pan
were used.
A sample of approximately 200 grams was obtained by reducing
a grab sample in a sample splitter. The sample was weighed
to the nearest 0.2 gram. The sieves were arranged in
numerical order with the smallest sieve number on top and
a pan on the bottom. The sample was poured into the top
sieve while tapping the stack of sieves. The stack was
next vigorously shaken in a rotary horizontal motion
for one minute. The sieves were then inserted in the shaker
and shaken for five minutes. After shaking,the contents
of each sieve and bottom,pan were weighed.
The percent in each sieve was calculated as follows:
% Retained - (Weight of material) x 100
% Retained (Total Weight)
104
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