United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 78-NHF-6
March 1979
Air
&EPA
Ammonium Sulfate
Emission Test Report
Valley Nitrogen
Helm, California
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SET 2635-01-0179
Final Report
PARTICULATE EMISSIONS FROM AN
AMMONIUM SULFATE PLANT
CONTROLLED BY A CYCLONIC SCRUBBER
EPA Contract No. 63-02-2813
Work Assignment No. 27
Prepared for:
Environmental Protection Agency
Emission Measurement Branch
ESED Mail Drop #13
Research Triangle Park, NC 27711
May 29, 1979
Scott Environmental Technology, Inc.
2600 Cajon Boulevard
San Bernardino, California 92411
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SET #2635-01-0179
TABLE OF CONTENTS
Page No.
1.0 INTRODUCTION 1-1
2.0 SUMMARY OF RESULTS 2-1
3.0 DISCUSSION OF RESULTS 3-1
4.0 PROCESS DESCRIPTION 4-1
5.0 SAMPLING AND ANALYTICAL PROCEDURES ...... 5-1
APPENDIX A - FIELD DATA A-l
Scott Environmental Technology Inc.
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1-1
SET #2635-01-0179
1.0 INTRODUCTION
Testing to determine participate emissions from an ammonium sulfate
plant was conducted by Scott Environmental Technology, Inc., for the U. S.
Environmental Protection Agency under Contract No. 68-02-2813, Work Assign-
ment No. 27. Three tests were conducted on December 6, 1978 on the Valley
Nitrogen Producers, Inc. ammonium sulfate plant No. 3 located in Helm, Cal-
ifornia.
Three particulate tests were simultaneously conducted at the in-
let and outlet of a cyclonic scrubber controlling emissions in the exhaust
gases from an ammonium sulfate drier using EPA Method 5. One test to de-
termine particle size distribution was also performed at the inlet to the
scrubber using an Anderson 2000 Cascade Impactor. Opacity of the gas
exiting from the scrubber was recorded during each test by a smoke reader.
Samples of the ammonium sulfate crystals were collected at the inlet and
outlet of the drier to determine moisture content. Also, samples of the
scrubber liquor were collected downstream of the scrubber.
The test arrangements were made through Myrlen Kelly, Manager of
Environmental Affairs with Valley Nitrogen. Frank Clay of the EPA was
present during the tests, as was Marvin Drabkin of Mitre Corporation, who
monitored the plant process.
Scott Environmental Technokyjy Inc.
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2-1
SET #2635-01-0179
2.0 SUMMARY OF RESULTS
The particulate concentration at the outlet of the scrubber
ranged from 0.0686 to 0.113 grains/scf and averaged 0.091 gr/scf for the
three runs. The average gas flow rate was 3430 dscfm resulting in an
average particulate mass flow rate of 2.7 Ibs/hr. Inlet particulate
concentrations averaged 3.91 gr/scf with an average gas flow rate of
3410 dscfm and particulate mass flow rate of 115.6 Ibs/hr. The average
collection efficiency of the scrubber was 97.3%. Complete Method 5 re-
sults are summarized in Table 2.1.
The results of the particulate size distribution sample are
shown in tabular and graphical form in Table 2.2 and Figure 2.1 respec-
tively.
The average moisture content of the ammonium sulfate crystals
was 1.08% at the drier inlet and 0.27% at the drier outlet. Complete re-
sults are shown in Table 2.3.
The opacity at the outlet averaged 10% during runs 1 and 2. No
opacity readings were taken during run number 3 because the run was performed
after dark. Opacity results are summarized in Tables 2.4 and 2.5.
The field data sheets are included in Appendix A.
Scorr Environmental Technokxjy Inc.
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SET #2635-01-0179
Table 2.'1
Summary of Method 5 Results
page 2-2
Plant- Valley Nitrogen Location
Producers Run No.
-Date: 12-6-78 Time Started
Time Ended
Barometric Pressure: P. (in. Hg.)
Static Pressure: PQ (in. H?0)
Area of Stack: A (ft2)
Pitot Coefficient: C
Meter Calibration -Factor: Y
Area of Nozzle: A (in2)
Total Sampling Time: ^(Min.)
Gas Sample Volume: Vm (ft3) .
Avg. Velocity Head: (V Ap~~)iivg. (in. H20)
Avg. Orifice Pressure: AH (in H20)
Avg. Stack Temperature: T (°R)
Avg. Meter Temperature: T (°R)
m * '
Volume of Liquid and Silica' Gel
Collected: Vlc .(ml.)
Gas Sample Volume @ Std. Cond.:
Vm(Std) (ft3) = 17.64 VmY (P. >AH/13.6V
Tm bai
Volume of Water Vapor:
Vw (std) (ft3) = 0.04707 YX
Moisture Content: B = Vw(Std)
w" - Vm(Std) + Vw(Std)
Molecular Weight of Stack Gas (dry):
Md =0.44 (% C02) + 0.32 (% 02) +
0.28 (% H2+% CO)
1
1050
1220
29.89
-0.075
1.571
0.838
0.94
0.0491
100
30.033
0.62
1.82
644
567
116
70.271
5.46
0(179
• U/ c.
28.87
.Inlet
2
1500
1600
29.86
-0.075
1.571
0.838
0.94
0.0491
30
22.879
0.63?^
fffil3
1.82
641
532
75
21 . 389
3.53
01 A?
. \'\c.
28.96
3
1910
2055
29.95
-0.075
1.571
0.838
0.94
0.0491
36
26.248
0.60
1.74
646
532
10
24.607
0.47
Om o
.uiy
28.96
. 1
1030
1135
29.89
+0.96
0.785
0.835
1.075
0.0347
60
52.228
2.29
3.27
600
524
129
56.949
6/07
.096
28.92
Outlet
2
1.455
1600
29.89
+0.96
0,785
0.835
1.075
0.0347
" 60 '
51.548
2.21
3.08
600 .
523
161
56.289
7.58
.119
28.93
i
3
1915
2040.
—
29.97
+0.96
0.785
0.835
1.075
0.0123
.60
20.448
2.27
0.43
596
507
32
22.945
1.51
.062
28.93
2 Area blocked by particulate at bottom of .duct excluded
3 Avg. velocity during sampling
Scott Environmental T&hixfoqvlnc Av9- velocity in entire duct
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#2635-01-0179
2-3
Table 2.1, Page 2 ^.^
Run Number
Molecular Weight of Stack Gas (wet):
VWi-U + u-°V
Stack Pressure: Pc (in. Hg) « P. + P/13.6
5 • Dor y
Stack Gas Velocity: 1/2
vs (ft/sec) = 85.49 Cp UPT^P^)
Stack Gas Volume Flow Rate:
Qsd (dscf /nin) = 1059 (l-B^ A P£/TS
Actual Stack Gas Volume Flow Rate:
Q {acf /min) = 60 v A
Weight of Particulate Collected: m (mg.)
Concentration of Particulate @ Std.Cond.(dry):
C (gr/scf) = 0.01542 m/V (std)
tc| (g/dscm) = 0.03529 mJJ/V™ (std)]
Mass Flow Rate. of Particulate:
Q (Ib/hr) = 0.008571 C$ Qsd
Isokinetic Rate:
I («« 13'.61 Vm(std)/PsvsAn9(l-Bws)
Control Efficiency, %
Inlet
i
8.09
9.88
9.41
537
654
22877.4
5.020
[11.489
152.2
91.6
2
?7.40
7v irv
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#2635-01-0179
2-4
TABLE 2.2
PARTICLE SIZE DISTRIBUTION ANALYSIS
Date: December 6, 1978
Location: Valley Nitrogen
.Sampling Location: Inlet
Traverse Point No. Sampled:
Pbar (in Hg)
Stack Temp. (°F)
Sample Time-(Min)
Sample Volume (cf)
Moisture (35 jj?0)
29.95
184
10
6.869
10.9
Meter Temp (°F) 73.5
Flow Setting, AH (in H?0) 2.0
Nozzle Diameter (In.) 0.250
Sample Flow Rate (at stack conditions) - 0.77 cfm
Plate
No.
1
2
3 .
4
5
6
7
8
Net Wt.
(mg)
450. 42
200.8
818.3
253.4
42.2
56.0
11.5
11.5
Back-up
Filter
Total
31.3
1875.4
24.0
10.7
43.6
13.5
2.3
3.0
0.6
0.6
1.7
Cumulative
%
100.0
76.0
65.3
21.7
8.2
5.9
2.9
2.3
1.7
ECD1
(Microns)
11.80 and larger
7.49
4.94
3.42
2.18
1.11
0.67
0.45
<0.45
1
ECD - Effective Cutoff Diameter of preceding plate.
Weight includes particulate collected on Plate No. 0 and in nozzle and
head of sampler upstream of the collection plates..
Scott Environmental Technokyjy Inc.
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10-
9_
8_
7_
93-99
- — I-I ••
99.9 99.8
99 98
.OIL!
eu«
95
OAK
CO.
2 CYCLES
90
80 70 60 50 40 30
20
10
0.5 0.2 010 05
0.01
10
eteuiitfem-i;1
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crons
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Figure 2.1
Particle Size Analysis
Scrubber Inlet
Valley Nitrogen Producers
12-6-78
Cumulative %, less Than Stated
Particle Size
-riTmTTTT
t::
-f-rkf-
0.01 005 0.1 0.2 0.5 1
50 70
98
90.8 S3 9
on 09
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#2635-01-0179
2-6
TABLE 2.3
AMMONIUM SULFATE CRYSTAL
MOISTURE ANALYSIS
Date
12-5-78
12-5-78
12-6-78
12-6-78
12-6-78
12-6-78
12-6-78
12-6-78
Time
1440
1435
1033
1047
1448
1449
1907
1905
Test
Run No.
...
—
1
1
2
2
3
3
Sample
Location
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Net Wt.
Wet, gms
324.8
359.2
242.4
306.7
377.1
372.5
305.1
395.3
Net Wt.
Dry, gms
320.5
357.2
239.0
306.2
374.6
371.7
302.2
394.7
Moisture
%
1.32
0.56
1.40
0.16
0.66
0.21
0.95
0.15
Average at dryer inlet - 1.08
Average at dryer outlet - 0.27
<$>
Scott Environmental Technology Inc.
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2-7
#2635-01-0179
TABLE 2.4
SUMMARY OF RESULTS OF OPACITY READINGS
Location: Scrubber Outlet
Test Run No.: 1
Date: 12-6-78
Color of Plume: White
Note: Readings every 30 seconds.
Stack Height: 50 feet
Distance to Stack:. 200 feet
Wind Direction: NW Speed: 10-20 mph
Sky Description: Clear
Therefore, average opacity = sum/12.
Set Time
Number Start .'End
1 10:37 10:43
2 10:47 10:49
3 10:49 10:55
4 10:55 11:01
5 11:01 11:07
6 11:07 11:13
7 11:13 11:19
8 11:19 11:25
9 11:25 11:31
10 11:31 11:37
Overall
Average
Opacity
Sum Average
85 5
100 10
110 10
125 10
110 10
110 10
85 5
95 10
105 10
110 10
10
Set Time Opacity
Number Start End Sum Averaae
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2-8
#2635-01-0179
TABLE 2.5
SUMMARY OF RESULTS OF OPACITY READINGS
Location: Scrubber Outlet
Test Run No.: 2
Date: 12-6-78
Color of Plume: White
Note: Readings every 30 seconds.
Set
Number
1
2
3
4
5
6
7
8
9
.10
Overal 1
Average
Time
Start .End
14:54 15:00
15:00 15:06
15:06 15:12
15:12 15:18
15:18 15:24
15:24 15:30
15:30 15:36
15:36 15:42
15:42 15:48
15:48 15:54
. Opacity
Sum Average
90 10
140 10
140 10
140 10
140 10
150 10
145 10
150 10
120 10
135 10
10
Set
Number
Stack Height: 50 feet
Distance to Stack:. 200 feet
Wind Direction: NW Speed: 10-25 mph
Sky Description: Clear
Therefore, average opacity = sum/12.
Time Opacity
Start End Sum Average
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SET #2635-01-0179
3.0 DISCUSSION OF TEST RESULTS
The concentration of participate matter at the inlet to the scrubber
proved to be much higher than anticipated. This high particulate loading caused
some difficulties in sampling due to plugging of the sampling nozzle and probe.
At times it was necessary to interrupt sampling to unclog the sampling nozzle.
The length of the tests was shortened to reduce the amount of nozzle and probe
plugging.
The average results at the inlet were based upon Test Runs til and #2.
Results from Run No. 3 were not consistent with the first two runs. The run was
non-isokinetic due to the low moisture measured during the run. Also, a very
large amount of particulate was collected.
The collection filter at the inlet was ruptured during Run No. 1,
apparently due to clogging of the sampling nozzle. The ruptured filter was not
discovered until after the sampling was completed. However, it is not felt
that the results were significantly affected due to the large amount of partic-'
ulate captured in the sample nozzle and probe. A stainless steel sampling
probe was used at the outlet during Run No. 3. The use of this probe did not
appear to affect the test results adversely.
The high concentration of relatively large particles at the scrubber
inlet also caused the first few collection plates of the particle size sampler
to be overloaded with particulate. This overloading combined with the loose
nature of the crystals could have caused a-slight downward shift in the particle
size distribution analysis. The use of a cyclone preseparator for the sampler
would have helped prevent overloading of the collection plates. However, due
to the small size of the duct, it would have been necessary to.locate the
sampler outside the duct.
Scott Environmental Technokxjy Inc.
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#2635-01-0179
4.0 PROCESS DESCRIPTION
Ammonium sulfate is crystallized from ammonia and sulfuric acid.
Liquid is then separated from the crystals in a centrifuge. The remaining
moisture is removed from the ammonium sulfate in a natural gas-fired rotary
drier. The drier exhaust gases, containing ammonium sulfate particulates,
pass through a Ducon cyclonic scrubber before being released to the atmosphere.
The ammonium sulfate is conveyed to a warehouse for storage. Figure 4.1
shows a schematic diagram of the process and the sampling locations. The
ammonium sulfate production rate is 400 tons per day.
Scott Environmental Technology Inc.
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#2635-01-0179
4-2
To Atmosphere
A
¥?4
Feed
.. Pjimp
Drier Exhaus
Gases
Drier Outlet^
Sampling loca
Ammonium
Sulfate
Crystal 1-
izer
Ducon
Cyclonic^
r v»i iKKov/
Scrubber In-
let Sampling
Location .
Scrubber
Solution to Crystallizer
Rotary Drier
Scrubber Outlet
Sampling Location
Centrifuge to
Separate Liquid
Ammonium
Sulfate
Liquid to
Crystal lizer
- Drier Inlet
Sampling Location
Natural Gas Burner
Ammonium Sulfate
to Warehouse
FIGURE 4.1
SCHEMATIC DIAGRAM OF AMMONIUM SULFATE
PLANT NO. 3 - VALLEY-NITROGEN PRODUCERS, INC.
HELM, CALIFORNIA
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#2635-01-0179
5.0 SAMPLING AND ANALYTICAL PROCEDURES
Gas sampling for total particulate content was conducted at the inlet
and outlet of the scrubber in accordance with EPA Reference Method #5. This
method involves the isokinetic extraction of a sample from the gas stream and
collection of the particulate on a heated out-of-stack filter. A dry gas
meter measures the volume of the gas sample. The gas velocity in the duct is
measured during the sampling with a Pi tot tube and inclined manometer. The
stack gas temperature is measured with a chromel-a'lumel thermocouple. The
quantity of particulate collected is determined gravimetrically with results
reported as grains of particulate per standard cubic foot of gas and grams
per cubic meter.
The sample for particle size distribution was collected using an
Andersen 2000 in-stack cascade impactor. The particles are collected by
impaction on a series of plates. The plates have increasingly smaller holes
so that the velocity of the particles is increased from plate to plate and
smaller and smaller particles are impacted. The particulate weight collected
on each plate is determined gravimetrically. The particle size distribution
is based on the equivalent aerodynamic size of the particles based on spherical
particles of 1 gram/cc density.
Opacity reading of the scrubber outlet gases was. made in accordance
with EPA Method #9. The moisture content of the ammonium sulfate samples from
the drier inlet and outlet was determined by weighing the samples before and
after drying.
Scott Environmental Technology Inc.
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