Section 440.55. Ammonium sulfate manufacture.

 

(1)   Applicability and designation of affected facility.

(a) The affected facility to which the provisions of this section apply is each ammonium sulfate dryer within an ammonium sulfate manufacturing plant in the caprolactam by-product, synthetic and coke oven by-product sectors of the ammonium sulfate industry.

(b) Any facility under par. (a) that commences construction or modification after February 4, 1980, is subject to the requirements of this section.

(2)   Definitions. As used in this section, terms not defined in this subsection have the meanings given in s. NR 440.02 .

(a) "Ammonium sulfate dryer" means a unit or vessel into which ammonium sulfate is charged for the purpose of reducing the moisture content of the product using a heated gas stream. The unit includes foundations, super-structure, material charger systems, exhaust systems and integral control systems and instrumentation.

(b) "Ammonium sulfate feed material streams" means the sulfuric acid feed stream to the reactor/crystallizer for synthetic and coke oven by-product ammonium sulfate manufacturing plants; and means the total or combined feed streams (the oximation ammonium sulfate stream and the rearrangement reaction ammonium sulfate stream) to the crystallizer stage, prior to any recycle streams.

(c) "Ammonium sulfate manufacturing plant" means any plant which produces ammonium sulfate.

(d) "Caprolactam by-product ammonium sulfate manufacturing plant" means any plant which produces ammonium sulfate as a by-product from process streams generated during caprolactam manufacture.

(e) "Coke oven by-product ammonium sulfate manufacturing plant" means any plant which produces ammonium sulfate by reacting sulfuric acid with ammonia recovered as a by-product from the manufacture of coke.

(f) "Synthetic ammonium sulfate manufacturing plant" means any plant which produces ammonium sulfate by direct combination of ammonia and sulfuric acid.

(3)   Standards for particulate matter. On or after the date on which the performance test required to be conducted by s. NR 440.08 is completed, no owner or operator of an ammonium sulfate dryer subject to the provisions of this section may cause to be discharged into the atmosphere, from any ammonium sulfate dryer, particulate matter at an emission rate exceeding 0.15 kilogram of particulate per megagram of ammonium sulfate produced (0.30 pound of particulate per ton of ammonium sulfate produced) and exhaust gases with greater than 15% opacity.

(4)   Monitoring of operations.

(a) The owner or operator of any ammonium sulfate manufacturing plant subject to the provisions of this section shall install, calibrate, maintain and operate flow monitoring device which can be used to determine the mass flow of ammonium sulfate feed material streams to the process. The flow monitoring device shall have an accuracy of " 5% over its range. However, if the plant uses weight scales of the same accuracy to directly measure production rate of ammonium sulfate, the use of flow monitoring devices is not required.

(b) The owner or operator of any ammonium sulfate manufacturing plant subject to the provisions of this section shall install, calibrate, maintain and operate a monitoring device which continuously measures and permanently records the total pressure drop across the emission control system. The monitoring device shall have an accuracy of " 5% over its operating range.

(5)   Test methods and procedures.

(a) In conducting the performance tests required in s. NR 440.08 , the owner or operator shall use as reference methods and procedures the test methods in Appendix A of 40 CFR part 60 , incorporated by reference in s. NR 440.17 , or other methods and procedures as specified in s. NR 440.08 (2) .

(b) The owner or operator shall determine compliance with the particulate matter standards in sub. (3) as follows:

1. The emission rate (E) of particulate matter shall be computed for each run using the following equation: - See PDF for diagram

where:

E is the emission rate of particulate matter, kg/Mg (lb/ton) of ammonium sulfate produced

c s is the concentration of particulate matter, g/dscm (g/dscf)

Q sd is the volumetric flow rate of effluent gas, dscm/hr (dscf/hr)

P is the production rate of ammonium sulfate, Mg/hr (ton/hr)

K is the conversion factor, 1000 g/kg (453.6 g/lb)

2. Method 5 shall be used to determine the particulate matter concentration - See PDF for diagram and volumetric flow rate (Q sd ) of the effluent gas. The sampling time and sample volume for each run shall be at least 60 minutes and 1.50 dscm (53 dscf).

3. Direct measurement using product weigh scales, or the results of computations using a material balance, shall be used to determine the rate (P) of the ammonium sulfate production. If production rate is determined by material balance, the following equations shall be used:

a. For synthetic and coke oven by-product ammonium sulfate plants:

P = ABCK ′

where:

A is the sulfuric acid flow rate to the reactor/crystallizer averaged over the time period taken to conduct the run, liter/min

B is the acid density (a function of acid strength and temperature), g/cc

C is the acid strength, decimal fraction

K ′ is the conversion factor, 0.0808 (Mg-min-cc)/(g-hr-liter) [0.0891 (ton- min-cc)/(g-hr-liter)]

b. For caprolactam by-product ammonium sulfate plants:

P = DEFK ,

where:

D is the total combined feed stream flow rate to the ammonium crystallizer before the point where any recycle streams enter the stream averaged over the time period taken to conduct the test run, liter/min

E is the density of the process stream solution, g/liter

F is the percent mass of ammonium sulfate in the process solution, decimal fraction

K , is the conversion factor, 6.0 10 -5 (Mg-min)/(g-hr) [6.614 10 -5 (ton-min)/g-hr)]

4. Method 9 and the procedures in s. NR 440.11 shall be used to determine the opacity.

History: Cr. Register, January, 1984, No. 337 , eff. 2-1-84; am (2) (intro.), Register, September, 1990, No. 417 , eff. 10-1-90; r. and recr. (5), Register, July, 1993, No. 451 , eff. 8-1-93; CR 06-109 : am. (5) (b) 3. (intro.) Register May 2008 No. 629 , eff. 6-1-08.