Source Emissions Testing Report 

Dyno Nobel Inc. 

Nitrogen Oxides (NOX) Testing 

Dynamic Spiking Procedure 

Acid Plants #1 and #2 

Cheyenne, Wyoming 

Report prepared for: Report prepared by: 

Dyno Nobel Inc. 

8305 Otto Road 

Cheyenne, Wyoming 82001 

 Matt McGregor 

Technical Writer 

Test Date: 

April 14, 2010 

APT Project: DYN0116
Table of Contents 

1. Introduction.................................................................................... 1

2. Methods......................................................................................... 2

3. Test Results Summary.................................................................. 2 

4. Test Program Summary................................................................. 4 

5. Test Method Details....................................................................... 4 

Tables 

Table 1.1: Contact Personnel...................................................... 1 

Table 3.1: Acid Plant #1 Test Results Summary........................ 3 

 

Table 3.2: Acid Plant #2 Test Results Summary........................ 3 

Table 4.1: Sampling and Analytical Methods Summary............... 4 

Appendices 

Testing Parameters and Sample Calculations......................... Appendix 1 

Field Data........................................................................ Appendix 2 

Calibration Data and Certificates.......................................... Appendix 3 

Schematics....................................................................... Appendix 4 
APT Project DYN0116 

Test Report – Acid Plants #1 & #2 NOX Dynamic Spiking 

page 1 

1. Introduction 

1.1. General

Air Pollution Testing, Inc. (APT) was contracted by Dyno Nobel Inc. to conduct a series of 

source emissions tests at their facility located in Cheyenne, Laramie County, Wyoming. 

The purpose of the testing program was to determine the concentrations and mass 

emission rates nitrogen oxides (NOX) from the exhaust of Acid Plants #1 and #2 in service 

at the facility. Concentration data were combined with concurrently collected oxygen (O2), 

carbon dioxide (CO2), moisture (H2O) and gas velocity data to determine NOX mass 

emission rates. 

The Dyno Nobel Inc. Cheyenne Plant is a nitric acid production facility and as such is 

subject to Subpart V of the Mandatory Reporting of Greenhouse Gases (40 CFR, Part 98) 

rule. The data collected during the testing are being used to comply with the above 

referenced rule. 

Table 1.1 below provides key project personnel, company affiliations, telephone and fax 

numbers. 

Dyno Nobel Inc. : Cheyenne, Wyoming Facility 

Acid Plants NOX Dynamic Spiking Testing Program Contact Personnel

Name, Title Company Address Phone, FAX 

Mr. Scott Horgen, 

Environmental Coordinator 

Dyno Nobel Inc. 

8305 Otto Road 

Cheyenne, Wyoming 82001 

307-771-5609, 

307-637-2739 

Mr. Chris Keefe, 

Operations Director 

Air Pollution Testing, Inc. 

5530 Marshall Street 

Arvada, Colorado 80002 

303-420-5949 ext. 24, 

303-420-5920 

Table 1.1: Contact Personnel

1.2. Sampling Location 

The identical sampling locations for Acid Plants #1 and #2 were 24" inside diameter (ID) 

vertical stacks with two sampling ports arranged 90 degrees apart in accordance with EPA 

Method 1. The sampling ports were located 15’ upstream and 105” downstream of any 

flow disturbances. A schematic of the sampling locations and sampling points can be 
APT Project DYN0116 

Test Report – Acid Plants #1 & #2 NOX Dynamic Spiking 

page 2 

found in Appendix 4. 

2. Methods 

The test program was conducted in accordance with the following USEPA source 

emissions test methods referenced in 40 CFR Part 60, Appendix A. 

• Method 1 – Sample and Velocity Traverses for Stationary Sources 

• Method 2 – Determination of Stack Gas Velocity and Volumetric Flow Rate (Type S 

Pitot Tube) 

• Method 3 – Gas Analysis for the Determination of Dry Molecular Weight 

• Method 4 – Determination of Moisture Content in Stack Gases 

• Method 7E – Determination of Nitrogen Oxides Emissions from Stationary Sources 

(Instrumental Analyzer Procedure) 

3. Test Results Summary 

The results of the testing program are summarized in Tables 3.1 and 3.2. Any emission 

parameters not found in the tables can be found in Appendix 1 – Testing Parameters and 

Sample Calculations. 

The following abbreviations are used in the tables:

• Temp. – temperature, degrees Fahrenheit 

• dscfm – gas flow rate, dry standard (one atm., 68° F) cubic feet per minute 

• %vd – diluent concentration, dry volume percentage

• %vw – moisture content, wet volume percentage 

• ppmvd – pollutant concentration; parts per million, dry volume basis 

• lb/hr – mass emission rate, pounds per hour 

• tons/year – mass emission rate, tons per year 
APT Project DYN0116 

Test Report – Acid Plants #1 & #2 NOX Dynamic Spiking 

page 3 

Dyno Nobel Inc. : Cheyenne, Wyoming Facility 

Acid Plant #1 NOX Test Results Summary (April 14, 2010)

Parameter Run #1 Run #2 Run #3 Average

Start time 9:30 10:42 11:57 

Stop time 10:30 11:42 12:57 

Stack Temp. (°F) 335 335 335 335 

Gas flow (dscfm) 8,638 8,620 8,661 8,639 

O2 (%vd) 0.5 0.5 0.5 0.5 

CO2 (%vd) 0.0 0.5 0.5 0.3 

H2O (%vw) 3.3 4.4 3.4 3.7 

Emissions Data 

NOX (ppmvd) 1.1 1.0 1.0 1.0 

NOX (lb/hr) 0.1 0.1 0.1 0.1 

NOX (tons/year) 0.3 0.3 0.3 0.3 

Table 3.1: Acid Plant #1 Test Results Summary 

Dyno Nobel Inc. : Cheyenne, Wyoming Facility 

Acid Plant #2 NOX Test Results Summary (April 14, 2010)

Parameter Run #1 Run #2 Run #3 Average

Start time 14:07 15:25 16:40 

Stop time 15:07 16:25 17:40 

Stack Temp. (°F) 319 319 319 319 

Gas flow (dscfm) 7,932 7,932 8,070 7,978 

O2 (%vd) 0.5 0.5 0.5 0.5 

CO2 (%vd) 0.5 0.5 0.0 0.3 

H2O (%vw) 3.0 4.2 4.0 3.7 

Emissions Data 

NOX (ppmvd) 5.4 5.5 5.4 5.4 

NOX (lb/hr) 0.3 0.3 0.3 0.3 

NOX (tons/year) 1.4 1.4 1.4 1.4 

Table 3.2: Acid Plant #2 Test Results Summary 
APT Project DYN0116 

Test Report – Acid Plants #1 & #2 NOX Dynamic Spiking 

page 4 

4. Test Program Summary 

APT provided all necessary equipment and labor for the determination of all emissions 

parameters detailed in Table 4.1 below. At each location, NOX emission levels were 

determined using an on-site chemiluminescent analyzer. The gas analyzer was housed in 

a mobile analytical trailer to provide a temperature-controlled environment for stable, 

accurate analyzer response. 

Three, 1-hour sample runs were conducted at the maximum achievable load at each unit’s 

exhaust to determine pollutant concentrations. Concentration data were combined with 

concurrently collected O2, CO2, H2O and gas velocity data to determine NOX mass 

emission rates. 

All testing was conducted in accordance with the appropriate EPA Reference Method 

requirements. All QA/QC requirements detailed in the appropriate reference test methods 

were strictly followed. All field data were recorded on appropriate data sheets. All pre-test 

/ post-test equipment calibration / preparation were conducted as required in the applicable 

reference test methods. 

Dyno Nobel Inc. : Cheyenne, Wyoming Facility 

Sampling and Analytical Methods

Gas Parameter Sampling Method Analytical Method Laboratory 

gas flow Methods 1, 2 draft gauge, thermocouple, pitot tube 

O2, CO2 Method 3 wet chemical 

H2O Method 4 gravimetric 

NO, NO2 Method 7E chemiluminescent analyzer – dynamic 

spiking and NO2 calibration 

APT, 

on-site 

Table 4.1: Sampling and Analytical Methods Summary

5. Test Method Details 

5.1. Stack Gas Flow, Oxygen, Carbon Dioxide, Moisture

Stack gas velocity, volumetric flow rate, O2, CO2, and moisture (H2O) content were 

measured in accordance with EPA Methods 1, 2, 3 and 4. 

Each sampling period consisted of conducting a temperature and differential pressure 
APT Project DYN0116 

Test Report – Acid Plants #1 & #2 NOX Dynamic Spiking 

page 5 

traverse of the stack using a K-type thermocouple and an S-type pitot tube. Concurrent 

with each traverse, a sample of gas for moisture determination was extracted from the 

stack at a constant flow rate of no more than 0.75 cubic feet per minute. The gas sample 

passed through a stainless steel probe, through a series of 4 chilled glass impingers, and 

through a calibrated dry gas meter. Please see Appendix 4 – Schematics for a drawing of 

the EPA Methods 1, 2 and 4 sampling train. 

Prior to sampling, the first two impingers were each seeded with 100 milliliters of water. 

The third impinger was empty. The fourth impinger was seeded with 250 grams of silica 

gel. 

Following sampling, the moisture gain in the impingers was measured gravimetrically to 

determine the moisture content of the stack gas. A sample of stack gas was collected in a 

clean, leak-free Tedlar bag for subsequent diluent (O2 and CO2) analysis using a wet 

chemical analyzer. 

All of the above data were combined to calculate the stack gas velocity and volumetric flow 

rate in units of feet per second (ft/sec), actual cubic feet per minute (acfm), dry standard (1 

atmosphere and 68° F) cubic feet per minute (dscfm), and pounds per hour (lb/hr). 

5.2. NOX Emissions

NOX concentrations were measured in accordance with EPA Method 7E. 

Each sampling period consisted of extracting a gas sample from the stack at a constant 

flow rate of approximately four liters per minute. The sample passed through a 

refrigeration-type gas conditioner to remove moisture and into a Thermo Environmental 

Instruments (TECO) Model 42C chemiluminescent NOX analyzer. The NOX concentration 

was displayed on the analyzer front panel in units of parts per million, dry volume basis 

(ppmvd) and logged as one-minute averages to a computerized data acquisition system 

(CDAS). Please see Appendix 4 for a schematic of the EPA Method 7E sampling train

schematic. 

Before and after each sampling period, the analyzer was challenged with EPA Protocol 1 

calibration gases to calibrate the instruments, to verify linearity of response, and to quantify 

zero and span drift for the previous sampling period. To ensure no system bias, the 

analyzer calibrations were conducted by introducing all gases to the analyzer at the 

sampling probe tip at stack pressure. 

Following sampling, the reference method CDAS data were averaged in one-minute 

increments, corrected for instrumental drift, and reported as average NOX emission 

concentrations for each sampling period in units of ppmvw. 
APT Project DYN0116 

Test Report – Acid Plants #1 & #2 NOX Dynamic Spiking 

page 6 

5.2.1. Dynamic Spiking

EPA requirements for the acid plant NOX testing included use of a dilution system to avoid

a moisture removal system, calibration with NO2 standards rather than NO standards, and 

use of the dynamic spiking procedures from Method 7E. All of these procedures were 

followed. 

A critical orifice and eductor dilution probe assembly was used to dilute the stack gas at a 

10:1 ratio to allow the Method 7E analyzer to read on a wet basis. EPA Protocol NO2

(balance nitrogen) calibration standards of 9.94 ppmv and 21.2 ppmv were used to conduct 

the Method 7E calibrations through the dilution probe. The dilution factor was then 

corrected electronically with a 10x multiplier in the data acquisition system to allow the 

logged data to be true wet-basis concentration values. 

The 9.94 ppmv NO2 standard and an additional 48.9 ppmv NO2 (balance nitrogen) 

calibration standard were used for the dynamic spiking. The dynamic spiking was 

performed by introducing the low and high level spike gases into the stack gas matrix 

through the same critical orifice eductor dilution probe assembly, using an additional critical 

orifice. The spike gas dilution ratio, which was necessary to allow calculation of spike 

recovery, was determined by spiking the two gases into zero air. The native stack level 

was determined immediately before and after each 5-minute spiking period, and the 

pre/post, drift-corrected average was used for spike recovery calculations. 

At each of the two acid plant stacks, the two spike gases were used before and after all 

testing, and every check met both the recovery percentage and absolute error limits of 

Method 7E.