### Date: May 2012 Subject: Secondary Impact Anal ysis Nitric Acid NSPS Review EPA Contract No. EP RTI Project No. 02103199.000.001 From: Melissa Icenhour To: Nathan Topham

OAQPS/SPPD/M U. S. Environmental Protection Agency Research Triangle Park, NC 27711 As part of the NSPS Review for Nitric Acid Plants, it is estimated that 5 newly constructed nitric acid production units and 1 modified nitric acid production unit will become s regulation in the next five years. See memo entitled (Updated Memo for Final NSPS) The purpose of this memo is to estimate the secondary impacts of reduction (SCR) control device on the modified production unit modified source is able to meet the final emission rate of 0.50 lb 100% nitric acid (0.50 lb NO X

### /ton The secondary

impacts from the installation of an SCR costs due to the increased electricity needed to operate the SCR. The increased electricity use leads to an increase in air p ollutants (CO 2 

### ). Secondary Impact Anal ysis

— SCR Nitric Acid NSPS Review EPA Contract No. EP
- D
- 11
- 084; Work Assignment No. 0

- 0 1 RTI Project No. 02103199.000.001

OAQPS/SPPD/M IC G (D243

- 02) U. S. Environmental Protection Agency Research Triangle Park, NC 27711 As part of the NSPS Review for Nitric Acid Plants, it is estimated that 5 newly constructed nitric acid production units and 1 modified nitric acid production unit will become s ubject to the regulation in the next five years. See memo entitled Impacts of Nitric Acid NSPS Review (Updated Memo for Final NSPS) dated May 2012 in Docket No. EPA

-HQ

- OAR

The purpose of this memo is to estimate the secondary impacts of installing a selective catalytic reduction (SCR) control device on the modified production unit . The SCR will ensure that the meet the final emission rate of 0.50 lb nitrogen oxides (NO /ton acid) under Part 60, Subpart Ga

. The secondary

impacts from the installation of an SCR include an increase in facility operating costs due to the increased electricity needed to operate the SCR. The increased electricity use ollutants such as NO X 

### , sulfur dioxide (SO 2 

### ), and carbon dioxide As part of the NSPS Review for Nitric Acid Plants, it is estimated that 5 newly constructed nitric ubject to the Impacts of Nitric Acid NSPS Review

— NO X



### - 2010

- 0750. installing a selective catalytic . The SCR will ensure that the nitrogen oxides (NO X

### ) per ton include an increase in facility operating costs due to the increased electricity needed to operate the SCR. The increased electricity use ), and carbon dioxide

### There is no known power equation specific to an SCR used to control NO X 

### emissions from a

nitric acid production train. However, according to EPA’s Air Pollution Control Cost Manual ( EPA Cost Manual ) 

### , the amount of power consumed by an SCR used to control emissions from a utility boiler can be estimated using the following equation:

= . ∗ + . + **Eq. 1** 

### where: P = p ower (kW) Q B 

### = b oiler heat input (MMBtu/hr) NO Xin 

### = c oncentration of NO X 

### into the SCR ( lb NO X

### /MMBtu) η NOX 

### = destruction efficiency of the SCR ΔP duct 

### = pressure drop across ductwork (inches H 2 

### O) ntotal 

### = number of layers in the SCR ΔP catalyst 

### = pressure drop across cataly st (inches H 2 

### O)
Equation 1 can be used to estimate the power requirement for an SCR installed on a nitric acid production train if we make some assumptions about the content of the gas entering the SCR. According to EPA Method 19, the molar heat content of natural gas is 8,710 dry standard cubic feet (dscf) per million Btu (MMBtu)

. According to the ICR from Agrium North Bend, the flow rate is 24,734 standard cubic feet per minute (scfm). Assuming minimal moisture co ntent, this is 1,484,040 dscf per hour. Also according to the IC R, the SCR at the Agrium North Bend plant has 6 catal yst layers. Table 1 contains actual data compiled b y CRICatalyst Company to show how much pressure drop is associated with the ductwork connecting the SCR to the emission stream. The average pressure drop is 7 inches H 2 

### O. Using Equation 1, the power required to operate the SCR is 123.46 kilowatts (kW). A ccording to the EPA Cost Manual , the cost of electricity is directly related to the amount of power required to the run the SCR, as shown by Equation 2.

= ∗ ∗ **Eq. 2** 

### where: C = cost of electricity ($) P = power (kW) EP = price of electricity ($/kWh) OpHours = number of hours the plant operates the SCR during the ye ar (hours)

### According to the ICR, the plant operates 8,200 hours per year. The plant is operating in Ohio and

according to this website (http://www.electricchoice.com/electricity-prices

- by

- state.php ), the industrial cost of electricity was 6.06 cents per kilowatt

- hour (kWh) in 2010. Using Equation 2, the cost of electricity to operate the SCR is $61,352 per year. According to this website ( http://www.cleanerandgreener.org/resources/pollutioncalculator.html 

### ), electricity use results in the creation of other air pollutants including NO X 

### , sulfur dioxide (SO 2 

### ), carbo n dioxide (CO 2 

### ), methane (CH 4 

### ), and nitrous oxide (N 2 

### O). Using the known inputs for Equation 1 and Equation 2 , shown in Table 2 , the secondary impacts of this SCR are shown in Table 3
. As described in the preamble to this final rule, the secondary impact s are minimal.

### Table **1 . Pressure Drop Across SCR units at Nitric Acid Plants** 

**Start Country**  **Capacity**

**(mt/day) Process**  **Flue gas (Nm3/hr)**  **Temp**

**(C ) Pressure** 

**(bar) NOX in** 

**(ppmv) NOX out** 

**(ppmv) NH3 out** 

**(ppmv) PD** 

**(mbar) PD** 

**(in ch**  **H2O)** 1995 South Africa 550 Krupp Uhde 70 205 1 1500 200 35 1998 Denmark 225 Krupp Uhde 30 210 3 1200 200 10 30 12 1999 USA 200 Grand Paroisse 27 190 6 2000 80 30 5 2 1999 USA 100 Weatherly 14,000 166 1 2100 100 10 20 8 1999 USA 200 Girdler 27.5 229 1 4800 400 30 20 8 1999 USA 180 21.5 450
- 515 6 3400 100 20 1999 Malaysia Cominco 31,500 477 6 1300 130
- 2000 Taiwan Stamicarbon 46,000 187 6,2 1200 100 35 2000 India Stamicarbon 8,100 200 1 4000 100 175 10 4 2000 Spain 370 Espindesa 50 220 3,5 4000 200 5 2001 Netherla nds 2000 Grand Paroisse 260 265 10,4 250 32 5 10 4 2003 Netherla nds 1700 Grand Paroisse 210,000 340 9 250 32 5 10 4 2001 UK 825 Krupp Uhde 107 225 6,5 1000 50 5 25 10 2001 UK 1100 Krupp Uhde 145,000 380 11,5 500 50 5 25 10
**average 17**  **7** Information from CRI Catalyst Company Nitric acid units with Shell DeNOX System http://www

- static.shell.com/static/cri_catalyst/downloads/business/cracker_fun_june2001.pdf

### Table **2 . Known**  **Values Element**  **Source Value**  Molar heat content of natural gas EPA Method 19; Table 19

- 2 8,710 dscf/MMBtu Flow rate of gas entering the SCR ICR
- Agrium North Bend 1,484,040 dscf/hr Destruction Efficiency of SCR (η NOX) Engineering Judgment 0.90 Pressure drop across catalyst (ΔP catalyst) EPA Cost Manual 1.0 in H 2 O per layer Number of catalyst layers (ntotal) ICR
- Agrium North Bend 6 Pressure drop across the ductwork (ΔP duct) Table 1 7.0 in H 2 O Uncontrolled NO X concentration Engineering Judgment 500 ppm Operating hours (OpHours) ICR
- Agrium North Bend 8,200 hours Price of electricity (EP) Electricity Choice website 6.06 cents per kWh NO X emissions from electricity use Cleaner and Greener website 3.3 lb per 1,000 kW SO 2 emissions from electricity use Cleaner and Greener website 13.2 lb per 1,000 kW CO 2 emissions from electricity use Cleaner and Greener website 1,911 lb per 1,000 kW CH 4 emissions from electricity use Cleaner and Greener website 0.02 lb per 1,000 kW N2 O emissions from electricity use Cleaner and Greener website 0.03 lb per 1,000 kW

### Table **3 . Calculated Values**  **Element Source**  **Value** Boiler Heat Input (Q B ) (Flow rate of gas entering the SCR) / (Molar heat content of natural gas) 170.4 MMBtu/hr Power (P) Equation 1 123.46 kW Total cost of electricity (C) Equation 2 $61,400 NO X emissions from operation of SCR Cleaner and Greener website 0.407 lb SO 2 emissions from operation of SCR Cleaner and Greener website 1.630 lb CO 2 emissions from operation of SCR Cleaner and Greener website 235.940 lb CH 4 emissions from operation of SCR Cleaner and Greener website 0.002 lb N2 O emissions from operation of SCR Cleaner and Greener website 0.004 lb