### Date: August 2 5 , 2010 (Updated December 17, 2010)

Subject: Summary of Test Data Received from Section 114 ICR

Nitric Acid NSPS Review EPA Contract No. EP

- D

- 06

- 118; Work Assignment No. 4

- 3 RTI Project No. 0210426.00 4 .0 03

Fr om: Melissa Icenhour

To: Bill Neuffer

OAQPS/SPPD/MMG (D243

- 02) U. S. Environmental Protection Agency Research Triangle Park, NC 27711



# I

. Introduction

The EPA is required by section 111(b)(1)(B) of the Clean Air Act (CAA) to review and, if appropria te, revise existing New Source Performance Standards (NSPS) at least every 8 years.

The nitric acid NSPS (part 60, subpart G) has been reviewed in the past but the last review took place in 1984

. As a result of this, EPA has received a citizen suit from S ierra Club and
Envir onmental Integrity Project prompting review of the standards

.



# II

. Test Data Review

EPA issued an Information Collection Request (ICR) under Section 114 authority to obtain NO X 

### emissions data using Methods 7, 7A, 7B, 7C, 7D, or 320. The in dustry was also allowed to use a modified version of Method 7E that contains provisions for addressing the loss of NO 2 

### in condensate (see memorandum entitled “Using EPA Method 7E for Measuring NO X 

### Emissions
from Nitric Acid Production Facilities” dated Dec ember 16, 2009).

The ICR also allowed EPA to collect NH 3 

### and N 2 

### O emissions data; nitric acid production rates ; startup, shutdown, and malfunction (SSM) provisions; continuous emission monitoring system (CEMS) data; N 2 

### O and NO X 

### abatement technologies; and i ndust ry opinions on the NSPS
Review.

### 2



# III

. NO X 

# Test Data

EPA plans to use the test data to determine if the NO X 

### emission limit in the Nitric Acid NSPS should be changed

.



## A

. Overall NO X 

## data

All NO X 

### emission test data are shown in Table 1. The emission limit for the NSPS will most likely stay in units of pound NO X 

### per ton of nitric acid (lb/ton), so those numbers
were evaluated. The data ranged from 0.01 lb/ton to 1.84 lb/ton and averaged 0.43 lb/ton
for the 1 2 nitric acid trains.

The NO X 

### emission data was furthe r evaluated by production pressure, abatement technology, and age to show any variations in NO X 

### data. The NO X 

### emission data originates from single pressure trains (high pressure, medium pressure, and low pressure) and dual pressure trains.

### 3



## B

. Single pressu re

All NO X 

### emission test data from single pressure trains are shown in Table s 2 through 4

. The data ranged from 0. 01 lb/ton to 1.84 lb/ton and averaged 0. 47 lb/ton for the 1 0 nitric
acid trains.



## 1

. High pressure

All NO X 

### emission test data from high pressure trains are shown in Table 2. The
data ranged from 0.0 1 lb/ton to 1.84 lb/ton and averaged 0. 55 lb/ton for the 6
nitric acid trains

. Only t wo of the six were greater than the average of 0.5 5 lb/ton: Train 4 ( 0.86 lb/ton) and Train 3 ( 1.84 lb/ton) at the PCS Nitrogen facility

.



## 2

. Medium pressure

All NO X 

### emission test data from medium pressure trains are sh own in Table 3.
The data ranged from 0. 3 5 lb/ton to 0. 46 lb/ton and averaged 0. 40 lb/ton for the 2
nitric acid trains.



## 3

. Low pressure

All NO X 

### emission test data from low pressure trains are shown in Table 4 . The
data ranged from 0.06 lb/ton to 0. 5 2 lb/ton and averaged 0. 29 lb/ton for the 2
nitric acid trains

.

### 4



## C

. Dual pressure

All NO X 

### emission test data from dual pressure trains are shown in Table 5 . The resu lts

were 0. 20 lb/ton and 0. 23 lb/ton and averaged 0. 22 lb/ton for the 2 nitric acid trains

. .



## D

. Control devices

The NO X 

### emission data are from trains controlled by nonselective catalytic reduction (NSCR), selective catalytic reduction (SCR), extended absorpt ion, and peroxide injection into the absorption tower.



## 1

. Hydrogen P eroxide I njection

All NO X 

### emission test data from trains controlled by hydrogen peroxide injection (into the absorption tower) are shown in Table 6 . The data show
0.53 lb/ton and 0.46 lb/ton for the 2 nitric acid train. The average of the 2
trains is 0.50 lb/ton.



## 2

. NSCR

All NO X 

### emission test data from trains controlled by nonselective catalytic reduction (NSCR) are shown in Table 7 . The data ranged from 0.0 1 lb/ton
to 0. 8 6 lb/ton and averag ed 0.3 2 lb/ton for the 6 nitric acid trains.



## 3

. SCR

All NO X 

### emission test data from trains controlled by selective catalytic reduction (SCR) are shown in Table 8 . The data ranged from 0.04 lb/ton

to 1.84 lb/ton and averaged 0.5 8 lb/ton for the 4 nitric acid trains. Only

one train had emissions greater than the average value of 0.5 8 lb/ton (1.84
lb/ton from t rain 3 at the PCS Nitrogen facility).

### 5



## E

. Age

All NO X 

### emission test data, along with the years that the trains became operational are
shown in Table 9

. The ages ranged from 10 to 46 years with a median age of 33 years. To evaluate whether differences in emissions were correlated by age of the nitric acid train, 4 age ranges were analyzed.



## 1

. 1 0

- 20 years

All NO X 

### emission test data from trains that began operat ion 10 to 20 years ago ranged from 0.04 lb/ton to 0.23 lb/ton and averaged 0.16 lb/ton for the 3 nitric
acid trains.



## 2

. 21

- 30 years

All NO X 

### emission test data from trains that began operation 21 to 30 years ago ranged from 0.06 lb/ton to 0.5 2 lb/ton and avera ged 0. 29 lb/ton for the 2 nitric
acid trains.



## 3

. 31

- 40 years

All NO X 

### emission test data from trains that began operation 31 to 40 years ago ranged from 0.53 lb/ton to 1.84 lb/ton and averaged 1.08 lb/ton for the 3 nitric
acid trains.



## 4

. 41

- 50 years

All NO X 

### emiss ion test data from trains that began operation 41 to 50 years ago ranged from 0.23 lb/ton to 0.46 lb/ton and averaged 0.23 lb/ton for the 5 nitric
acid trains.

### 6



## F

. NO X 

## Conclusions

The NO X 

### emissions from these test results are below the NSPS emission limit of 3.0
lb/ton.

The lowest NO X 

### emissions (0.01 lb/ ton ) originated from two high pressure train s that began operation 41

- 50 years ago and are controlled by an NSCR. The highest NO X 

### emissions (1.84 lb/ ton ) originated from a high pressure train that began ope ration 31

- 40

years ago and is controlled by a combination of SCR and extended absorption

. However, even the highest emissions are 60% of the current NSPS NO X 

### emission limit.

When comparing production pressure s , b oth the highest and lowest emissions origin ate from high pressure train s

. Therefore, the type of train does not necessarily result in higher NO X 

### emissions.

A s far as controls are concerned , t he lowest emissions originate from two trains controlled by NSCR. The highest emissions originate from a t rain controlled by SCR. But, as shown by the data, the third lowest emissions originated from a train controlled by SCR. Both abatement technologies are capable of emitting less than 0.05 lb/ton of
NO X



### . Therefore, the type of abatement does not necessar ily result in higher NO X 

### emissions.

When comparing age of the process trains, t he lowest emissions originate from 2 trains that are 41 to 50 years of age, while the highest emissions originate from a more recently
built train from 31

- 40 years ago. Three o f the four age groups had similar averages of 0.16, 0. 29 , and 0.23 lb/ton, while the age group with the highest emissions (aged 31

- 40 years) averaged 1.08 lb/ton. A newer train does not necessarily translate to lower NO X 

### emissions.

The analysis of NO X 

### emi ssions shows that there are no great differences in emissions resulting from the choice of control device, the production pressure, or the age of the
nitric acid trains. The data received as part of the ICR support a lowering of the NSPS
NO X 

### emission limi t. Only t he highest two of the 1 2 nitric acid trains emit at rate s above
0.62 lb/ton : t rain 4 at PCS Nitrogen ( 0.86 lb/ton ) , and t rain 3 at PCS Nitrogen ( 1.84
lb/ton )

. .

St ate operating permits limit the emissions of NO X 

### to 0.6 lb/ton for Coffeyville a nd Agrium

- Kennewick and 0.61 l b /ton for Agrium

- North Bend.

### 7



# IV

. N 2 

# O Test Data

EPA did not request N 2 

### O test data as part of the ICR but received this information from 5 nitric
acid trains. The data are shown in Table 10. The N 2 

### O emissions ranged from 0.43 l b/ton to 18.11 lb/ton and averaged 9.44 lb/ton. The data were also given in parts per million. The data ranged from 32.52 ppm to 1,261.94 ppm and averaged 639.94 ppm.

Only the lowest emission rate is controlled by an NSCR. All other trains are controll ed by SCR.

The amount of N 2 

### O data was more limited than the NO X 

### data and the data vary much more significantly. This can be explained by the fact that none of these nitric acid trains currently
have limits on N 2 

### O emissions

.

Only two of the 5 trains em it at a higher rate than 10 lb/ ton: Agrium

- North Bend ( 14.90 lb/ton)
and train 5 at PCS Nitrogen ( 18.11 lb/ton).

Further information gathering will be performed if an N 2 

### O emission rate is to be determined for
the NSPS.



# V

. NH 3 

# Test Data

To evaluate ammonia slip , w e received information from 3 nitric acid trains with SCR control

. The data are shown in Table 11. The NH 3 

### emissions ranged from 0.02 lb/ton to 0.1 lb/ton and averaged 0.05 lb/ton ; ranged from 5.85 ppm to 17.33 ppm and averaged 10.05 ppm ; and rang ed
from 0.57 pound NH 3 

### per hour (lb/hr) to 2.3 lb/hr and averaged 1.44 lb/hr

.

In addition to the data received, there are also two nitric acid trains that are subject to an NH 3 

### emis s ion limit . El Dorado Nitrogen has a limit of 25.6 tons per year and 5.9 lb/hr and Agrium

North Bend has a limit of 410 micrograms per cubic meter (μg/m 3 

### ) of ammonia slip.

Only one of the trains with ICR test data emits at a higher rate than 2.30 lb/hr.

### 8

Table 1. ICR Test Data for NO X 

### Emissions from Nitric Acid Trains

Compa ny City State Production line Production Pressure Nitric

acid type Abatement

technology Nitric acid

production (tons/day) Test

Method Emissions

(lb/ton) %

H2O Test Dates(s)

Dyno Nobel Cheyenne W Y Acid Plant 1 high 57% NSCR 112.24 EPA 7E 0.01 3.70 April 1 4, 2010

Dyno Nobel Cheyenne W Y Acid Plant 2 high 57% NSCR 89.04 EPA 7E 0.01 3.73 April 14, 2010 Coffeyville Resources Nitrogen Fertilizers, LLC Coffeyville K S #1 Nitric Acid high 54% SCR 546.43 EPA 320 0.04 0.68 March 24, 2010 JR Simplot Helm C A Line 1 low 57% NSCR 242.00 EPA 7 0.06 2.27 April 8, 2010 PCS Nitrogen Geismar L A Line 5 (Train 5) dual 65% SCR 1,532.36 EPA 7A 0.20 0.30 April 21, 2010

El Dorado Nitrogen Baytown T X Line 1 dual 65% SCR, extended absorption 1,306.00 ASTM 6348

- 03 0.23 May 19, 2009 Dyno Nobel Deer Island O R Line 1 medium 58% NSCR 70.00 EPA 7A 0.35 3.80 May 5, 2010

Agrium North Bend O H Line 1 medium weak acid SCR, Extended

Absorption, H2O2 injection 281.74 EPA 7D 0.46 2.70 February 11, 2010

Agrium Kennewick W A Plant 9 h igh 57% extended absorption, H2O2 injection 566.40 EPA 320 0.53 0.18 March 31, 2010

CA Agrium US, Inc West

Sacramento C A Line 1 low 53% NSCR 196.30 EPA 320 0.5 2 0.24 May 1 2 , 2010 PCS Nitrogen Geismar L A Line 4 (Train 4) high 65% NSCR 504.48 EPA 7A 0. 86 1.82 April 22, 2010

PCS Nitrogen Geismar L A Line 3 (Train 3) high 65% SCR, Extended Absorption 461.04 EPA 7A 1.84 1.05 April 20, 2010

### 9

Table 2. NO X 

### Emissions from Nitric Acid Trains Operated with High P ressure

Company City State Production
line Nitr ic

acid type Abatement

technology Nitric acid

production (tons/day) Test

Method Emissions

(lb/ton) %

H2O Test

Dates(s)

Dyno Nobel Cheyenne WY Acid Plant 1 57% NSCR 112.24 EPA 7E 0.01 3.70 April 14,
2010

Dyno Nobel Cheyenne WY Acid Plant 2 57% NSCR 89.04 EPA 7E 0.01 3.73 April 14,
2010

Coffeyville

Resources Nitrogen Fertilizers,
LLC Coffeyville KS #1 Nitric Acid 54% SCR 546.43 EPA 320 0.04 0.68 March 24,
2010

Agrium Kennewick WA Plant 9 57% extended absorption, H2O2 injection 566.40 EPA 320 0.53 0.18 Mar ch 31,
2010

PCS Nitrogen Geismar LA Line 4 (Train 4) 65% NSCR 504.48 EPA 7A 0.86 1.82 April 22,
2010

PCS Nitrogen Geismar LA Line 3 (Train 3) 65% SCR, Extended Absorption 461.04 EPA 7A 1.84 1.05 April 20,
2010

### 10

Table 3. NO X 

### Emissions from Nitric Aci d Trains Operated with M edium P ressure

Company City State Production
line Nitric

acid type Abatement

technology Nitric acid

production (tons/day) Test

Method Emissions

(lb/ton) %

H2O Test

Dates(s)

Dyno Nobel Deer

Island OR Line 1 58% NSCR 70.00 EPA 7A 0.3 5 3.80 May 5,
2010

Agrium North

Bend OH Line 1 weak
acid SCR, Extended

Absorption, H2O2 injection 281.74 EPA 7D 0.46 2.70 February 11, 2010



### Table 4. NO X 

### Emissions from Nitric Acid Trains Operated with Low P ressure

Company City State Production
line Nit ric

acid type Abatement technology Nitric acid

production (tons/day) Test

Method Emissions

(lb/ton) %

H2O Test Dates(s)

JR Simplot Helm CA Line 1 57% NSCR 242.00 EPA 7 0.06 2.27 April 8,
2010

CA Agrium US, Inc West

Sacramento CA Line 1 53% NSCR 196.30 EP A 320 0.5 2 0.24 May 1 2

, 2010

### 11

Table 5. NO X 

### Emissions from Nitric Acid Trains Operated with Dual P ressure

Company City State Production
line Nitric

acid type Abatement

technology Nitric acid

production (tons/day) Test

Method Emissions

(lb/ton) %

H2O Test Dates(s)

PCS Nitrogen Geismar LA Line 5 (Train 5) 65% SCR 1,532.36 EPA 7A 0.20 0.30 April 21,
2010

El Dorado Nitrogen Baytown TX Line 1 65% SCR, extended absorption 1,306.00 ASTM
6348

- 03 0.23 May 19,
2009



### Table 6. NO X 

### Emissions from Nitric Acid T rains Controlled by Extended A bsorption

Company City State Production
line Production

Pressure Nitric

acid type Abatement

technology Nitric acid

production (tons/day) Test

Method Emissions

(lb/ton) %

H2O Test Dates(s)

Agrium Kennewick WA Plant 9 high 57% extended absorption,
H2O2 injection 566.40 EPA
320 0.53 0.18 March 31,
2010

Agrium North Bend OH Line 1 medium weak
acid SCR, Extended

Absorption, H2O2 injection 281.74 EPA 7D 0.46 2.70 February 11, 2010

### 12

Table 7. NO X 

### Emissions from Nitric Acid Trains Controlled by NSCR

Company City State Production
line Production

process Nitric

acid type Abatement technology Nitric acid

production (tons/day) Test

Method Emissions

(lb/ton) %

H2O Test Dates(s)

Dyno Nobel Cheyenne WY Acid Plant 1 high 57% NSCR 112.24 EPA 7E 0.01 3.70 April 14,
2010

Dyno Nobel Cheyenne WY Acid Plant 2 high 57% NSCR 89.04 EPA 7E 0.01 3.73 April 14,
2010

JR Simplot Helm CA Line 1 low 57% NSCR 242.00 EPA 7 0.06 2.27 April 8,
2010

Dyno Nobel Deer Island OR Line 1 medium 58% NSCR 70.00 EPA 7A 0.35 3.80 May 5,
2010

CA Agrium US, Inc West

Sacramento CA Line 1 low 53% NSCR 196.30 EPA
320 0.5 2 0.24 May 1 2

, 2010

PCS Nitrogen Geismar LA Line 4 (Train 4) high 65% NSCR 504.48 EPA 7A 0.86 1.82 April 22,
2010

### 13

Table 8. NO X 

### Emissions from Nitric Acid Trains Controlled by SCR

Company City State Production
line Production

process Nitric

acid type Abatement

technology Nitric acid

production (tons/day) Test

Method Emissions

(lb/ton) %

H2O Test Dates(s)

Coffeyville

Resources Nitrogen
Fertilizer s, LLC Coffeyville KS #1 Nitric Acid high 54% SCR 546.43 EPA 320 0.04 0.68 March 24,
2010

PCS Nitrogen Geismar LA Line 5 (Train 5) dual 65% SCR 1,532.36 EPA 7A 0.20 0.30 April 21,
2010

El Dorado Nitrogen Baytown TX Line 1 dual 65% SCR,
extended
absor ption 1,306.00 ASTM
6348

- 03 0.23 May 19,
2009

PCS Nitrogen Geismar LA Line 3 (Train 3) high 65% SCR,
Extended Absorption 461.04 EPA 7A 1.84 1.05 April 20,
2010

### 14

Table 9

. NO X 

### Emissions and Age of the P lant

Company City State Production
line Producti on

Pressure Abatement

technology Nitric acid

production (tons/day) Test

Method Emissions

(lb/ton) %

H2O Year began Operation Test

Dates(s)

Dyno Nobel Cheyenne WY Acid Plant 1 high NSCR 112.24 EPA 7E 0.01 3.70 1964 April 14,
2010

Agrium North Bend OH Lin e 1 medium SCR, Extended Absorption, H2O2 injection 261.18 EPA 7D 0.34 2.20 1965 February 10, 2010

Agrium North Bend OH Line 1 medium SCR, Extended Absorption, H2O2 injection 281.74 EPA 7D 0.46 2.70 1965 February 11, 2010

Dyno Nobel Cheyenne WY Acid Pl ant 2 high NSCR 89.04 EPA 7E 0.01 3.73 1968 April 14,
2010

Dyno Nobel Deer Island OR Line 1 medium NSCR 70.00 EPA 7A 0.35 3.80 1968 May 5,
2010

PCS Nitrogen Geismar LA Line 4 (Train 4) high NSCR 504.48 EPA 7A 0.86 1.82 1970 April 22,
2010

Agrium Ken newick WA Plant 9 high extended absorption, H2O2 injection 566.40 EPA 320 0.53 0.18 1977 March 31,
2010

PCS Nitrogen Geismar LA Line 3 (Train 3) high SCR, Extended Absorption 461.04 EPA 7A 1.84 1.05 1978 April 20,
2010

JR Simplot Helm CA Line 1 low N SCR 242.00 EPA 7 0.06 2.27 1980 April 8,
2010

### 15

Company City State Production
line Producti on

Pressure Abatement

technology Nitric acid

production (tons/day) Test

Method Emissions

(lb/ton) %

H2O Year began Operation Test

Dates(s)

Agrium West

Sacramento CA Line 1 low NSCR 196.30 EPA 320 0.5 2 0.24 1982 May 1 2

, 2010

PCS Nitrogen Geismar LA Line 5 (Train 5) dual SCR 1,532.36 EPA 7A 0.20 0.30 1999 April 21,
2010

El Dorado Nitrogen Bayt own TX Line 1 dual SCR, extended absorption 1,306.00 ASTM
6348

- 03 0.23 1999 May 19,
2009

Coffeyville

Resources Nitrogen Fertilizers, LLC Coffeyville KS #1 Nitric
Acid high SCR 546.43 EPA 320 0.04 0.68 2000 March 24,
2010

### 16

Table 10 . ICR Test Data for N 2 

### O Emissions from Nitric Acid Facilities

Company City State Production
line Production

Pressure Nitric

acid type Abatement technology Nitric acid

production (tons/day) Test

Method Emissions

(lb/hr) Emissions

(lb/ton) Emissions

(ppm)
@0% O2 Test

Dates(s)

PCS Nitrogen Geismar LA Line 4 (Train 4) high 65% NSCR 504.48 EPA
320 9.16 0.43 32.52 April 22,
2010

Coffeyville

Resources Nitrogen Fertilizers,
LLC Coffeyville KS #1 Nitric
Acid high 54% SCR 546.13 EPA
320 147

6.46 427.60 March 24, 2010

PCS Nitrogen Geismar LA Line 3 (Train 3) high 65% SCR,
Extended Absorption 461.04 EPA
320 127.12

7.28 462.69 April 20,
2010

PCS Nitrogen Geismar LA Line 5 (Train 5) dual 65% SCR 1,532.36 EPA
320 1,159.8 18.11 1,261.94 April 21,
2010

### 17

Table 1 1 . ICR Test Dat a for NH 3 

### Emissions from Nitric Acid Facilities

Company City State Production
line Production

Pressure Nitric

acid type Abatement technology Nitric acid

production (tons/day) Test

Method Emissions

(lb/hr) Emissions

(lb/ton) Emissions

(ppm)
@0% O2 Test

Date s(s)

PCS Nitrogen Geismar LA Line 5 (Train 5) dual 65% SCR 1,532.36 EPA 320 1.43 0.02 5.85 April 21,
2010

PCS Nitrogen Geismar LA Line 3 (Train 3) high 65% SCR,
Extended Absorption 461.01 EPA 320 0.57
0.03 6.96 April 20,
2010

Coffeyville

Resources

N itrogen Fertilizers,
LLC Coffeyville KS #1 Nitric
Acid high 54% SCR 552.80 EPA 320 2.3

0.10 17.33 March 24, 2010