Tenn. Comp. R. & Regs. 1200-03-16-.32 - AMMONIUM SULFATE MANUFACTURE

(1) Applicability.

(a) The affected facility to which the provisions of this rule 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 subparagraph (a) of this paragraph that commences construction or modification after February 28, l983 is subject to the requirements of this rule.

(2) Definitions.

"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, superstructure, material charger systems, exhaust systems, and integral control systems and instrumentation.

"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.

"Ammonium sulfate manufacturing plant" means any plant which produces ammonium sulfate.

"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.

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

"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 1200-3-16 - .01(5) is completed, no owner or operator of an ammonium sulfate dryer subject to the provisions of this rule shall 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 percent opacity.

(4) Monitoring of operations.

(a) The owner or operator of any ammonium sulfate manufacturing plant subject to the provisions of this rule shall install, calibrate, maintain, and operate flow monitoring devices 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 percent over its range. However, if the plant uses weigh 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 rule 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 percent over its operating range.

(5) Test methods and procedures.

(a) Reference methods in 1200-3-16-.01(5)(g) of this chapter, except as provided in 1200-3-16-.01(5)(b), shall be used to determine compliance with 1200-3-16-.32(3) as follows:

1. Method 5 as specified in 1200-3-16-.01(5)(g) 5. for the concentration of particulate matter.

2. Method 1 as specified in 1200-3-16-.01(5)(g) 1. for sample and velocity traverses.

3. Method 2 as specified in 1200-3-16-.01(5)(g) 2. for velocity and volumetric flow rate.

4. Method 3 as specified in 1200-3-16-.01(5)(g) 3. for gas analysis.

(b) For Method 5, the sampling time for each run shall be at least 60 minutes and the volume shall be at least 1.50 dry standard cubic meters (53 dry standard cubic feet).

(c) For each run, the particulate emission rate, E, shall be computed as follows: E = Qsd x Cs 1000

1. E is the particulate emission rate (kg/h).

2. Qsd is the average volumetric flow rate (dscm/h) as determined by Method 2; and

3. Cs is the average concentration (g/dscm) of particulate matter as determined by Method 5.

(d) For each run, the rate of ammonium sulfate production, P (Mg/h), shall be determined by direct measurement using product weigh scales or computed from a material balance. If production rate is determined by material balance, the following equations shall be used.

1. For synthetic and coke oven by-product ammonium sulfate plants, the ammonium sulfate production rate shall be determined using the following equation:

P = A x B x C x 0. 0808 where:

P = Ammonium sulfate production rate in megagrams per hour.

A = Sulfuric acid flow rate to the reactor/crystallizer in liters per minute averaged over the time period taken to conduct the run.

B = Acid density (a function of acid strength and temperature) in grams per cubic centimeter.

C = Percent acid strength in decimal form.

0.0808 = Physical constant for conversion of time, volume, and mass units.

2. For caprolactam by-product ammonium sulfate plants the ammonium sulfate production rate shall be determined by using the following equation:

P = D*E*F*(6.0x10^-5)

where:

P = Production rate of caprolactam by-product ammonium sulfate in megagrams per hour.

D = Total combined feed stream flow rate to the ammonium sulfate crystallizer before the point where any recycle streams enter the stream in liters per minute averaged over the time period taken to conduct the test run.

E = Density of the process stream solution in grams per liter.

F = Percent mass of ammonium sulfate in the process solution in decimal form. (6.0 x 10-5) = Physical constant for conversion of time and mass units.

(e) For each run, the dryer emission rate shall be computed as follows:

R = E/P

where:

1. R is the dryer emission rate (kg/Mg);

2. E is the particulate emission rate (kg/h) from (c) above; and

3. P is the rate of ammonium sulfate production (Mg/h) from (d) above.

Notes

Tenn. Comp. R. & Regs. 1200-03-16-.32

Original rule filed January 27, 1983; effective February 28, 1983.

Authority: T.C.A. §§ 68-25-105 and 4-5-202.