Featured Project: Ammonia Vapor Control at CF Industries – LDEQ ESL & EPA BACT Compliance (Case Study)
At an ammonia production facility in Ascension Parish, Louisiana, producing nearly 8 million tons of nitrogen products annually — ammonia emissions from storage tanks, loading operations, and process vents pose significant odor and health risks near residential areas. Under LDEQ 30 TAC §101.20: Toxic Air Contaminants, ammonia has ESLs of 0.14 mg/m³ (acute odor) and 1.3 mg/m³ (chronic), requiring BACT for exceedances or nuisances. For anhydrous ammonia storage, 30 TAC §106.477: Anhydrous Ammonia Storage PBR allows operations without atmospheric venting if emissions <25 tpy VOC equivalents. Envent’s recirculating wet scrubbers integrate these controls, ensuring odor-free operations and zero NOVs, as demonstrated in our support for the complex’s decarbonization efforts, including CO2 capture for blue ammonia production.
The Challenge: Ammonia Vapor Emissions from Ammonia Storage & Venting
The Donaldsonville Complex, with its six ammonia plants and extensive pipeline/rail/barge shipping, generates ammonia vapors during filling, venting, and maintenance—exceeding LDEQ’s ESL-odor threshold and risking public complaints in nearby communities.
Key Risks:
- Odor & Health Hazards: Ammonia at >50 ppm causes eye/respiratory irritation; uncontrolled venting triggers §101.20 investigations for effects screening.
- Regulatory Pressure: Facilities must demonstrate compliance via dispersion modeling (e.g., SCREEN3 per LDEQ guidelines); exceedances incur $10,000–$100,000/day fines under La. R.S. 30:2050.3, plus EPA NESHAP reporting for HAPs.
- Operational Constraints: Previous carbon-only systems saturated quickly, requiring frequent change-outs and halting production amid §106.477 PBR limits on emissions.
Envent’s Solution: EVAC-3000 Recirculating Wet Scrubber for Ammonia Capture
Envent secured a LDEQ minor source authorization under §106.4 and deployed the EVAC-3000—a 3,000 CFM mobile wet scrubber optimized for ammonia streams, routing tank vents via vapor recovery lines.
Treatment Process:
- Ammonia Absorption: Two-stage packed tower with alkaline media (caustic soda solution, pH 10–11) achieved >99% removal efficiency (inlet 5,000+ ppm → outlet <10 ppm), per EPA BACT for chemical manufacturing vents—converting NH3 to ammonium salts for safe disposal. Automated pH/ORP sensors and media recirculation prevented breakthrough.
- Polishing & Safety: Integrated mist eliminator and HEPA filter for <1 ppm stack emissions; real-time monitoring (NH3 analyzers, flow meters) ensured §101.20 ESL compliance without atmospheric release.
- Integration: Tied into plant SCADA for automated shutdowns; handled variable flows during filling (up to 500 gpm).
System operated continuously for 4 weeks with 99% uptime. For ammonia-specific setups, explore Envent’s wet scrubber rentals.
Official Resources:
- LDEQ 30 TAC §101.20: Toxic Air Contaminants ESLs – Ammonia odor/health screening levels and evaluation requirements.
- LDEQ 30 TAC §106.477: Anhydrous Ammonia Storage PBR – Conditions for storage without atmospheric venting.
- EPA Ammonia Control Options – Wet scrubbing tech for >99% efficiency in chemical plants.
- EPA NESHAP for Chemical Manufacturing (40 CFR Part 63 Subpart FFFF) – HAP controls including ammonia.
Proven Benefits: Odor Elimination, Compliance, & $50K+ Savings
Envent’s scrubber turned a high-risk operation into a compliant success, outperforming alternatives:
| Benefit | Project Impact |
|---|---|
| Ammonia Removal Efficiency | >99% — inlet 5K+ ppm → outlet <10 ppm, meeting §101.20 ESLs & EPA BACT. |
| Media Life Extension | >40 days vs. carbon’s <5 days — aligned with §106.477 PBR limits. |
| Cost Savings | $50,000+ vs. carbon-only (fewer swaps, no disposal fees). |
| Compliance Assurance | Zero odors/NOVs; full modeling records for LDEQ audits. |
| Uptime & Safety | 99% availability; <1 ppm stack NH3 protected workers/communities. |
This Donaldsonville project highlights Envent’s expertise in LDEQ ammonia vapor controls, where BACT prevents enforcement risks amid the complex’s blue ammonia expansion.
Need Ammonia Controls for Your Louisiana Chemical Ops? Get a Free LDEQ ESL Review & Quote Contact Envent’s engineers at 888-997-9465 or email [email protected] for a no-obligation assessment. We’re Louisiana specialists—explore our wet scrubbers.
