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Acid Plant Database June 3, 2011
Owner | PCS Phosphate Company Inc. | |||||
Location | 1530 NC
HWY 306 South Aurora, North Carolina USA 27806 |
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Background |
1966 - Site opened Part of Potash Corporation |
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Website | www.potashcorp.com | |||||
Plant | Plant No. 3 | Plant No. 4 | Plant No. 5 | |||
Coordinates* | - | - | - | |||
Type of Plant | Sulphur Burning | Sulphur Burning | Sulphur Burning | |||
Gas Source | Elemental Sulphur | Elemental Sulphur | Elemental Sulphur | |||
Plant Capacity | 1850 STPD | 1850 STPD | 3600 STPD | |||
SA/DA | DA | DA | 3/1 DA | |||
Emissions |
SO2: 4 lb/ton Acid Mist: 0.15 lb/ton NOx: 5.8 lb/ton Opacity: 10% |
SO2: 4 lb/ton Acid Mist: 0.15 lb/ton NOx: 5.8 lb/ton Opacity: 10% |
SO2: 4 lb/ton Acid Mist: 0.15 lb/ton NOx: 5.8 lb/ton Opacity: 10% |
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Status |
Shutdown 2010 37 year life |
Shutdown 2010 36 year life |
Operating | |||
Year Built | 1973 | 1974 | - | |||
Technology | - | - | - | |||
Contractor | - | - | - | |||
Remarks | Planned increase to 2000 STPD was not done | - | Plant equipped with a MECS HRS | |||
Plant No. 3 and 4 to be shutdown when Plant No. 7 is started. Some equipment in the plants will be salvage and sold and then the plants demolished. | ||||||
Plant | Plant No. 6 | Plant No. 7 | - | |||
Coordinates* | - | - | - | |||
Type of Plant | Sulphur Burning | Sulphur Burning | - | |||
Gas Source | Elemental Sulphur |
Elemental Sulphur 11.5% SO2, 9.46% O2 |
- | |||
Plant Capacity | 3800 STPD | 4500 STPD | - | |||
SA/DA | 3/1 DA |
3/1 DA 99.85% conversion |
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Emissions |
SO2: 4 lb/ton Acid Mist: 0.15 lb/ton NOx: 5.8 lb/ton Opacity: 10% |
SO2: < 2 lb/ton, < 200 ppm Acid Mist: 0.075 lb/ton NOx: 0.6 lb/ton Opacity: 10% |
- | |||
Status | Operating | Operating | - | |||
Year Built | - |
2010 Site Mobilization: April 2008 Start-up: January 26, 2010 26 month schedule |
- | |||
Technology | - | MECS | - | |||
Contractor | - |
The Roberts Company (Winterville, NC) - Fabrication and
installation of equipment
www.robertscompany.com
|
- | |||
Remarks | Plant equipped with a MECS HRS | Upon initial startup of Plant No. 7 combined SO2 emissions for No. 3, 4 and 7 shall be less than 2006 tons per consecutive 12 month period Blower:
Siemens AG (KKK) w/steam turbine and IGV |
- | |||
Remarks | Site Power Generation: 52 MW |
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Permit |
North Carolina Department of Environment and Natural Resources, Division of
Air Quality Facility ID: 0700071 Title V Permit |
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Permit No. | Issue Date | Expiry Date | Details | |||
04176R23 | September 24, 2003 | - | Permit for Plant No. 4 | |||
04176T36 | December 17, 2007 | - | BART determination for Plant No. 3 and 4 | |||
04176T37 | January 4, 2008 | - | To construct/operate Plant No. 7 | |||
04176T41 | November 19, 2008 | - | - | |||
04176T36 | - | May 21, 2010 | - | |||
Pictures | ||||||
No. 7 Plant (Pictures extracted from Reference No. 2) | ||||||
General | - | |||||
References | 1.
Sulphuric Acid Today, Spring/Summer 2010, pp. 7-10 2. Baker, T., et. al., "PCS Phoshate's New 4500 STPD Sulfuric Acid Plant in Aurora, NC", AIChE Clearwater Convention, June 12, 2010 |
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News |
March 15, 2009
- Environmental groups have filed a challenge to a decision by state water
quality regulators to allow an expansion of PCS Phosphate's mining operation
in Beaufort County, which would involve massive destruction of wetlands near
the Pamlico River. The permit, issued in January by the state Division of
Water Quality, allows the company to mine about 11,000 acres adjacent to its
current open-pit mine over 35 years. The effects on 4.8 miles of streams
and more than 3,900 acres of wetlands represent the largest destruction of
wetlands ever permitted in North Carolina. PCS Phosphate, part of an
international company headquartered in Canada, has worked the mine since
1995 to produce phosphate for fertilizer and animal feed supplements and for
use in food additives such as phosphoric acid, a flavor enhancer in
Coca-Cola and jellies. It is the largest employer in Beaufort County, with
more than 1,000 workers. "This permit challenge asks whether PCS's mine
expansion has to comply with the laws protecting the environment, fisheries
and public health," Geoff Gisler, a lawyer with Southern Environmental Law
Center said in a statement Thursday. "The long-term economic and
environmental health of eastern North Carolina depends on the state holding
PCS to those standards." The challenge was filed on behalf of Environmental
Defense Fund, the N.C. Coastal Federation, Pamlico-Tar River Foundation and
the N.C. Sierra Club in state administrative court, where agency decisions
are initially appealed. Ross Smith, environmental manager for PCS
Phosphate, said the company had not yet reviewed the legal challenge and
couldn't comment. Meanwhile, in a separate permitting decision involving PCS, a state administrative law judge has ruled that state air regulators erred in issuing a permit to the company to overhaul its fertilizer plant without properly notifying federal wildlife officials and that it used the wrong baseline for predicting whether the plant would harm air quality at the Swanquarter National Wildlife Refuge. Last year, the state Division of Air Quality allowed the company to build a new sulfuric acid plant to replace two existing plants at the site near Aurora. The new plant will produce about 4,500 tons of sulfuric acid a day, 1,000 tons more than the existing facility. The acid is mixed with phosphate ore mined on site to produce phosphoric acid. The U.S. Department of Interior challenged the permit, saying air emissions from the larger phosphate plant could harm visibility at the wildlife refuge about 20 miles east. Judge Fred Morrison of the state Office of Administrative Hearings, ruled that the state did not properly notify the Fish & Wildlife Service, part of the Interior Department, of PCS's plans. Morrison also found state environmental regulators used too lenient a baseline for estimating whether the added pollution from the plant would harm air in the Swanquarter refuge. The judge's decision is advisory. The state Environmental Management Commission, an appointed panel, will make the final decision, which could change the baseline that air regulators use for comparing whether added air emissions would harm air quality and visibility. - The News & Observer Publishing Company) |
MTPD - Metric Tonne per Day
STPD - Short Ton per Day
MTPA - Metric Tonne per Annum STPA - Short Ton per
Annum
SA - Single Absorption
DA - Double Absorption
* Coordinates can be used to
locate plant on Google Earth