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Sulphuric Acid on the WebTM Technical Manual DKL Engineering, Inc.

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Acid Plant Database  September 29, 2016

Owner J.R. Simplot Company
Simplot Phosphates, LLC

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515 South Highwat 430
Rock Springs, Wyoming
USA  82902

Background Formerly
Stauffer Chemical
1981 - Chevron Resources Co.
1991 - SF Phosphates Ltd. Co., joint venture between J.R. Simplot and Farmland Industries
Website www.simplot.com
Plant Lurgi Plant Monsanto Plant
Coordinates* 41° 32' 29" N, 109° 7' 55" W 41° 32' 25" N, 109° 7' 58" W
Type of Plant Sulphur Burning Sulphur Burning
Gas Source Elemental Sulphur Elemental Sulphur
Plant Capacity 1905 MTPD (2100 STPD) 1197 MTPD (1320 STPD)
1380 MTPD (1520 STPD) permitted expansion
Emissions SO2: 316.67 lb/h or 4 lb/ton of acid (100% H2SO4)
H2SO4: 11.88 lb/h or 0.15 lb/ton of acid (100% H2SO4)
NOx: 53.53 lb/h
Opacity: <10%
Emissions @ 1197 MTPD
SO2: 220 lb/h or 4 lb/ton of acid (100% H2SO4)
H2SO4: 8.25 lb/h or 0.15 lb/ton of acid (100% H2SO4)
NOx: 16.28 lb/h
Opacity: <10%
Status Operating Operating
Year Built 1986 1995
Technology Outotec (Lurgi) MECS (Monsanto)
Contractor Badger -
Remarks - -
Pictures   JR-Simplot-Rock-Springs-2.JPG (59480 bytes)
General The original SF Phosphates mine – near Vernal Utah – was developed by the San Francisco Chemical Company in 1960.  Chevron Resources Company purchased the mine in 1981, and in 1984 began construction of the slurry pipeline and the fertilizer manufacturing plant near Rock Springs, Wyoming.  Chevron’s plant and pipeline operations were underway by 1986.  Spring of 1992 saw the formation of SF Phosphates Limited Company with the purchase of the mine, pipeline and fertilizer plant in a joint venture between the J.R. Simplot Company and Farmland Industries, Inc.  In 2003, the J.R. Simplot Company purchased Farmland Industries’ interest in the operation, renaming it “Simplot Phosphates, LLC”.
References -
News September 28, 2016 - The J.R. Simplot Company in Pocatello was cited for violating air pollution control rules for "acid mist and fine particulates." EPA alleged that Simplot made modifications at its five sulfuric acid plants without applying for or obtaining necessary Clean Air Act permits and violating "best available control technology" limits for SO2, and for sulfuric acid mist and fine particles at its Pocatello plant.  In response, the company agreed to significantly cut sulfur dioxide emissions at five plants in Pocatello,Idaho, Lathrop, California and Rock Springs,Wyoming and pay an $899,000 civil penalty.  Simplot will spend an estimated $41.5 million to cut sulfur dioxide emissions at all five plants. That will reduce SO2 emissions by more than 50 percent. It will reduce emissions at Simplot's Pocatello plant by approximately 825 tons per year.  The settlement was announced late last year and approved in April 2016.  The Idaho Department of Environmental Quality was a party to the settlement and will receive $167,000 of the penalty.

December 3, 2015
- An agreement to make modifications at five sulfuric acid plants, including the Don Plant in Pocatello, and pay a civil penalty of $899,000 has resolved a Clean Air Act violations issue between the J.R. Simplot Co., U.S. Department of Justice and the Environmental Protection Agency.According to a news release from the Region 10 EPA office, J.R. Simplot has agreed to spend approximately $41.5 million on pollution controls to cut sulfur dioxide emissions at plants in Pocatello, Lathrop, Calif., and Rock Springs, Wyo.  The Idaho Department of Environmental Quality will receive $167,000 of the total civil penalty Simplot has been ordered to pay.  “Today’s settlement is good news for Idaho residents and will result in significant reductions of sulfur dioxide emissions from Simplot’s Pocatello plant,” said Dennis McLerran, EPA regional administrator in Seattle. “Idahoans will breathe cleaner air thanks to the pollution control improvements Simplot has made and will be making under this settlement.”  Once fully implemented, the settlement will reduce sulfur dioxide emissions from Simplot’s five sulfuric acid plants by more than 50 percent for approximately 2,540 tons per year of total reductions. Upgrades at Simplot’s Pocatello plant will reduce those emissions by approximately 825 tons per year. Simplot will also implement a plan to monitor sulfur dioxide emissions continuously at all five plants.“This settlement helps address public health risks for local communities in California, Idaho and Wyoming, and furthers EPA’s commitment to reduce harmful air pollution from the largest sources,” said Cynthia Giles, assistant administrator for EPA’s Office of Enforcement and Compliance Assurance. “The system-wide pollution controls Simplot will install will significantly reduce sulfur dioxide emissions, which can cause serious respiratory problems and exacerbate asthma.”  EPA and DOJ alleged that Simplot made modifications at its five sulfuric acid plants without applying for or obtaining the necessary Clean Air Act permits and “best available control technology” limits for sulfur dioxide, and for sulfuric acid mist and fine particles at its sulfuric acid plant in Pocatello.  Short-term exposures to sulfur dioxide can lead to serious respiratory problems, including constriction of airways in the lungs and increased asthma symptoms. It is also a precursor to the formation of fine particulates, which causes a wide variety of health and environmental impacts, including asthma attacks, reduced lung function, and aggravation of existing heart disease.  This settlement is part of EPA’s national enforcement initiative to control harmful emissions from large sources of pollution, which includes acid plants, under the Clean Air Act’s Prevention of Significant Deterioration requirements. This will be EPA’s 13th acid settlement under the initiative and the ninth sulfuric acid settlement. The emission rates secured in this settlement will result in the best-controlled, system-wide emissions achieved in any sulfuric acid plant settlement to-date.  The consent decree formalizing the settlement was lodged with the U.S. District Court in the District of Idaho and is subject to a 30-day public comment period and final court approval. http://www.idahostatejournal.com/
The proposed consent decree can be viewed at: http://www.justice.gov/enrd/consent-decrees.

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