Significant ammonia emissions from animal facilities need to be controlled due to its negative impacts on human health and the environment. The use of acid spray scrubber is promising, as it simultaneously mitigates and recovers ammonia emission for fertilizer. Its low pressure drop contribution on axial fans makes it applicable on US farms. This study develops a full-scale acid spray scrubber to recover ammonia emissions from commercial poultry facilities and produce nitrogen fertilizer. The scrubber performance and economic feasibility were evaluated at a commercial poultry manure composting facility that released ammonia from exhaust fans with concentrations of 66–278 ppmv and total emission rate of 96,143 kg yr⁻¹. The scrubber consisted of 15 spray scrubber modules, each equipped with three full-cone nozzles that used dilute sulphuric acid as the medium. Each nozzle was operated at 0.59 MPa with a droplet size of 113 μm and liquid flow rate of 1.8 L min⁻¹. The scrubber was installed with a 1.3-m exhaust fan and field tested in four seasons. Results showed that the scrubber achieved high NH₃ removal efficiencies (71–81%) and low pressure drop (<25 Pa). Estimated water and acid losses are 0.9 and 0.04 ml m⁻³ air treated, respectively. Power consumption rate was between 89.48 and 107.48 kWh d⁻¹. The scrubber effluents containing 22–36% (m/v) ammonium sulphate are comparable to the commercial-grade nitrogen fertilizer. Preliminary economic analysis indicated that the break-even time is one year. This study demonstrates that acid spray scrubbers can economically and effectively recover NH₃ from animal facilities for fertilizer.

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