## Comprehensive Performance Test Plan

for

Rotary Kiln Incinerator Unit 4

in A ccordance with

40 CFR §63 Subpart EEE

Prepared for:

Veolia ES Technical Solutions , L.L.C.

7 Mobile Avenue

Sauget, IL 62201

Prepared by:

URS Corporation

9400 Amberg len Blvd.

Austin, TX 78729

June 28, 2015 September 5, 2012ii 

### Table of Contents

Page

1.0 Introduction

................................ ................................ ................................ ..................... 1

- 1

1.1 Program Summary

................................ ................................ ................................ .. 1

- 1

1.2 Facility/Unit Identification

................................ ................................ ...................... 1

- 2

1.2.1 General

................................ ................................ ................................ ........ 1

- 2

1.2.2 Facility ID, Mailing Address, and Primary Contacts

................................ 1

- 2

1.2.3 Incinerator Overview

................................ ................................ .................. 1

- 3

1.3 Purpose and Objectives of the Performance Test

................................ ................... 1

- 3

1.3.1 General

................................ ................................ ................................ ........ 1

- 3

1.3.2 Test Protocol Summary

................................ ................................ .............. 1.4 Performance Test Plan Organization

................................ ................................ ......

2.0 Engineering Description

................................ ................................ ................................ ... 2

- 1

2.1 Process Overview

................................ ................................ ................................ .... 2

- 1

2.2 Waste F eed Systems

................................ ................................ ................................ 2

- 1

2.2.1 Unit 4 Liquid Waste Feed System and Blending Operations

.................... 2

- 1

2.2.1.1 Organic and Aqueous Liquid Waste Feeds

................................ .. 2

- 3

2.2.1.2 Packaged and Bulk Solids

................................ ............................. 2

- 3

2.2.1.3 Specialty Liquid Feeds

................................ ................................ .. 2

- 4

2.3 Manufacturer, Make and Model of the Incinerator

................................ ................ 2

- 4

2.3.1 Combustion Chamber and Burners

................................ ............................ 2

- 4

2.3.2 Secondary Combustion Chamber

................................ ............................... 2

- 6

2.3.3 Location of Combus tion Zone Temperature Device

................................ . 2

- 6

2.3.4 Hazardous Waste Residence Time

................................ ............................. 2

- 7

2.3.5 Combustion System Leak

................................ ................................ ........... 2

- 7

2.3.6 Emer gency Safety Vent

................................ ................................ .............. 2.4 Procedures for Rapidly Stopping Hazardous Waste Feed and Controlling Emissions

During EquipmentMalfunction

................................ ................................ ............... 2.5 Air Pollution Control Equipment

................................ ................................ ............ 2.5.1 Air Pollution Control System Descriptions

................................ ............... 2.5.1.1 Tempering Chamber

................................ ................................ ...... 2.5.1.2 Lime System

................................ ................................ .................. 2.5.1.3 Spray Dry Absorber

................................ ................................ ....... 2.5.1.4 Fabric Filter

................................ ................................ .................... 2.5.1.5 Carbon Injection

................................ ................................ ............ 2.5.1.6 Induced Draft Fan and Stack

................................ ......................... 2 .6 Stack Emissions Monitoring

................................ ................................ ................... 2.6.1 CEM System Description

................................ ................................ ............. 2.7 Process Monitoring and Contr ol

................................ ................................ ............. 2.8 Automatic Waste Feed Cut

- off System

................................ ................................ .. 2.8.1 AWFCO System Testing

................................ ................................ ..............iii 

### Table of Contents (continued)

Page

2.9 Air Pollution Control Equ ipment Maintenance Practices

................................ ...... 2.9.1 Program Overview

................................ ................................ ........................ 2.9.2 Test Pr ogram Preparation Activities

................................ .............................

3.0 I ncinerator Feed Stream Descriptions

................................ ................................ ............ 3

- 1

3.1 General

................................ ................................ ................................ ..................... 3

- 1

3.2 High Volume Wastes

................................ ................................ .............................. 3

- 1

3.2.1 Liquid Wastes

................................ ................................ ............................. 3

- 1

3.2.2 Bulk Solids

................................ ................................ ................................ .. 3

- 1

3.2.3 Containerized Waste

................................ ................................ ................... 3

- 2

3.2.4 Gaseous Wastes

................................ ................................ ............................. 3

- 2

3.3 Auxiliary Fuels

................................ ................................ ................................ ........ 3

- 2

4.0 Performance Test Protocol

................................ ................................ ............................... 4

- 1

4.1 General Description

................................ ................................ ................................ . 4

- 1

4.2 Performance Standards

................................ ................................ ........................... 4

- 1

4.3 Test Condition s

................................ ................................ ................................ ........ 4

- 2

4.3.1 Maximum Feedrate of Ash and Chlorine, Minimum Sorbent and Carrier

Fluid Flowrates to the SDA Maximum Feedrate of Metals and Chlorine

. 4.3.2 Maximum Feedrate of Met als and Chlorine, Maximum Waste Feedrates,

Minimum Temperatures in the Rotary Kiln and SCC , Minimum Carbon

Feedrate Maximum Feedrate of Ash and Chlorine

................................ ..... 4.3.3 Maximum Waste Feedrates and Minimum Combustion Temperatures

... 4.4 Establishing Operating Parame ter Limits

................................ ............................... 4.5 Waste F eed Spiking

................................ ................................ ................................ . 4. 5 .1 Inorganic Constituents

................................ ................................ ................ 4. 5 .2 Spiking for the LVM Category

................................ ................................ .. 4. 5 .3 Spiking for the SVM Category

................................ ................................ ... 4. 5 .4 Spiking for Mercury

................................ ................................ ................... 4. 5 .5 Spiking for Chlorine Loading

................................ ................................ ..... 4. 5 .6 Spiking for Ash Loading

................................ ................................ ............ 4. 6 Metals Extrapolation Method

................................ ................................ ................. 4. 7 Description, Preparation, and Delivery of Fe eds for the Performance Test

.......... 4. 8 Testing During Cleaning Cycles

................................ ................................ ............. 4. 9 Conditioning Time Needed to Reach Steady State

................................ ................ 4. 10 AWFCO System During the Test

................................ ................................ ........... 4. 1 1 Anticipated Test Sched ule

................................ ................................ ...................... 4.1 2 Reporting

................................ ................................ ................................ .................

5.0 Sampling, Analysis, and Monitoring Procedures

................................ .......................... 5

- 1

5.1 Sampl ing Locations and Procedures

................................ ................................ ....... 5

- 1

5.1.1 Liquids Sampling Procedures

................................ ................................ ..... 5

- 1iv 5.1.2 Solids Sampling Procedures

................................ ................................ .......v 

### Table of Contents (continued)

Page

5.1.3 Stack Gas Sam pling Procedures

................................ ................................ . 5.1.3.1 Sample Port Location

................................ ................................ .... 5.1.3.2 EPA Methods 2 and 4

................................ ................................ .... 5.1.3.3 EPA Method 29

................................ ................................ ............. 5.1.3.4 EPA Method 5 / EPA Method 26A

................................ .............. 5.1.3.5 SW

- 846 Method 0023A

................................ ................................ 5.1.3.6 Continuous Emissions Monitoring

................................ ............... 5.2 Analysis Pro cedures

................................ ................................ ................................ 5.2.1 Composition and Physical Parameters Analysis

................................ ........ 5.2.2 Metals Analysis

................................ ................................ ........................... 5.2.3 Particulate Matter Analysis

................................ ................................ ........ 5.2.4 HCl and Cl 2 Analysis

................................ ................................ .................. 5.2.5 Dioxins/Furans

................................ ................................ ............................ 5.3 Process Monitoring Procedures

................................ ................................ .............. 5.4 Quality Assurance/Quality Procedures

................................ ................................ ... 5.4.1 Sampling QA/QC

................................ ................................ ........................ 5.4.2 Procedures for Analytical Quality Control

................................ ................

APPENDIX A Continuous Monitoring System Performance Evaluation Test Planvi 

### List of Tables

Page

1

- 1 Applicable HWC MACT Emission Standards

................................ ................................ ... 1

- 4

1

- 2 Data Used to Establish OPLs

................................ ................................ .............................. 1

- 7

1

- 3 Cross Reference s of Perf ormance Test Requirements

................................ ....................... 1

- 9

2

- 1 Technical Information Summary on Unit 4

................................ ................................ ........ 2

- 5

2

- 2 Unit 4 Continuous Emission Monitors

................................ ................................ ................ 2

- 3 Current HWC MACT AWFCO Param eters and Limits for Unit 4

................................ ...

3

- 1 Summary of Major HAPs Processed

................................ ................................ .................. 3

- 2

3

- 2 Top Volume Liquid Waste Streams

................................ ................................ .................... 3

- 3

3

- 3 Top Bulk Solid Waste Streams

................................ ................................ ........................... 3

- 3

3

- 4 Top Containerized Solid Waste Streams

................................ ................................ ............ 3

- 4

3

- 5 Typical Properties for Natural Gas

................................ ................................ ...................... 3

- 4

4

- 1 Target Feedr a tes and Operating Conditions

................................ ................................ ....... 4

- 2 HWC MACT OPLs to be Established During t h e Comprehensive Performance Test

..... 4

- 3 Emission Standards versus Operating Parameters

................................ .............................. 4

- 4 Metals Evaluation Plan

................................ ................................ ................................ ........ 4

- 5 Daily Schedule for the Subsequent CPT of Unit 4

................................ .............................

5

- 1 Measurement Frequency

................................ ................................ ................................ ..... 5

- 2 Sampling Methods

................................ ................................ ................................ ............... 5

- 3 Summary of Analytical Methods

................................ ................................ ........................ 5

- 4 Summary of Matrix Specific QC Sample Requirements

................................ ...................



### Figure List

Page

2

- 1 Unit 4 Process Flow Diagram

................................ ................................ ............................. 2

- 2

2

- 2 Hydrated Lime Specifications

................................ ................................ ............................. 2

- 3 Carbon Specifications

................................ ................................ ................................ ..........1

- 1



### 1. 0 Introduction

1. 1 Progra m Summa ry [4 0 CF R § 63

. 1207(f ) an d § 63.7(c)(2)(i)]

V e oli a E S Tech n i ca l Sol u tions , L.L.C. (Veolia ) operates three incinerators at it s Sauget

,

Illin oi s facility

. Two of the incinerators are fixed hearth units (Units 2 and 3), and the third

incinerator is a rotary kiln unit (Unit 4). All of the incinerato rs tr e at certai n w a st es tha t ar e

classifie d as hazardou s unde r stat e an d /o r federa l re g ulation s

, and are subject to the National

Emission Standards for Hazardous Air Pollutants (NESHAPs) for Hazardous Waste

Combustors (Title 40 of the Code of Federal Regulati ons, Part 63 [40 CFR Part 63], Subpa rt

EEE), (i.e., the HWC MACT).

In August and September of 2008, Veolia conducted tests of Units 2, 3, and 4 required

by the information collection requests from USEPA Region 5 dated June 5, 2008 and

September 12, 2008. Those tests began on August 11, 2008 for Unit 2, August 5, 2008 for

Unit 3, and August 21, 2008 for Unit 4 . The test plans for these tests were approved by

USEPA Region 5. The tests were designed to demonstrate compliance with the applicable

emission stan dards of the HWC MACT for metals codified at 40 CF R § 63. 1 2 19(a)(2), 40 CF R

§ 63. 1 2 19(a)(3), and 40 CF R § 63. 1 2 19(a)(4) for mercury, cadmium and lead (i.e., Semi v olatile

Metals

– SVM), and arsenic, beryllium, and chromium (i.e., Low Volatil ity Metals

- LVM ).

The tests also established Operating Parameter Limits (OPLs) for mercury, and SVM and LVM

codified at 40 CF R § 63. 1 209 (l) and 40 CF R § 63. 1 209 (n), respectively.

The initial Comprehensive performance tests of Units 2, 3, and 4 commenced on December 8,

2009 for Unit 2; on December 1, 2009 for Unit 3; and on December 16, 2009 for Unit 4. The

Comprehensive Performance Tests were performed in accordance with Comprehensive

Performance Test Plans approved by USEPA Region 5 on November 25, 2009. The HWC

MAC T, at 40 CF R § 63.1207(d), states “The date of commencement of the initial comprehensive

performance test is the basis for establishing the deadline to commence the initial confirmatory

performance test and the next comprehensive performance test. You may conduct performance

testing at any time prior to the required date. The deadline for commencing subsequent

confirmatory and comprehensive performance testing is based on the date of commencement of

the previous comprehensive performance test.” Veolia Saug et understands that EPA Region 5‘s

position regarding commencement of the subsequent CPTs is based on the initiation of the metals

tests performed in 2008, stating in a letter dated August 3, 2012 ―Veolia must submit to EPA a

notification of intent to cond uct a CPT and a site

- specific test plan for the CPT at least one year

before the performance test. 40 CF R § 63. 1 207 (e)(1)(i)...by September 5, 2012‖. Veolia is

submitting to EPA its notification of intent and site

- specific test plan for the subsequent CPT by

this date.1

- 2

Thi s docum e n t i s a Comprehensive Performance Test Plan fo r Unit 4 for the subsequent

comprehensive performance test (CPT) and provides notification that Veolia Sauget intends to

start the CPTs of the three incinerators at the Sauget facility by September 5, 2013. A ll of the

applicable parameters of the HWC MACT including dioxins/furans, total hydrocarbons (THC),

carbon monoxide (CO), particulate matter (PM), hydrogen chloride/chlorine gas (HCl/Cl 2 ),

mercury, SVM, and LVM will be determined dur ing the CPT

.

Per 40 CFR §63.1206(b)(7)(i)(A), compliance with the DRE standard is required to be

demonstrated only one time, and Veolia Sauget demonstrated DRE during RCRA Trial Burns of

Units 2, 3, and 4 performed in January 1993 , November 1996, and Dece mber 1995, respectively.

The HWC MACT requires that DRE only be demonstrated one time as long as ―you do not feed

hazardous waste at a location in the combustion system other than the normal flame zone‖ (§

63.1207(c)(2)(iv))

. Veolia will not re

- demonstrate DRE for Unit 4 in the subsequent CPT

. DRE,

and the associated OPLs, were demonstrated during the 199 5 trial burn , and operations of the

incinerator have not significantly changed since that test

.

This test (i.e., the subsequent CPT ) is designed to demons trate applicable emission

standards and establish OPLs as required by the HWC MACT for dioxins/furans, total

hydrocarbons (THC), carbon monoxide (CO), particulate matter (PM), hydrogen

chloride/chlorine gas (HCl/Cl 2 ), mercury, SVM, and LVM

. The results of this test will be

used to revise the current NOC.

1. 2 Facilit y

/Uni t Identification

1.2. 1 G e neral

T h i s Comprehensive Performance T es t Pla n h a s bee n designed to demonstrate applicable

emission standards and establish OPLs as required by the HWC MACT for m ercury, SVM,

and LVM. Thi s i s a commercia l hazardou s wast e incine r atio n facilit y tha t treat s li q ui d an d solid

waste s th a t a

r e classifie d a s both hazard o u s an d non

- h azardous.

1.2. 2 Faci l it y I D

, M a il i n g A dd r es s

, a n d Pri m ar y Contacts

Th e facilit y a d dres s i s : Th e facilit y c o ntac t is:

Veoli a E S T e chnica l S o lution s Mr

. D a v e Kla r ich

7 Mobil e Av e nu e Phone : 618

- 271

- 2804

Sauget

, I L 6 2 20 1 Email : Davi d .Klarich@v eoliaes.com

Fa c il i t y ID # : I L D0 9 86 4 24241

- 3

1.2. 3 Inc i nerat o r Ov e r v iew

Unit 4 i s a rotary kiln i n cineratio n sy s t e m with primar y an d s e condar y comb u stio n

chamb e rs tha t treat s soli d waste s a s wel l a s aque o u s an d organi c liquid s

. T h e proces s i s

monitore d an d c ontrolle d b y a distrib u te d c o ntro l s y ste m ( DCS ) capabl e o f cont i nuousl y

monitorin g th e proces s t o assur e al l op e rational parameter s a r e with i n reg u lator y an d pe r mi t

limit s whil e wast e i s bein g fe d t o th e unit

. I n ad d ition

, this incinerato r i s equippe d wit h a

Co n t i nuou s Emission s Monitorin g Syste m (CEMS ) tha t co n t inuo u sl y samp les th e e x haus t g ase s

fo r carb o n mon o xid e and o xy g e n i n th e stac k ga s exhau s t s t ream.

1. 3 Pu r p o s e an d Ob j ect i v e s o f t h e Per f or m a n c e Test

1.3. 1 G e neral

This document presents Veolia‘s plan for the subsequent CPT for the Final Replacement

Standards of the HWC MACT and is designed to demonstrate compliance with the standards and

associated OPLs of the HWC MACT for existing incinerators at § 63.1219

. T h e CPT is designed

to:

Demonstrate th at the incinerator meets the applicable HWC MACT emission

limits while treating hazardous waste; and

Re

- establish operating parameter limits (OPLs) on key operating variables that

will ensure that the incinerator operates within the HWC MACT emission limit s

while treating hazardous waste.

Th e te s t prog r a m wil l inclu d e fee d in g a variet y o f liq u i d an d soli d w a st e m a terial s t o

th e inciner a tor

, sampling an d analyzin g th e fee d s t reams

, spiking waste feed streams with

metals and chlorine, mo n i to ri n g certai n pr o ces s parameter s

, an d con d uctin g e mission s

testing

. Th e emissio n s standard s t h a t wil l b e demonstrated unde r th e HW C MAC T

regulatio n s ar e summa

r i ze d in Tabl e 1

- 1

.1

- 4 Tabl e 1

- 1

. Applic a bl e HWC M A C T Emis s i o n Standa r ds

Emissions Parameter Limit Citation

Dioxin s/Furans (TEQ basis) ≤ 0.40 ng/dscm 40 CFR § 63.1219(a)(1)(i)(B)

Mercury ≤ 130 g/dscm 40 CFR § 63.1219(a)(2)

Semivolatile Metals (SVM) (Cadmium and

Lead) ≤ 230 g/dscm 40 CFR § 63.1219(a)(3)

Low Volatile Metals (LVM) (Arsenic,

Beryllium and Chromium) ≤ 92 g/dscm 40 CFR § 63.1219(a)(4)

Carbon Monoxide (CO) ≤ 100 ppmv, dry 40 CFR § 63.1219(a)(5)(i)

Total Hydrocarbons (THC) ≤ 10 ppmv, dry 40 CFR § 63.1219(a)(5)(ii)

Hydrogen Chloride & Chlorine (HCl/Cl 2 ) ≤ 32 ppmv dry, as Cl

40 CFR § 63.1219(a)(6)

P articulate Matter (PM) ≤ 0.013 gr/dscf 40 CFR § 63.1219(a)(7)

Destruction and Removal Efficiency (DRE) ≥ 99.99 % 40 CFR § 63.1219(c)(1)

Note: All emission concentrations are corrected to 7% oxygen.

The objectives for the subsequent CPT for the Final Re placement Standards of the HWC

MACT are:

Demonstrate compliance with stack gas emissions less than or equal to the

following limits, corrected to 7% O 2 :

— Carbon M onoxide: 100 ppmv, dry;

— Total H ydrocarbons: 10 ppmv, dry;

— Dioxins/F urans: 0. 4 0 ng TEQ/ds cm;

— Particulate M atter (PM): 0.013 grains/dscf;

— Mercury: 130 g/dscm;

— Semivolatile M etals (SVM) (Cd and Pb combined): 230 g /dscm;

— Low V olatil ity M etals (LVM) (As, Be and Cr combined): 92 g /dscm; and

— Hydrogen C hloride/ C hlorine (HCl/Cl 2 ): 32 p pmv as Cl

equivalent, dry.

Compliance with the DRE standard (99.99% DRE) is demonstrated using data from a

previous RCRA Trial Burn

.

Establish limits for operating parameters.

Conduct a Continuous Monitoring System (CMS) performance evaluation test.

Cond uct a Relative Accuracy Test Audit (RATA) for the CO and O 2 Continuous

Emissions Monitoring Systems (CEMS) if a RATA of the CO and O 2 CEMS does not

occur within 60 days of the CPT.1

- 5

1.3.2 Test Protocol Summary

A brief description of the objectives of the subsequent CPT is provided below

, and a

definition of the applicable emission limits and the resulting operating parameter limits (OPLs)

are given in Section 4.0. The test condition of the subsequent CPT of Unit 4 will include one

mode of operation , and on e set of OPLs will be developed.

In the first part of the test, Veolia will demonstrate compliance with the particulate matter

and HCl/Cl 2 standards of the HWC MACT while the plant is operating to establish the maximum

ash feedrate, maximum chlorine feedr ate, maximum combustion gas flowrate, and other

applicable OPLs as required by the HWC MACT for the particulate matter and HCl/Cl 2

standards. Compliance with the standard for carbon monoxide will also be demonstrated during

this t est.

In the second part of the test, Veolia will demonstrate compliance , and develop OPLs,

with dioxins/furans, THC

, CO, LVM, SVM, and the mercury , SVM, and LVM standards of the

HWC MACT while the plant is operating to establish maximum total hazardous waste feedrate,

maximum pu mpable hazardous waste feedrate, minimum primary combustion chamber (PCC)

temperature, minimum secondary combustion chamber (SCC) temperature

, maximum LVM,

SVM, and Hg metals fe e drates, maximum chlorine feedrate, maximum combustion gas flowrate,

and maximu m inlet temperature to the baghouse and other OPLs as required by the HWC MACT

for the mercury, SVM, and LVM standards

. Ash will be fed to the incinerator at normal (or

higher) levels during this t est. Compliance with the standard for carbon monoxide will a lso be

demonstrated during this t est.

Veolia will demonstrate compliance with the particulate matter and HCl/Cl 2 standards of

the HWC MACT while the plant is operating to establish the maximum ash feedrate, maximum

chlorine feedrate, maximum combustion g as flowrate, and other OPLs as required by the HWC

MACT for the particulate matter and HCl/Cl 2 standards. Compliance with the standard for

carbon monoxide will also be demonstrated during this t est.

Veolia will demonstrate compliance with the dioxins/fur ans, total hydrocarbons, and

carbon monoxide standards of the HWC MACT while the plant is operating to establish the

minimum primary combustion chamber (PCC) temperature, minimum secondary combustion

chamber (SCC) temperature, maximum total hazardous wast e feedrate, maximum pumpable

hazardous waste feedrate, maximum combustion gas flowrate, and other OPLs as required by the

HWC MACT for the dioxins/furans, total hydrocarbons, and carbon monoxide standards

.

Chlorine will be fed to the incinerator at normal (or higher) levels during this t est.

Per 40 CFR §63.1206(b)(7)(i)(A) compliance with the DRE standard is required to be1

- 6

demonstrated only one time and Veolia demonstrated DRE for Unit 4 in a December 1995

RCRA trial burn

. Veolia will not re

- demonstrate DRE for Unit 4 in the subsequent CPT for the

Final Replacement Standards of the HWC MACT

. DRE, and the associated OPLs, were

demonstrated during the 199 5 trial burn , and operations of the incinerator have not significantly

changed since that test

. The resu lting OPLs associated with the standard for DRE, from the

NOC, are:

Maximum Total Pumpable Waste Feedrate to the Kiln 3,312 lb/hr ;

Maximum Total Pumpable Waste Feedrate to the SCC 1,788 lb/hr;

Maximum Total Waste Feedrate to the Kiln 18,667 lb/hr ;

Max imum Total Waste Feedrate to the SCC 1,788 lb/hr ;

Minimum Stack Gas Flowrate 44,900 acfm ;

Minimum Temperature in the Primary Combustion Chamber 1, 415 o F ; and

Minimum Temperature in the Secondary Combustion Chamber 1, 798 o F

Per 40 CFR §63.120 9 (i) , whe n an operating parameter applicable to multiple standards is

demonstrated in performance tests not performed simultaneously, the most stringent limit

applies. The OPLs required for DRE and for dioxins/furans are the same. The OPLs for

maximum pumpable ha zardous waste feedrate, maximum total hazardous waste feedrate,

minimum temperature in the PCC, minimum temperature in the SCC, and maximum stack gas

flowrate will be the more stringent demonstrated in the 1993 trial burn and the subsequent CPT.

The OPL f

or maximum stack gas flowrate will be the most stringent demonstrated in the 1993

trial burn and the first and second portions of the subsequent CPT.

THC is typically demonstrated in conjunction with DRE

. The OPLs for THC (i.e.,

minimum combustion chambe r temperature in the primary combustion chamber , minimum

combustion chamber temperature in the secondary combustion chamber , maximum flue gas

flowrate, maximum pumpable hazardous waste feedrate, and maximum total waste feedrate) are

the same as the OPLs fo r DRE (that the same for dioxins/furans). Even though DRE will not be

demonstrated, THC will be demonstrated during the subsequent CPT of Unit 4 during the

dioxins/furans portion of the CPT.

The CPT will be performed to demonstrate compliance and establis h OPLs for targeted

standards

, recognizing that p er 40 CFR §63.1209(h)(1), ―if the performance tests...are not

performed simultaneously, the most stringent limit for a parameter derived from independent

performance tests applies‖ . Operating conditions during the subsequent CPT represent the

―extreme range of normal‖ conditions which will allow for establishment of HWC MACT OPLs

that provide adequate operational flexibility

. The operating parameter data will be used as shown

in Table 1

- 2 to develop HWC MACT OP Ls

. Wastes utilized during the CPT will be typical of1

- 7

the wastes normally treated in Unit 4 . The constituent spiking approaches are presented in

Section 4.5. Upon completion of the subsequent CPT, a Notification of Compliance (NOC) will

be prepared, and th e OPLs of this NOC will replace those in the current NOC.1

- 8 Table 1

- 2. Data Used to Establish OPLs

Demonstrated OPLs Emission Parameters to be Demonstrated

During the CPT

Maximum Pumpable Waste Feedrate DRE 199 5

THC 

Dioxins/Furans 

Maximum Total Waste Feedrate DRE 199 5

THC 

Dioxins/Furans 

Maximum Stack Gas Flowrate SVM 

LVM 

PM 

HCl/Cl 2 

DRE 199 5

THC 

Dioxins/Furans 

Minimum Combustion Chamber Temperature

in the Rotary Kiln DRE 199 5

THC 

D ioxins /F urans 

Minimum C ombustion Chamber Temperature

in the SCC DRE 199 5

THC 

Dioxins/Furans 

Maximum Total Feedrate of LVM (As, Be,

Cr) LVM 

Maximum Pumpable Feedrate of LVM (As,

Be, Cr) LVM 

Maximum Feedrate of SVM (Pb, Cd) SVM 

Maximum Feedrate of Mercury (Hg) Hg 

Maximum Feedrate of Ash PM 

Maximum Feedrate of Total

Chlorine/Chloride HCl/Cl 2 

LVM 

SVM 

Maximum Baghouse Inlet Temperature THC 

D ioxins /F urans 

LVM 

SVM 

Minimum Carbon Feedrate D ioxins /F urans 

Hg 

Minimum Sorbent Feedrate HCl/Cl 2 

Minimum Carrier Fluid Flowrate HCl/Cl 2 

199 5

– December 199 5 RCRA Trial Burn1

- 9

1. 4 Per f or m a nc e Tes t P l a n O r gani z a tion

Thi s te s t p l a n ha s bee n or g anize d i n a fo r ma t typical l y use d fo r complianc e

dem o nstratio n te s t programs. Tabl e 1

- 3 i s include d s o th a t th e requir e ment s i n th e HW C

MAC T r ul e ca n b e c r oss

- referenc e d wit h the section s i n t h i s pla n

. Th e r emainde r o f th e

documen t ha s bee n or g anize d a s follows:

Sectio n 2

. 0 p rovide s a ge n era l p h ysica l descriptio n o f th e fixe d hea r t h incineratio n

syste m and associate d u n i t operation s (includin g th e a i r pollut i o n c o ntro l system ) a s

wel l a s a n overvie w o f t

h e automati c wast e fee d c u tof f (AWFCO ) syste m an d

maintenanc e procedures.

Sectio n 3

. 0 p resent s a bri e f d iscussio n o f th e p h ysica l an d c h emical paramete rs of

the waste streams treated in the incinerator that impact thermal oxidation and

summarizes the hazardous air pollutants presently identified in the waste streams.

Sectio n 4

. 0 p resent s th e T es t Pr o t oco l includin g pla n ne d fee d an d operating

conditio n s

, rational e f

o r the test design, anticipated test schedule, and final report

format.

Sectio n 5

. 0 presents the sampling and analysis that will be performed during the test

,

a nd p rovides an overview of the QA/QC protocols that will be followed. A Quality

Assur ance Project Plan (QAPjP) has been prepared for the tests of Units 2, 3, and 4,

and full y describe s al l samplin g an d analysi s procedure s an d associate d QA/Q C

pr o t o cols . The QAPjP is provided as a separate document.

Appendix A contains the Continuous Monit oring System Performance Evaluation

Test Plan (CMS PETP) to be performed in conjunction with the CPT of Unit 4

.1

- 10 Tabl e 1

- 3. C r os s Refere n c e o f Perfo r manc e T es t Requiremen t s

Topic R e gu l a t o r y C i t a tion Se c tio n i n this

Doc u m e nt

Pr o g r a m S u m m a

ry 4 0 C F R § 6 3

. 12 0 7( f ) a n d § 6 3 .7( c ) ( 2) ( i ) 1.1

T e s t S ched u le 4 0 C F R § 6 3 .12 0 7(f)

, (f)(1)(v ) a n d §

6 3 .7(c)(2)( i ) 4.11

Da t a Q u a l i t y O b

j ec t i v e s (DQ O s) 4 0 C F R § 6 3

. 12 0 7( f ) a n d § 6 3 .7( c ) ( 2) ( i ) QAPjP

– 3.0

In t e r n a l a n d E x te

r n a l Q u a l i t y A ss u r anc e P la n 4 0 C F R § 6 3

. 12 0 7( f ) a n d § 6 3 .7( c ) ( 2) ( i ) QAPjP

– 9.0 &

12.0

Anal y s i s o f F e edst

r eam s ( a s f

i r ed)

H e a t i n g v alu e

, a s h c o nt e nt

, s e mi

- vol at il e m e t a ls

, l o w vol a til e m e t a ls

,

m e rc u ry a n d t o ta l ch l orine

Vi s cosi ty

Id en t i f i c a tio n a n d q ua n t i f

i c a ti o n o f re a s o nably exp e ct e d H A Ps 4 0 C F R § 6 3 .1 2 0 7(f)( 1 )( i )

4 0 C F R § 6 3 .12 0 7(f)( 1 )( i ) (A)

4 0 C F R § 6 3 .12 0 7(f)( 1 )( i ) (B)

4 0 C F R § 6 3 .12 0 7(f)( 1 )(i i )(A ) & (B) 3.0

De t a i le d E ngi n e e r i n g D es c r i p t i o n o f C o m b us t o r

Man u facturer/m a

k e /mod e l o f H W C

T y p e o f H W C

Max i m u m d e sig n c a

p a c i ty

Fee d s y s t e m s

L o c at io n o f c o m

b u s t i o n z on e te m

p e r at ur e d e vice

H aza r d o u s w a st e AWF C O s y st e m

D esig n

, o p e r a

t io n an d m a i n tena n c e o f APC

Jus t i f i c at io n o f al t e

r n a t i v e ga s fl o w r a t e m

e a s u r e m e n t t e c h n iq ue

D esig n

, o p e r a

t io n an d m a i n tena n c e o f stac k g a s mo ni t o rin g s y st e m s 4 0 C F R § 6 3 .12 0 7(f)( 1 )(i i i)(A)

4 0 C F R § 6 3 .12 0 7(f)( 1 )(i i i)(B)

4 0 C F R § 6 3 .12 0 7(f)( 1 )(i i i)( C )

4 0 C F R § 6 3 .12 0 7(f)( 1 )(i i i)( D ) & (E)

4 0 C F R § 6 3 .12 0 7(f)( 1 )(xix)

4 0 C F R § 6 3 .12 0 7(f)( 1 )(i i i)(F)

4 0 C F R § 6 3 .12 0 7(f)( 1 )(i i i)(G)

4 0 C F R § 6 3 .12 0 7(f)( 1 )(xv i i )

4 0 C F R § 6 3 .12 0 7(f)( 1 )(i i i)( H ) 2.0

2.3

2.3

2.3

2.2

2.3.3

2.8

2.5

N/A

2.6

D escri p tio n o f W a st e H an d lin g a n d B l end i ng

O p e r at io ns 4 0 C F R § 6 3 .12 0 7(f)( 1 )(i i )( C ) 2.2.1

De t a i le d T es t P

r o t o c o l I n c l udi n g :

D e scri p tio n o f s a m

p lin g

, m o n i t o r i n g a n d a

n al y t i c a l proced u r e s

D escri p tio n o f Pla n ne d Fee d a n d Op e r a ting c on di t i o n s durin g t

h e

P er f o rm a n c e T est 4 0 C F R § 6 3 .12 0 7(f)( 1 )( i v )

4 0 C F R § 6 3 .12 0 7(f)( 1 )(vi ) & (vi i ) 5.0

4.0

Proced u r e s f

o r R a p idl y S top p in g H azardo u s W a ste F e e d an d C on t ro l li n g

E m i s sio n s d u rin g M a l fu n ct i on 4 0 C F R § 6 3 .12 0 7(f)( 1 )(vii i ) 2 .3.6

De t e r min a

t i o n o f H a z a

r do u s W as t e R e s i d e n c e T i m e 4 0 C F R § 6 3

. 12 0 7( f) ( 1) ( ix ) 2.3.4

M e t a l F ee d r a

t e L im i t E x trapo la

t io n ( i f use d ) 4 0 C F R § 6 3 .12 0 7(f)( 1 )(x) 4.6

CMS and CEMS performance evaluation plans 40 CFR § 63.8(e)(4) and 1207(b)(1) Appendix A

D o c u m en t a

t i o n o f E x p e ct e d L e v e l s o f R e g ul a t e d C o ns t i t

u e nt s i n O t h e r

F ee d st r e am s t h a t a r e no t A n al y z ed 4 0 C F R § 6 3 .12 0 7(f)( 1 )(xi) 3.0

D ocum en t a t i o n o f T esting during C leaning C ycle 4 0 C F R § 6 3 .12 0 7(g)( 1 )( i )(C) 4.8

D ocum en t a t i o n o f C o n d i t i oni n g T i m e N ee d e d t o R e a c h S tead y S t a t e P ri o r

t o T e st i ng 4 0 C F R § 6 3 .12 0 7(f)( 1 )(xi i ) 4.9

A l t e rn a tiv e M on i torin g F re q ue n c y f o r W e t S crubb e r s ( i f u s e d ) 4 0 C F R § 6 3 .12 0 7(f)( 1 )(xxii i ) N/A

Ot h e r I n f o r m a t io n D e e m e d N e c es s a

ry b y t h e A g e ncy 4 0 C F R § 6 3 .12 0 7(f)( 1 )(xxvi i )

---2

- 1



### 2. 0 Engineerin g Description

2. 1 Pr o ces s O ve r view

Veoli a operate s two Fixe d H e art h Dua l Ch a m bere d Inci n erator s (Unit s 2 an d 3 ) an d on e

rota r y kil n inciner a t or (Uni t 4 ) a t th e Saug e t

, I L f a cility

. Th e t w o fixe d hea r th un i t s ar e r a t e d a t

1 6 mi l lio n Btu/h r each

. Incineration Uni t N o

. 3 i s a mirro r imag e o f Uni t No

. 2

. B o t h o f thes e

unit s h a v e th ei r ow n wast e handlin g sy s tem s as describe d i n th e section s th a t follow

. Th e onl y

d i f f eren c e bein g Uni t No

. 2 i s eq u i p pe d with fou r (4 ) baghouse modules

, whil e Uni t No

. 3 i s

equippe d with thre e (3 ) b a ghous e mod u les

. Howeve r

, eac h incine r ato r is operate d ide n ticall y

with onl y thre e b a gh o us e module s i n servic e durin g operation

. Uni t 4 i s r a t e d a t 5 0 million

Btu / h r an d i s equippe d wit h it s ow n tan k far m syste m, dru m storag e

, bul k solid s storag e an d fe e d

system s

.

A process flow diagram for Unit 4 is presented in Figure 2

- 1.

2. 2 Wast e Fee d S y stem s [4 0 CF R § 63

. 1207(f)(1)(ii)(c ) an d (f)(1)(iii)(D ) an d (E)]

2.2. 1 Un i t 4 L i qu i d W a st e F e e d S y ste m an d Bl e nd i n g O p er a ti o ns

Th e Uni t 4 R o tar y Kil n ca n incinerat e a n y o f th e wast e tha t Veoli a i s a uthorize d an d

perm i tte d t o r ece ive

. All physica l for m s o f waste s w i l l b e handl e d an d fe d b y t h e syste m ‘ s w ast e

fee d d e v i ces

. L i quid s wil l b e fe d to eithe r th e kil n o r th e Secon d ar y Combustio n Ch ambe r

( S CC ). Bul k soli d waste s wil l b e fe d t o th e kil n through th e ra m feede r

. Containerize d waste s

wil l b e fe d t o th e kil n th r oug h th e ra m feede r o r th e auxiliar y ram feeder

. Thi s u ni t ca n receiv e

an y combi n atio n o f wast e s

- - liq u i d

, s e mi

- solid

, o r soli d

- - with a h e a t valu e o f up t o 5 0 millio n

Btu/h r

.

Uni t 4 i s supporte d b y s t or a g e tank s locate d i n Tan k F a r m #3

. Thes e tank s ar e use d t o

stor e th e liqui d organic waste

, aque o u s wastes

, a n d pumpabl e sludge s t o b e fe d t o t h e s y stem

.

Unlik e T an k Far m # 1

, al l o f th e tanks i n Tan k Far m # 3 ca n b e use d a s fee d t a nk s t o th e

incinerator

. Sev e ra l crite r i a ar e impo r tan t i n designin g a blen d fro m r e ceive d wast e s

. Thes e

includ e compati b ility

, prope r r a ng e o f he a ti n g v a lue

, an d permit restriction s r e gardin g elementa l

comp o s itio n (base d o n emissio n limit a t ions)

. Pump s t o tran s fe r thes e wastes t o th e syste m ar e

inst a lle d i n th e tan k farm

. Th e m a te r i a l i s transfer r e d throug h a

b ovegroun d pi peline s from th e

tan k far m t o th e inciner a t or

. Pip e line s use d t o transfe r liqui d org a ni c wast e an d aqueou s wast e

are equippe d with strainers.2

- 2 Figure 2

- 1. Unit 4 Process Flow Diagram2

- 3

I n comp lianc e with th e Benzen e NES H AP

, a l l tank s ar e vente d t o individua l carbo n

adsorptio n c a nister s for remova l o f o r ganic s befor e vapo r i s d ischarge d t o th e atmosphere

.

Eac h carbo n adsorbe r caniste r is essentiall y e q uivale n t t o a 5 5 g a llo n cont a i ne r o r gre a te r

, i f

necessary

. Al l tank s ar e equippe d with conservatio n vent s

, i n ad d itio n t o th e carbo n caniste r

adsorber

. Al l tank s ar e gr o unded

, an d flam e arre stors ar e inst a lle d b etwee n th e c a rbo n

adsorber s an d th e ta n ks.

2.2.1.1 Organi c an d Aqueou s L i q ui d Wast e F e eds

Th e liqui d wast e i n

jector s u se d i n th e combustio n cha m ber s ar e air

- atomizin g

i n j e ctors

. Thes e ar e use d for injectio n o f p u mpabl e slud g es

, aqueou s waste s an d o r gani c

liq u i d w aste s t o th e kil n an d fo r i n j e ctio n o f organi c liq u i d wast e t o th e SCC

. Dua l f l ui d

i n jectio n n ozzle s wil l b e use d fo r a t o m izatio n o f th e waste

. Eac h of th e injector s i s rate d a t 0

-

3 0 0 gph

. Th e liqui d wast e f e e d nozzle s a

r e serv e d b y p aralle l redun d an t p u mp s a n d

recirculatio n s y stem s wit h b ac k pressur e control.

2.2.1.2 Package d a n d Bul k Solid s

Container s o f waste s ar e s a mple d an d a n alyze d a fte r r eceip t i n acc o rdanc e wit h th e

facility‘ s HWC MACT Feedstream Analysis Plan and RCRA W a st e An al ysis Pla n

. Thes e waste s

ca n t h e n b e d e live r e d directl y t o U n i t 4 o r rep a cke d int o sm a l l combu s tibl e container s at th e

facility

. R e package d container s ar e d e livere d to

, an d stage d

, i n th e Containe r Storag e Uni t N o

. 6

adjace n t t o th e Uni t 4 inciner ator

. W he n schedule d fo r fee d in g t o th e sy s t em

, th e co n t aine r s o f

wast e ar e transferre d b y forklift s t o th e fee d co n v ey o r s servin g Uni t 4

.

Bul k solid s a n d non

- pump a bl e waste s a r e delivere d a n d discharge d i n t o wast e fee d bin s

i n th e B u l k S o lids Storag e B u i ldin g afte r b e in g receive d

, s a mpled

, an d a nalyzed

. A clamshel l

ope r atin g fro m a n overhea d cr a ne i s use d t o tra n sfe r thes e waste s f r o m th e bin s t o th e fe e d

hopper s di s chargin g t o t h e system‘ s r a m fee d er. Th e weig h h o ppe r i s eq u i p pe d with wei g h cell s

s o eac h charg e o f w ast e ca n b e w eighe d b e for e i t is discharge d int o th e ra m fe e der

. Fugitiv e

emission s ar e controlle d b y a baghouse

, cyclone

, an d carbon adsorptio n s yste m connecte d t o

thi s s y stem.

Th e ra m fee d e r i s a 25

- inc h wid e b y 4 2 i n c h hig h ( i nsi d e dimensi ons ) rectangula r tub e

operate d b y a hydraulicall y drive n ram

. T h e ra m tub e i s equippe d with a vertical

, h y dra u licall y

o perate d char g e doo r nea r t h e kil n en d

. T h i s doo r i s ope n e d befor e th e ra m begin s a d v ancin g t o

p us h a charg e int o th e kil n

. Afte r th e ram ha s fu l l y retr a cted

, a lim i t switc h trigger s th e doo r t o

c l os e s o a s t o p rotec t th e ra m feede r fro m th e kiln‘s radian t heat

. Th e ra m i s c a pabl e o f ope r atin g

fro m 0

- 3 0 cycles/hou r

.2

- 4

Th e to p fac e o f th e ra m fe e de r ha s a 2 ‘ x 2 ‘ openin g w h ic h receive s wast e charge s fro m

th e hop p er

. Th e ram feede r isolati o n gat e

, th e c h arg e door

, a n d th e ra m op e rat e i n sequ e nce

. A t

th e b eginnin g o f a cycle

, th e ram i s f u ll y r e tracted

. O n a ―st a rt ‖ comman d fro m th e oper a t o r o r

th e pro g rammabl e c o ntrolle r

, th e r a m fee d er isolat io n g a t e open s t o receiv e a charg e o f wast e

fro m th e hoppe r

. T h e gat e the n closes

, th e c h arg e door opens

, an d t h e ra m be g in s it s a d vance

.

Onc e th e ra m reache s it s f u l l e xtension

, i t begin s t o ret r act

. Whe n th e ra m i s full y retracted

, th e

charg e doo r i s clo se d an d th e cycl e ca n b e r epeated

. Thi s system‘ s sequenced operatio n

combine d with th e negativ e p ressur e i n th e kil n preve n t fugitiv e emission s fro m escapin g th e

kiln ra m feede r system.

Th e ra m fee d e r als o receive s container s o f waste s de l ivere d b y a n a ux iliar y fee d s y stem

.

Th e a uxiliar y feed conveyo r i s c apabl e o f ha n dlin g charg e weight s o f 1 t o 10 0 pound s

. Th e

syst e m i s capabl e o f handlin g cha r ge size s u p t o 2 4 inche s i n di a m ete r an d 2 4 inche s t a l l

. T h e

auxilia r y f e e d conv e y o r i s capabl e o f makin g 60 cha rge s a n h ou r o r on e complet e cycl e ever y

min u t e

.

2.2.1.3 S peci a l ty Li q ui d Feed s

Th e Speci a lt y Fee d Syste m associate d with Unit 4 i s a Di r ec t Injec t Liq u i d Fee d Syst e m

.

2. 3 Manufacturer

, Mak e a nd Mode l o f th e I n c i nerato r

[4 0 CF R § 63

. 1207(f)(1)( i ii)(A)]

2.3. 1 Co m bu s ti o n Cha m be r an d B u r n er s [ 4 0 CF R § 63.1 2 07(f)( 1 )(i i i)(B ) a n d (C)

Unit 4 feature s a two

- stag e c o mbustio n process

. Ignitio n o f wast e materia l take s pl a c e i n

th e kil n

, o r primar y c o mbustio n chambe r (PCC). The current OPL for the minimum temperatu re

of PCC is 1,499 ° F. A secondar y c o mbustio n c hambe r (SCC ) serve s a s a n ―afterburner‖ fo r

proces s g ase s an d i s al s o permitte d t o inciner a t e hi g h B t u liq u i d waste

. Igniti o n o f th e wast e

take s p l ac e a t temperature s i n e x ces s o f 1

, 60 0 o F . The current OPL for the minimum temperature

of the SCC is 1,886 ° F.

Th e rota r y kil n i s fabricate d o f carbo n st e el

. I t ha s ap p roxim a t e d i mension s o f 8‘ 8 ‖

O.D

. X 3 5 ‘ l o ng

. I t is supporte d o n a one

- degre e slop e b y tw o stee l tire s o r ridin g r i ng s

. Eac h

ridin g rin g ride s o n tw o pair s o f ste e l trunnion s an d hav e a n app r oxim a t e outsid e diam e t e r o f 9

f ee t 5 inc h es

. Th e thic k nes s an d fac e width o f the trunnion s ar e approxim a tel y 6 in c he s an d 9

inches

, respectiv e ly

. Ta

b l e 2

- 1 pr o v id e s a summar y o f the incinerato r d e sig n specific a tions

.2

- 5 Tabl e 2

- 1

. T e chnic a l Info r m atio n Summa ry for Unit 4

Manufacturer Trad e Wast e Incineration

Mode l N o

. TWI

- 2000

, S e rie s 2

Type Rotar y Kiln

Date of Manufacture 1989

Dimen s ions Primar y Ch a mber Secondar y C hamber

Externa l Le n gth 35‘ 48‘6‖

Externa l Di a m eter 8‘8‖ 10‘6‖

Intern a l Di a meter 7 ‘ 9‘

Cross

- sectiona l A rea 3 8 squa r e fe e t 6 4 squa r e fe e t

Burners Primar y Ch a mbe r Burner Secondar y C hambe r Bur n er

Manufacturer Nort h American Tran e Thermal

Siz e 12. 0 M i l lio n Bt u /hr 3 0 M i llio n Btu/hr

Fuel Natura l Gas Natura l Gas

Prime Mov e r Induce d Draf t Fa n 4

, 00 0 acf

m @ 40 0 ° F satur a ted

, 2 0 i n

. w a te r column

Th e kil n i s li n e d wit h appr o x im a tel y 7 1⁄2 inche s o f den s e ab r asion

- resistan t high

alumin a firebri c k refractory. Wit h thi s refr a ctor y s y stem

, th e kil n ha s a n ins i d e diamete r o f

appr o ximat e l y 7 fe e t an d a lengt h of approxim a tel y 3 5 fe e t

, a n i n tegra l cross

- sectio n are a o f

approximat e l y 3 8 squar e fee t an d a n i n terna l volume o f appr o x im a tel y 1,34 6 cubi c fe e t.

Al l kil n feed s wil l e n te r thr o ug h th e uppe r kil n fac e pl a t e whic h i s lo c ate d o n th e f e e d

en d o f th e kiln

. Th e p l ate contain s a primar y burne r

, thre e liq u i d fe e d nozzle s (fo r pumpabl e

sl u dge

, aqueou s waste

, an d hig h Bt u liq u i d waste)

, a ra m feede r an d a surg e ve n t.

Th e prima

r y b urne r i s equivalen t t o a Nort h Ame r ica n  ̳ F ue l Directe d ‘ burne r o f 2 5 MM

Btu / h r

. a n d burn s No

. 2 fue l oi l o r natu ra l gas

. Th e burne r syst e m i s sup p lie d w i th

appr o x imatel y 4

, 00 0 acf

m c o mbu s ti o n ai r a t a s t atic pressur e o f 20 ‖ wate r colum n (WC)

. Th e

pil o t fo r th e primar y burne r wil l bur n n a tur a l gas.

Th e fu e l s y st e m fo r th e kil n (an d secondar y combustio n chamber ) i s c ontrolle d b y a

Factor y Mutu a l appr o v ed burne r managemen t s y ste m complet e w i th interlock s an d safet y

valves.2

- 6

2.3. 2 Sec o nd a r y Co m bu s ti o n Cha m ber

Th e SC C i s a vertical

, cylin d rica l chambe r havin g appr o x im a t e dime n sion s o f 10‘

- 6 ‖

O. D

. x 71 ‘ high

. I t is fabricate d o f c arbo n stee l a n d line d with a n inne r cours e (ho t face ) o f

appr o x im a tel y si x inche s o f h ig h a lumi n a refractor y an d a n o u te r cou r s e o f app r oximatel y tw o

i n che s o f insul a ti n g refracto r y

. Wit h thi s in s t alled refractory

, th e SC C ha s a n insid e diam e t e r o f

approxima t el y n i n e fe e t

. Th e effectiv e len g t h (ga s retention length ) o f th e chambe r i s

a pproxim a tel y 48 ‘

- 6‖

. Con s equently

, th e SC C ha s a c r oss

- sectio n are a o f 64 squar e fe e t a n d a n

e ffectiv e v o lum e o f a pproxim a tel y 3,08 4 cubi c f e et

. A t maximu m combusti o n ga s flows, th e

combusti o n ga s reside n c e tim e i s gr e ate r tha n tw o seconds.

Combustio n g ase s fro m th e kil n ente r t h e botto m o f th e SC C throug h a refracto r y

- line d

sid e du c t an d exi t from th e to p o f th e SC C throug h a refracto r y

- line d duc t t o t h e tem p erin g

c hamber

. Th e floo r o f th e c h ambe r is slope d t o facilit a t e th e rem o va l o f as h an d solid s throu g h

a sla g tap.

Th e SC C i s e quippe d wit h on e burne r mounte d o n th e sidewal l o f t h e c hambe r n e a r th e

bottom

. Th e burne r is a Tran e The r ma l Mod e l

, o r equivale n t

, w i th a desig n h ea t r e leas e o f

approximat e l y 3 0 millio n Btu/hr

. This burne r i s su p plie d with No

. 2 fu e l o i l o r n a tura l ga s an d

combustio n ai r.

A s with th e kil n burner

, th e SC C burn e r i s suppl i e d with atomizin g ai r an d i s equi p pe d

with a b u rner managemen t system

. Thi s syste m co n t r o l s th e ig n i tio n an d initi a te s a n aut o m ati c

shutof f whe n ther e i s a loss o f flam e

, combustio n a i r s u pply

, and fuel pre s sure

, at o mizi n g ai r

pressure

, p il o t b urne r o r I D fa n

.

Th e SC C bu r ne r i s a high

- intensity

, vort e x typ e u n i t w i th a spi n van e assembly

, lo c ate d

withi n th e wind b ox to impar t a n int e ns e rotar y m o tio n t o th e c o mbustio n a i r

. Thi s rota r y motio n

an d th e burne r desig n provide complet e mixin g o f ai r an d fuel

, an d recir c ulatio n o f t he gase s

withi n th e combusti o n chambe r p r omote s rapid combustio n a n d hig h hea t intensity.

2.3. 3 Loc a ti o n o f Co m bu s ti o n Z o n e Te m perat u r e D e vic e

[4 0 C F R § 63

. 120 7 (f)(1)(xi x )]

Th e pyr o met e r th a t mon i tor s temper a tur e i n th e ro ta r y kil n i s locate d top

- cente r i n th e

transitio n s ection betwee n th e r otar y kil n an d th e SC C ab o u t tw o fe e t d o w n strea m fr o m th e

e x i t o f th e kil n

. Th e thermocouple tha t mo n i tor s temperatur e i n th e SC C i s locate d o n th e

wes t sid e o f th e chambe r n ea r th e SC C exi t du c t.2

- 7

2.3. 4 Haz a r d ou s Wast e Res i denc e T i m e [4 0 CF R § 63.1 2 07(f)( 1 )(i x )]

Th e hazardou s wast e ga s r esidenc e tim e fo r th e Uni t 4 R o tar y Kil n I n cinerato r i s calculate d

a s follows using the OPL for the stack gas flowrate in the current NOC :

Rotary Kil n Volume

– 1,346 ft 3 ;

Secondary Combustion Chamber Volume

– 3,084 ft 3 ;

Total Volume

– 4,430 ft 3 ;

Maximum Flue Gas Flowr ate

– 37,432 acfm (624 ft 3 /sec); and

Total Combustion Zone Residence Time = (4,430 ft 3 ) / (624 ft 3 /sec = 7.1 sec.

Solids residence time in the Unit 4 kiln is dependent upon the kiln rotation rate, solids

bed depth, and a number of other parameters set by design. The maximum solids hazardous

waste residence time for the Unit 4 incinerator (i.e., in the rotary kiln) is 30 minutes based on

c alculations using an equation from Chemical Engineering Handbook, Perry‘s 5 th Edition.

Based on the equation :

Ø

= [(0.19L)/(NDS)]

W here:

Ø is the residence time in minutes,

L is the kiln length in feet,

N is the rotational speed in revolutions per mi nute,

S is the kiln slope in feet per feet, and

D i s the internal diameter in feet.

Inserting the known values for L (35), N (2), S (0.0174), and D (6.5) result in a solids residence

time for the rotary kiln of 30 minutes.

2.3. 5 Co m bu s ti o n S y st e m L eak

Th e kil n itsel f i s equippe d with a dou b l e s ea l sy s t e m th a t i s compris e d o f o v erlapping

,

a d justabl e

, s t ainless stee l sprin g plate s o n both th e fee d an d d i scharg e end s o f th e kiln

. T h e

sealin g e d ge s o f eac h plat e ar e fitted with a si n t er e d

- meta l wea r sho e si mila

r t o a brak e sh o e with

th e in n e r sea l restin g o n th e kil n shell

. The powdere d meta l form u l atio n fo r th e sea l shoe s

includ e graphit e granules

, whic h mak e th e shoe s self

- lubricatin g

. T h e v o i d b e tw e e n th e seal s

a n d th e o u te r s h e l l o f th e kil n i s pressuri ze d t o furthe r preven t fugitive emissions

. I n additio n t o

th e kil n sea l s y stem

, Uni t 4 a l s o utilize s a n i nduce d draf t fa n th a t mai n tain s a vacu u m o f

– 0

. 5 t o

– 1

. 0 inche s wate r colum n w h il e wast e i s b e in g fire d int o th e system.2

- 8

2.3. 6 Em e r g e n c y Safet y V e nt

Uni t 4 i s equippe d wit h tw o emergenc y vents

, on e loca t e d a t th e kil n inle t whic h

a c t s a s a n eme r gency pressur e relief

, th e secon d i s locate d a t the to p o f th e SC C a s a

therma l relie f vent.

Th e emerge n c y ven t a t th e kil n i n le t woul d onl y b e re q u ire d fo r a n o ccurrenc e tha t

o v erwhelm s th e a

b ilit y o f th e I D fa n t o c ontro l th e pr e ssur e o f th e kiln

. Th e ven t an d chut e

o p enin g i s desi g ne d suc h th a t wast e fro m th e bul k solid s c h ut e woul d n o t imped e th e e scapin g ga s

flow

. A deflecto r separate s th e fee d flo w f r o m th e vent opening

. Th e entr a inmen t o f solid s

thro u g h th e surg e v en t i s mi n imal

. A s a n ext r a precautio n

, th e e x haust openin g o f t h e ve n t i s

an gl e d t o provid e a horizont a l e x i t

, thereb y m i nimizin g soli d s entrainme n t i n t o th e air. Th e v e n t i s

k e p t close d b y weighte d louvers

. Thes e l o uver s wil l op e n onl y i f th e p r essur e i n th e kil n suddenly

rise s beyon d th e compensatin g capacit y o f th e I D fa n

. A l imi t switc h o n th e lo u v e r s wil l

aut o m aticall y shut o ff a ll wast e feed s t o th e kil n an d SC C whe n th e ve n t i s ope n ed.

Th e inciner a to r i s a l s o equippe d with a n emergenc y s af e t y ve n t (ESV ) loc a te d a t th e to p

o f th e secondary combustio n c hamber

. Thi s ES V i s a r e fractory

- line d e m e r genc y th e rma l relie f

ve n t (TRV ) whic h i s h e l d i n the close d positi o n b y a pneumati c c y linde r

. Th e contro l valv e i n

th e li n e supplyin g ai r t o th e cylin d e r an d the cylinde r ve n t valv e whic h o pen s th e TR V ar e

locate d i n t he contro l r o o m fo r eac h u nit

. V a lv e lo c k s (wit h keys attached ) ar e uti l ize d t o d e te r

indiscrimi n at e oper a t io n o f thes e va l v e s

. Open in g o f th e TR V a l l o w s hot co mbu s tio n g a s t o

ve n t fr o m th e co mb u s tio n s y s te m durin g emer g enc y shutdo w n eve n ts

. T h e purpos e o f the TR V

i s t o protec t th e down s trea m APC S fro m excessiv e tem p eratur e situ a t ion s

. A lim i t switc h o n

th e TRV shut s of

f al l w ast e feed s t o th e syste m a s i t sense s th a t th e ca p i s op e ning.

2. 4 Procedure s fo r Rap i d l y Stopp i n g Haza rd o u s Wast e Fee d and Controlling

Emissions Dur i n g Equip m ent Malfunctio n [4 0 CF R §63.1207(f)(1)(viii)]

E quipmen t mal f

unction s a r e iden t i fi e d b y th e con t

ro l sys t em

, observa ti o n o f proces s

con t ro l v ariables

, o r by regula r fiel d i n spections.

I n th e eve n t o f mino r eq u i p men t malfunction s ( e .g

. w a st e fee d o r scrubbe r leaks)

, th e

contro l r o o m operator wil l b e n o t i fie d

. Th e contr o l r oo m operato r wil l the n clos e th e wast e

fe e d v a lve s an d disabl e th e w ast e feed pumps.

I n th e eve n t o f m a

jo r eq u i p men t malfunction s ( e .g

. fir e )

, th e e m ergenc y sto p b u tt o n

locate d i n th e contro l ro o m wil l b e push e d

. I f thi s butt o n i s pushe d

, a l l eq u ipme n t wil l sw i t c h t o

i t s fail

- saf e p o sitio n

.

The extent to which emissions can be controlled in an equipment malfunction is

dependent upon the type of malfunction that occurs. Waste feeds are stopped in equipment2

- 9

malfunctions, and depending on the nature of the malfunction, the air pollution control system

remains in operation. Emissions are controlled during malfunctions by stopping all waste

feeds (may occur manually or automatically), maintaining combustion zone and scrubber

system temperatures within OPLs, keeping the ESV in a closed state, and maintaining

negative pressure in the combustion zones.

2. 5 Ai r Pollut i o n Contro l Equipmen t [4 0 CF R §63.1207(f)(1)(iii)(G)]

2.5. 1 A i r Pol l ut io n Contr o l S y s te m s De s cr i pt i ons

Th e ai r poll u tio n contro l sy s t e m consist s o f a temperi n g chamber

, tw o spra y d r y e r

absorbers

, a n d fab r i c filter baghous e m o dules

. Th e ai r poll u tio n co n t ro l s y ste m n e utralize s

aci d i c compound s an d remove s particul a te fro m th e exh a us t gas

. Tw o subsystem s

, th e spra y

dry e r absorbe r a n d th e fab r i c filter

, carr y ou t th e chemical neutraliz a t io n an d particulat e remov a l

fu n ctions

, respectively

. A t h ir d subsystem

, t h e lim e s y stem

, i s use d to prepar e an d p rovid e lim e

s l urr y t o th e spra y d r ye r abs o rbe r fo r us e i n th e chemica l neutraliz a t io n process

. The induce d

draf t fa n an d stac k provid e th e mechan ica l en e rg y require d t o transpor t th e flu e ga s th r oug h the

interconnecti n g ductwork

, t o it s e v entu a l d i scharg e poin t t o a t mosphere.

2.5.1.1 Tempe r in g Chamber

Th e t e mperi n g chambe r i s a ve r t ical

, c y lindrica l uni t d e signe d t o coo l th e combustio n

gase s usi n g a serie s of interna l dual

- f lui d (wate r a n d air ) spr a y n ozzles

. Th e c ombustio n g a se s

ente r th e to p o f th e ch a m

ber

, flow downwar d throug h th e spr a y p a tter n an d exi t fro m th e

botto m o f th e chamber

. T h e spra y patte r n i s designed t o e liminat e direc t contac t o f wate r w ith

refractory

, an d th e chambe r i s designe d t o maint a i n a dr y botto m under al l oper a t in g

c ondition s

. T h a t is

, th e i n jectio n rat e o f s p r a y wate r i s controlle d s o t h a t i t i s compl e tel y

vaporized an d carrie d o u t o f th e ch a m be r i n th e c ombustio n g a s e s

. Th e temperin g cham be r i s

appr o x imatel y 4 9 ‘ h i gh wit h 1 1 ‘ I.D

. a n d i s fabric a t e d o f 1⁄4 inc h n omina l pl a t e thicknes s

car b o n stee l (AS T M A36 ) an d line d with refractory

. T h e spra y nozzle s an d e x ten s ion s ar e

fabri c ate d o f 30 4 S S m a teri a l

.

Th e t e mperi n g chambe r i s size d s o th a t a combustio n ga s retentio n tim e o f gre a t e r tha n

on e s e con d wil l be maint a ine d a t al l ga s flows

. Becaus e s o m e molte n p a rti c ul a t e m a t e rial s i n th e

c o mbustio n gase s ar e coole d in thi s proces s u ni t t o belo w th ei r fusio n p o i n t

, som e solid s ar e

gener a t e d an d collect e d i n th e chamber.

Therefore

, th e chambe r ha s a con e bo t t o m an d a slid e gat e t o facilit a t e th e remov a l o f

solids

. T h es e solid s are discharge d ont o a conv e y o r system

, w h ic h transport s the m t o a ho p per.2

- 10

2.5.1.2 Lim e S y st e m

Th e lim e s y ste m prepare s lim e slur r y fo r us e i n th e chemica l ne u traliza t io n proce s s i n

s u fficien t suppl y and concentratio n t o mai n tai n c ontinuou s flu e ga s treatme n t i n th e spra y drye r

absorb e r

. Th e syst e m ha s been designe d fo r batc h m i xin g t o provid e thi s service

. Veol i a

utilize s h y d r ate d lim e a s it s neutra l i zin g agen t in the ai r po l lutio n c ontro l syste m s

. Th e k e y

n e utraliz a t io n p a ramete r o f th e hydr a t e d lim e i s th e ―Ca O Equivale n t ‖

. Figur e 2

- 2 i s th e

specific a t io n shee t fo r th e hydr a t e d lim e th a t Ve o l i a uses

. Ve o l i a ha s use d thi s specific produc t

fo r o ve r 2 0 year s a n d plan s t o continu e with it s u s e

. Althou g h

, i f Ve o li a d o e s chang e supplier s

o r type o f lim e i n th e future

, i t wo u l d hav e a ―Ca O Equ i vale n t ‖ s pecificatio n e qua l t o o r gr e ate r

tha n th e 72.6 % shown o n Figur e 2

- 2

.

Figure 2

- 2. Hydrated Lime Specifications2

- 11

Hydrate d lim e i s s t ore d i n a storag e bi n a bov e th e l i m e preparatio n a r ea

. Th e stor a g e bi n

i s siz e d t o hold enoug h hydr a t e d lim e t o m a intai n sever a l day s o f s y st e m operatio n a t th e

maxim u m combustio n rat e o f the incinerator

. Lim e i s d i scharge d throug h th e conica l s t o rag e b i n

bott o m

. Th e flo w o f th e mate r i a l fro m th e bi n is aide d b y a vi b ratin g ―liv e b o ttom, ‖ o r b i n

a ctiv a tor

. A v a riabl e spee d scre w feede r i s use d t o m e t e r the hydrate d lim e i n th e propo r tio n s

require d fo r batc h mixi n g lim e slur r y

. Th e lim e i s mixe d with wat e r i n a tank beneat h th e lim e

storag e bin

. Th e scre w feede r spee d an d the rat e tha t w a te r i s a dde d t o th e lim e slurr y tank ar e

varia b l e s o th a t th e des i re d lim e soli d s concentrat i o n ca n b e ach i eve d i n th e t a nk

. Th e vari a bl e

feed adjustme n t s a llo w wate r a n d l i m e t o b e a dde d t o th e l i m e slurr y tan k a t a rat e th a t wil l a llo w

a b a tc h mod e of mixing

. A n a git a t o r i s pro v ide d i n th e slu r r y tan k t o mi x th e w a te r an d lim e an d

t o maintai n th e s u spens io n of lim e solids

. T h e m i xe d lim e slurr y i s pu m pe d a t a cont i nuou s rat e

o f flo w throug h a recirculatio n loo p t o the SD A nozzle s a t a rat e o f u p t o 1 0 gp m t o eac h nozzle.

2.5.1.3 Spr ay D ry A bsorber

Uni t 4 i s equippe d wit h tw o Spr a y Drye r Absorber s (SDA ) l ocate d immediat e l y

d ownstrea m o f th e Temperi n g Chamber

. E a c h SD A uni t i s fab r icate d o f 3/ 8 inc h car b o n steel

. Th e

functio n o f th e SDA s i s t o :

Further cool the combustion gases from 600

– 800 ° F to 300

– 500 ° F;

Neutralize and remove HCl and other acids fr om the combustion gases; and

Remove a portion of the particulate (fly ash) from these gases.

Slurr y flo w t o eac h spra y d r ye r absorbe r ( S DA ) i s m e t e re d b y a flo w c ontro l v a lv e t o obt a i n

th e p r ope r feed concentratio n t o th e spra y drye r absorb e r

. Manua l adju stmen t t o t h e flo w i s ma d e

a s a fun c ti o n o f th e SDA outl e t tempe r atur e an d a s a fun c tio n o f th e outp u t fr o m a h y drochlori c

aci d (HC l ) analyze r i n th e ga s duct downstrea m o f th e fabri c filter

. Sinc e th e Temperin g C hambe r

accomplishe s i n iti a l coolin g o f t h e gases

, no addition a l w a te r i s use d i n th e SDA s fo r g a s

temper a tu r e control.

The combined units are sized to remove more than 820 lbs/hr of chlorine from the

combustion gases. Each SDA is approximately 72‘ high by 10‘7‖ in diameter. Each unit

includes a he a d sectio n

, an d a 6 0 o conical hopper

. Eac h SD A chamb e r ha s on e acces s doo r i n

th e uppe r section

. Eac h ho p pe r ha s on e a cces s door

, a flange d clea n

- ou t po r t

, an d a drai n

connection

. Th e S D A hea d sectio n consist s o f a flange d i n l e t connection an d a h o t ga s in l e t

plenum

. Th e d u al

- flui d atomizin g n ozzle s includ e stai n l es s st e e l housing s a n d stellited inserts

.

Th e nozzle s ar e a ssemble d t o p ermi t fiel d r e mova l fr o m t h e pipin g

. T h e tw o lim e slur r y p iping

header s hav e automati c is o latio n valves.2

- 12

Combustio n g ase s ente r t h e to p o f eac h o f thes e u n it s

, flo w downwar d throug h a c entra l

duc t a n d are disperse d symmetricall y f r o m th i s duc t int o th e absorbe r chambe r a t a velocit y a n d

directio n th a t assures optim a l co n t a c t w i th th e cl o u d o f a t omiz e d l i m e slur r y d roplet s in tro d uce d

int o th e chambe r b y d ual

- fl u i d (lime slurr y an d air ) nozzles

. Th e gase s the n flo w do w nwar d

throug h eac h absorbe r chambe r an d e x i t throug h a botto m sid e d uct

. A s th e g ase s contac t an d pas s

thr o ug h th e clou d o f a t omize d lim e slurry

, th e wate r i n the slurr y e v apo r ates

, coolin g th e gases

. Simultaneously

, th e l im e i n t h e slurr y react s with th e h y d r oge n chloride i n th e gase s t o produc e

calciu m salts

. Som e o f th e r e sultin g dr y m a terial

, consi s tin g o f calciu m salts

, fl y ash an d exces s

lime

, fall s t o t

h e co nica l b o tto m o f eac h u ni t

. Th e dr y materia l fro m eac h uni t i s discharge d t o a

conveyo r syste m whic h tra ns port s i t t o a d um p tr a ile r o r equivale n t ty

p e system.

2.5.1.4 Fabri c F ilter

Ga s exhaust e d fro m th e sp r a y d r ye r abs o rber s i s dist r i b ute d t o tw o f

a bri c filte r mo d u le s

connect e d i n parall e l. Eac h modul e i s divide d i n t o thre e compa r tment s conn e cte d i n parall e l

,

whic h cont ai n m u lti p l e fab r i c filte r bags throug h whic h th e combustio n gase s pas s t o remov e

p ar t icul a t es

. Withi n eac h c ompartme n t

, th e ga s is passe d thro u g h Teflon

- coate d fiber g las s clot h

bag s

. T h e ga s passe s fro m th e o u tsid e t o th e insid e o f th e filter bags

. Pa r t ic u l at e entr a ine d i n th e

ga s s t rea m i s me c hanicall y deposite d o n th e outsid e o f th e filte r bag s a s t h e ga s passe s t

h roug h

th e cl o th.

Eac h c ompartmen t h a s a clea n ai r plen u m an d housi n g sec t io n t o c ontai n approximat e l y

30 8 b ags

. Eac h b a g i s approximatel y 5 ‖ i n d i a m ete r b y 5 ‘ lon g

. Th e bagho u s e s ar e fabri c ate d

fro m 3/ 1 6 ‖ mil d ste e l p l at e

, o f weld e d construction

, ga s tig h t an d stiffene d t o withs tan d th e

maximu m ope r atin g negativ e pressure

. E a ch compartmen t ha s a tub e s h ee t th a t sup p ort s th e

bag s an d provide s fo r to p ba g /c a g e remov a l

. Acces s t o the clea n ai r ple n u m i s vi a a b o lte d

acces s door

. Eac h t

r aile r mou n te d u ni t contain s th e compresse d ai r headers, ga s inl e t an d outl e t

manifolds

, an d th e c onveyo r

.

Th e fab r i c fi l t e r cleanin g m e chanis m utili z e s jet s o f ai r t o clea n th e fi l te r bags

.

Per i odically

, th e c l eaning sequenc e wil l b e in i t i a te d

. T h e sequenc e i s starte d whe n t he

d i fferentia l pressur e a c ros s th e fi l t e r reache s a predetermin e d setpoi n t o f a pproxim a tel y 8.0 ‖ w. c

.

o r w he n th e oper a t o r initi a te s a cycle

. Th e c o ntrolle r then sequence s t o eac h ro w o f filte r bag s i n

e a c h modul e

, r e leasin g a bur s t o f ai r oppo s it e t o th e d i rectio n o f gas flow

. Th e q u ickl y release d

burs t o f ai r di s l odge s dus t cak e o n th e e xterio r o f eac h ba g a s i t tr a v e l s fro m th e t o p t o th e botto m

o f th e bags

. Release d fr o m th e ba g

, th e dus t cak e f a ll s b y gr a v it y int o th e hopp e r a t th e b o tt o m

o f th e modul e

. Fro m ther e i t i s dischar g e d t o a con ve yo r syste m whic h transport s i t t o a dump

t r ailer

, or equivale n t ty

p e system.2

- 13

Treate d b y th e spra y drye r absorber s an d filtere d b y th e fab r i c filters

, th e cleane d flu e

ga s e x it s th e fab r i c filter compartment s t o a n o u tl e t manif o l d fo r e x hau st.

2.5.1.5 Carbo n Inje c tion

Th e carbo n i n

jectio n syst e m wil l a i r i n

jec t a c tivat ed carbo n i n t o th e plenu m i m mediatel y

up s tre a m o f the baghouse s an d allo w fo r a mor e efficie n t mean s o f co n t rollin g d i o x i n / f ura n an d

m e rcur y emissi o ns

. This syste m wil l b e con trolle d b y a n existin g PL C whic h w il l contro l th e

in p u t o f a c tiv a te d carbo n t o th e baghouse inle t plen u m

. Two t o 2 0 poun d s pe r hou r o f powdere d

act i v a te d carbo n wil l b e ai r i n j e cte d i n t o th i s plenu m and allo w fo r d i rec t co n t ac t wit h th e s t ac k

gase s exitin g th e SDA‘s. Figur e 2

- 3 i s th e specific a t io n shee t fo r th e carbon th a t Ve o l i a uses

.

I f Ve o li a d o e s chang e supplier s o r type o f carbon i n t h e future

, i t wo u l d meet the s pecificatio ns

in Figur e 2

- 3

.

Th e amou n t o f carbo n i s d o se d i n a dust

- fre e manne r i n t o a lo w pressur e ai r s t rea m vi a

pne u mati c eductio n

. Th e educto r u se s a blowe r fo r th e m o tiv e air

. Hig h an d lo w ai r pressur e

switche s e nsur e tha t th e blowe r is operatin g correctl y an d th a t th e carbo n d e live r y syste m i s clea r

fro m o bstruction

. T h e mi n imu m hig h pressure settin g i s 4 p s i g an d th e m a ximu m lo w p r essur e

settin g i s 1 inc h wate r column

. T h e carbon/ai r strea m wil l th en trav e l throug h pipin g t o th e

injectio n nozzl e i n t o th e du c twork

. Th e c a rbo n wil l contac t th e ga s st r ea m e x iting th e SDA‘ s a n d

allo w fo r th e adsorptio n o f an y di o x i n /fu r an s an d mer c ur y tha t migh t b e prese n t i n t h i s stream.

Adsorptio n wil l continu e a s th e stac k gas e s procee d t h r oug h th e ba g houses

. Th e clea n stac k g a s

wil l exi t the fina l stac k vi a th e induce d d raf t fa n an d t h e capture d solid s wil l b e di s charge d fro m

th e baghous e s vi a the scre w conveyin g sy s t e m int o a n enclose d dump tra i le r fo r disposa l a t a

Su b t itl e C l a ndfill.

2.5.1.6 Induce d Dra f t Fa n a n d S t ack

Th e induce d draf

t fa n an d stac k ar e loc a te d downstr e a m o f th e fab r i c filter

. Co mbustio n

gase s ar e drawn throug h th e syste m b y a 4 0 0 h p induce d draf t (ID ) fa n

, rate d a t 5 3 ,0 0 0 acf m a t

400 o F satur a ted

, an d 25 ‖ w a ter colum n pressure

. Th e ind u ce d draf t fa n provide s th e mechanis m

f o r transportin g th e incinerat o r fl u e gas throug h th e spra y d r ye r a b sorber

, fab r i c filter

, an d al l

interconnecti n g ducts

. Th e I D fa n includ e s a n i n let volum e cont r o l dampe r t o b e use d t o c o ntro l

th e v e lo c i t y o f th e ga s withi n th e du c tin g an d tre a tmen t d evices.

Treate d gas e s ar e exhauste d fro m th e i n duce d draf t f a n t o th e a t m o spher e throu g h a

100

- ft

. hi g h stac k. The stac k diamet e r fo r Uni t 4 i s 4 8 inche s I. D

. Th e stac k i s equippe d with

instrume n t samplin g port s a n d a samplin g p l atfor m fo r emission s testing

. F i gur e 5

- 1 in the

QAPjP p r o vide s det a il s o n th e desig n an d sampl e p or t locations an d configur a t ion s fo r th e

stack.2

- 14 Figure 2

- 3. Carbon Specifications2

- 15

2. 6 Stac k Em i ss i on s Monitorin g [4 0 CF R §63

. 1207(f)(1)( i ii)(H)]

Th e continu o u s emission s monitorin g ( C EM ) sy s t e m consist s o f s a mpl e p r obes

, sampl e deliv e r y an d conditioni n g a pparatus

, an d ga s analyze r s

. Samp le s a r e extracte d f r o m

th e samplin g port s o n th e stack

. A CE M performanc e tes t an d qualit y assu r anc e prog r a m ha s

bee n implemente d i n accordanc e with the Appendi x t o Subpar t EE E o f Par t 63

— Quali ty

Ass u ranc e P roc e dure s fo r C o ntinuou s Emissi o ns Monitor s U s e d fo r Hazardou s Wast e

Combustors.

Response s fro m eac h CEM S are fe d t o th e Co n t ro l Syste m (CS ) wher e th e C O hourl y

rollin g averag e is calculate d a n d i n terlocke d t o th e wast e f e e d cut o f f val v e s a s par

t o f th e

A u tom a ti c Wast e Fee d Cutof f Sy s t e m (AWFCO ) discusse d i n Se c t io n 2. 8

, bel o w

. Th e

followin g pr o v ide s a bri e f descriptio n o f th e CEMS instrument s i n cludin g th e o p eratin g rang e

an d measuremen t p r incipal.

2.6. 1 CE M S y st e m Des c ri p t i on

Th e Continu o u s Emission s Mo nitorin g System s (CEMS ) on Unit 4 a nalyze s for

opacity

, carbo n mon o xid e

, hydroge n chloride

, t o ta l h y drocarbon s

, an d oxyge n

. T hes e

monitors

, e x cept opacity

, ar e e x tractiv e d e vice s mounte d i n samplin g p o rt s o n th e sta c k

.

Tabl e 2

- 2 summ a rize s the analyze r spe c ific a t ions.

Tabl e 2

- 2

. U n i t 4 Contin uo u s Emis s i o n Monitors 1

Parameter Curren t Mf g

. Range Prin c i p l e

Oxygen COSA 0

- 25% Electrochemical

Carbo n Monoxide Ecoche m M C 3 0

- 20 0 ppmv

0

- 300 0 ppmv Infrared

Tota l H ydrocarbons Thermoe l ect r on 0

- 10 0 ppmv FID

Hydroge n C hloride Ecoche m M C 3 0

- 1,00 0 ppmv Infrared

Opacity Teledyne 0

- 100% Whit e lig h t

Stac k G a s F l o w PSE/Rosem o unt 0

- 55 ,00 0 a c fm Pressur e drop

1 Only the carbon monoxide, oxygen, and stack gas flowrate are parameters, and monitors, regulated and

required by the HWC MACT. The other CEMS are required by the RCRA permit for the facility.

T h e opacit y monito r conti n uousl y measure s th e s t ac k ga s opacit y a n d report s t h e

measureme n t s t o an indicato r an d a recorder

. A n opacit y th a t exceed s a p r ese t limi t

trig g er s a n alar m an d i n terlock.

Carbo n monoxid e an d h y d r oge n chlorid e ar e mo n i tor e d with ex tractiv e non

- d ispers ive

inf r are d a n alyzers

. T o tal hydrocarbo n s i s monitore d w i th a n e xt r activ e flam e io n ization

d etec t o r a n alyzer

. Oxyge n i s monitore d with a zirconiu m ox id e cell.2

- 16

Stac k ga s fl o w rat e i s continuousl y monitore d as actual cubic feet per minute (acfm)

usin g a n A n n uba

r TM

.

Only the carbon monox ide, oxygen, and stack gas flow rate are parameters, and

monitors, regulated and required by the HWC MACT. The other CEM S are required by the

RCRA permit for the facility. The carbon monoxide and oxygen CEMS have been certified

according to the requirements of 40 CFR Part 60, Appendix B, Performance Specification 4B.

A Relative Accuracy Test Audit (RATA) of the CO and O 2 CE MS is conducted annually. In

addition, a RATA of the CO and O 2 CEMS will be conducted within 60 days of the

Comprehensive Performance Test to coincide with the performance test as required by Section

5 of the Appendi x t o Subpar t EE E o f Par t 63

.

2. 7 Pr o c es s M onit o rin g an d Control

Th e facilit y i s equippe d wit h a s t ate

- o f

- th e

- ar t mo n i tor in g an d co n t

ro l system

, whi c h

facilitate s complianc e with permi t conditions

, an d oth e rwise

, colle c ts proces s contro l

i n form a t io n

, fac i litate s efficien t oper a t i o n an d d e tects a n d preve n t s damag e t o t h e facility

. Th e

sys t e m consist s o f thre e majo r compon e nts:

A human

- machine interface (HMI) system;

Programmable logic controller‘s (PLCs); and

A high speed Ethernet cable connects all control system components.

Th e desire d c ontro l functio n s ar e im p lemente d throug h th e HM I sy s tem

. Al l di g i t a l contro l

an d e m ergency interlock s ar e accomplishe d b y th e PLC.

Th e contro l syste m i s capabl e o f mon i torin g th e ―operationa l envelope ‖ o f th e

incinerato r an d i s c apabl e of performin g a numbe r o f activitie s includi n g:

Control room indication of processor sensors located within the incinerator system

(such as pressure indication of the field installed pressure transmitter);

Process controller for single instrument loops or an individual sub

- system , such as a

temperature control loop involving a sensor reading from one temperature transmitter

affecting the function of one temperature control valve; and

Alarm for an exceedance of a designated setpoint, such as a high pressure or low

temperature.2

- 17

T h e proces s contro l comp ute r wil l c ontinuousl y co n t r o l an d monit o r th e opera t i o n o f th e

incin e rator

. Whe n out

- of

- rang e con d ition s exist

, i t wil l n o t i f y th e operato r o f t

h os e conditio n s

. Th e

proces s contro l co m pute r is programme d t o shut

- dow n equipmen t (i.e.

, brin g th e s y ste m i n t o a s af e

m o de ) w h e n designat e d parameters ar e exceede d

, whic h i s a p r otectiv e mec h anis m again s t

pote n ti a l eq u ipmen t dama g e

, oper a t io n o utsid e o f permi t limits

, o r c ondition s tha t mig h t le a d t o a

releas e t o th e e n vir o nment.

Continuou s monitorin g o f th e inciner a t o r an d scrubbe r syste m i s a n importan t as p ec t o f

th e syste m desig n

. A digit a l reado u t o f al l mo n itorin g instrume n tatio n i s d ispl a ye d o n th e mai n

contr o l screen

. A n a udi b l e an d visual alar m ale r t s th e inciner a t o r operato r t o sign ifica n t

d e v i ation s fro m n orma l oper a t in g conditions

. T h i s sy s t em allow s a n immediat e respons e t o

adve r s e condition s b y th e operator

. A u tom a ti c wast e fee d cut

- of f and incineratio n s hutdow n

me c hanism s ar e als o i n terlocke d with th e monitorin g sy s te m a t o r pri o r t o reaching permi t limi t

l e vels

. M onitorin g method s a n d calibr a tio n frequencie s required by the HWC MACT a r e li s te d

i n T a bl e 2

- 3

.

Th e i ncinerato r ha s a n in d ependen t pr o ces s contro l compu t e r th a t interface s t o th e

Quant u m programmable controllers

. T h e p roces s compute r i s ca p abl e o f co n t

roll i n g th e

incin e rato r i n cas e o f a failur e i n a HM I server. Thi s comput e r run s a RSVIE W HM I cont r o l

softwar e th a t pr o v ide s o perato r i n te r f a c e t o al l in s t

r u mentatio n a n d controls.2

- 18 Tabl e 2

- 3. C u rren t HWC MACT AWFC O Par a mete r s an d Limit s fo r Unit 4

S ys t e m D e v i c e Uni t s Current L i mi t s

in NOC

T o t a l Pumpa

b l e Wast e Fee dra te to Primary

Combustion Chamber 1 M a s s fl ow m e ter/sc a l e s lb /

h r ≤ 3,291 (H R A 2 )

T o t a l Pumpa

b l e Wast e Fee dra te to Secondary

Combustion Chamber 1 M a s s fl ow m e ter/sc a l e s lb /

h r ≤ 1,176 (H R A )

T ota l W as t e F ee drate to Primary Combustion

Chamber 1 Ma s s f l o w m e t e r/s c a l es lb / h r ≤12,897 ( H R A)

T ota l W as t e F ee drate to Secondary Combustion

Chamber 1 Ma s s f l o w m e t e r/s c a l es lb / h r ≤1,176 ( H R A)

Total LV M F eedr a te 1 Ma s s fl o w m e t er/s c ales lb / h r ≤ 50 ( 1 2

- HRA 3 )

Pumpable LV M F eedr a te 1 Ma s s fl o w m e t er/s c ales lb / h r ≤ 47 ( 1 2

- HRA)

SV M F e edr a t e 1 Ma s s f l o w m e t e r/s c a l es lb / h r ≤ 64 ( 1 2

- H R A)

M e r c ur y F e e dra te 1 M a s s flo w m e t e r/s c a l es lb / h r ≤ 0.026 ( 1 2

- HR A)

C h l o r i n e Fe e dr a te 1 M a s s flo w m e te r/s c a l e s lb / h r ≤ 229 (1 2

- H RA )

As h F ee dra te 1 Ma s s fl o w m e t er/s c ales lb / h r ≤ 6,444 ( 12

- HRA)

Pr ima r y C o m bus t i o n Ch a m

b e r T emp e r at

ur e P y

r o m e t e r °F ≥ 1,499

Seco n da r y C o mbusti o n Ch a mber T emperature T y p e K T h e rmocou p le °F ≥ 1,886

Pr ima r y C o m bus t i o n Ch a m

b e r P r es s u r e Pr es s u r e t r a n s m it t e r in

. w

. c. ≥ a t mos p h e r i c

( i nsta n t an e o u s)

S e con d ar y C omb u sti o n C h amb e r P r e s s ure Press u r e tra n sm i tt e r in

. w

. c. ≥ a t mos p h e r i c

( i nsta n t an e o u s)

Sorbent Feedrate Flow Meter lb/lb Cl 2 ≥ 2.25 (HRA)

Carrier Fluid Flowrate Flow Meter gal/lb Cl 2 ≥ 3.10 (HRA)

Baghouse Inlet Temperature (i.e., Sp r a y D r y e r

A d so r b e r O u t le t T e m

p e r at ur e) T y p e K T h er m o c ou p l e °F ≤ 400

C arbo n Injection F e e dr ate Screw Feeder lb / h r ≥ 6.2 (HRA)

Stack Ga s Fl o w r a te Annu b ar a cfm ≤ 37,432 (H R A )

Sta c k C a r b o n M o n o x id e Corrected to 7% Oxygen Inf r a r e d p pmv ≤ 1 0 0 ( H RA)

1 Feedr ate is tabulated within the DAS using measured individual stream feed rates. Total pumpable hazardous

waste and total hazardous waste feed rates are summations of the applicable individu al waste feed rates. Total

LVM, pumpable LVM, SVM, mercury, chlorine, and ash feed rates are calc ulated based on the stream

feed rates and analytical results of the applicable waste streams.

2 HRA

– Hourly Rolling Average

3 12

- HRA

– 12

- Hour Rolling Average2

- 19

2. 8 Automat i c Wast e Fee d Cut

- of f S y s t e m [4 0 CF R §63

. 1207(f)(1)(iii)(F)]

Th e inciner a to r ha s a n A u tomati c Wast e Fee d C u t

- Of f (AWFCO ) Syste m tha t wil l

shu t wast e f

e ed s of f i n the even t cert a i n operatin g parameter s d e viat e fro m allo w abl e se t

poi n ts

. Th e PL C c ontinuousl y monitors operatin g parameters

, makin g adju s tme n t s t o th e

proces s a s neede d fo r prope r c ontrol

. Alar m logi c is incorporate d int o th e PL C s y ste m t o

a u t o maticall y i n iti a t e a n AWFC O

. Tabl e 2

- 3 summar ize s t h e current HWC MACT AWFC O

se t p oints

. AWF C O limit s hav e bee n establishe d base d o n severa l fa c t o r s th a t ar e summarized

below:

Regulatory L imit s

– E stablishe d t o compl y wit h cu r rent limits in the NOC

. A n ex a mpl e

o f thi s typ e o f limit i s th e lo w temperatur e limit

, belo w whic h wast e canno t b e fe d u n ti l

th e prope r limi t i s establis h ed.

I n ad d ition

, th e HW C MA C T regul a t ion s requir e th a t t h e AWFC O s yste m b e

i n terlocke d with th e span o f eac h proces s instrumen t tha t i s par t o f th e Co n tinuo u s

Monitorin g Syst e m (CM S )

. A listin g o f these CM S in s t rument s an d th e i r i n terlocke d

s pa n setpoi nt s i s mai n taine d a s par t o f Ve o lia‘ s Oper a t i n g Record.

P rocess Sa f

ety L imi t s

– E st a blishe d t o as s ur e proces s equip m en t i s protecte d an d u nsaf e

oper a t ing conditions do not occur. An example of this is inadequate excess air in th e

combustion chamber that can lead to fuel rich conditions.

Util i ty or Po w e r F a ilur e

– E s tablishe d t o f a cilit a t e a co n t

r olle d sh u t dow n o f th e proc e s s

durin g los s of process air, steam, water or electricity. An example of this is the loss of

instrument ai r that is necessary for certain types of process instruments to function

properly. Wastes will not be re

- introduced into the incinerator until proper operation of

key instruments is re

- established.

I n ad d itio n t o th e AWFC O s y stem

, ope r a tor s ca n man u all y shutdow n wast e feed s o r th e

entir e p roces s should thi s b e need e d.

2.8. 1 AW FC O Syste m Te s ti n g

§63.1206(c)(3)(vii) provides for AWFCO operability testing to be performed less

frequently than weekly, but at a minimum, the testing must be performed monthly. Veoli a test s

th e AWFC O s ystem s bi

- we e kly

, a s wee k l y te s t in g woul d undul y restrict and upset int e r f e r e with

operation s

. Waste feeds are ceased when AWFCO operability testing is performed and

restarted upon completion of the testing. B b y ceasin g an d r es tartin g wast e feed s

, p o t e ntiall y

inc r eas ed in g emissions

, such as elevated CO concentrations in the stack gas, can occur due to

the unsteady state of the operation during these periods . Besides incurrin g e x c essiv e downtime

, during these testing periods

, in creased bur n i ng addition a l costs are experienced due to much

higher n atura l ga s consumption during this idling period to maintain the hourly average

combustion zone temperatures. By performing the AWFCO testing on a bi

- weekly basis,

decreased emissions ca

n be achieved and a reduction in fossil fuel usage realized. duri n g th e

downtime

, an d incre a sin g operati n g costs

.2

- 20

T h e curren t t e stin g progra m ha s bee n i n plac e unde r the RCR A permi t fo r o v e r 2 0 y e ar s

an d ha s p rove n t o b e a dequat e i n d e tectin g probl e m s

. T hi s rati o nal e is include d i n th e facility‘ s

A W FC O Pla n

. I n som e cas e s thi s te s t in g occur s mor e fr e quentl y dep e ndin g o n how ofte n actu a l

AWFCO s occ u r a t th e unit

. When these AWFCOs occur, verification of the system operability

is confirmed by the actuation of closed limited switches on the waste feed shutoff valves. Pe r

th e req u ire d frequen c y

, inciner a t o r p ersonne l chec k the function a lit y o f AWFC O lo gi c th a t i s

par t o f th e incine r a tor‘ s PL C s y ste m t o mak e sur e th a t sho u l d process condition s d e vi a t e fro m

all o w abl e limits

, th e compute r logi c wil l i n itiat e wast e fee d shutdown s a s required.

Thi s i s accomplishe d b y m a nuall y sim u l a tin g proces s condition s th a t a r e outsid e

all o wabl e lim i t s a n d observing an d docume n tin g whe n th e contro l o r blo c k valv e softwar e logi c

o n th e wast e fee d lin e begin s t o initi a t e v a lve closure

. Sh o ul d actu a l A W FCO s occu r durin g a

gi v e n testin g pe r iod

, thes e ar e documente d b y o perating personne l t o satisf y reg u lator y

requirem e nt s fo r sy s t e m te s t in g

. Result s o f t h i s testin g ar e doc u m ente d o n a separat e A W FC O

Testin g Lo g an d mai n taine d a s pa r t o f th e u n it‘ s Operatin g Record.

2. 9 Ai r Pollut i o n Contro l Equip m en t Maintenanc e P r act i c e s

[4 0 C F R §63.1207(f)(1)(iii)(G)]

2.9. 1 Pro g ra m Over v iew

Ve o li a u t i l ize s a n e xt e nsiv e pr e v e n tativ e mai n te n anc e (PM) progra m t o k e e p equipme n t

operationa l a n d preve n t breakdown s an d f a ilures

. B a se d upo n th e typ e o f equipmen t a n d

histo r ica l o p eration s an d maintenanc e experience

, s chedule s fo r v a riou s inspectio n an d PM

activitie s ar e followed

. Thi s include s as p ect s s uc h a s documentin g detaile d m a intenanc e

historie s on equipment

, routin e inspectio n an d lubri c atio n program s fo r h i g h we a r equipme n t

a n d non

- destr

u ctiv e testin g o f pipin g an d v e ssel s usin g t e chnique s lik e ultrasoun d t o a sses s

integrity

. Th e freq u enc y o f the s e activities varie s depe n din g upo n th e equipme n t

, P M activit y

an d th e inciner a t o r‘ s shutdow n schedule.

Fo r example

, frequen t (i.e.

, weekly ) i n s t rumen t an d certai n mechani c a l equ i pmen t

check s ar e mad e fo r critical proces s items

. Lubrication

, vibratio n ana lysi s an d othe r mechanica l

integrit y check s ar e don e a t longer frequencie s lik e mont h l y o r quarterly

. Such item s a s

inspectin g r e fractor y bric k fo r w ear are ty p i call y pe r f o rme d whe n t h e entir e incin e rato r i s shu t

d ow n fo r mai n tenance.

2.9. 2 Tes t Pro g r a m P re p arat i o n Activ i ti e s

In accordance with the Continuous Monitoring System Performance Evaluation Test

Plan (CMS PETP) in Appendix A, p rio r t o t esting

, ins t rumenta t io n associate d wi th ke y

par a meter s o f th e te s t w i l l b e checked

, calibrated

, or replaced

, a s a ppropriate

, t o ensur e2

- 21

pro p e r operatio n o f th e instrum e ntatio n du r in g te s t in g (i. e

. , wast e feed flow m e ter s a n d

scales

, CEM‘s

, pressur e transmi t ters

, thermocouples

, stac k flow meters

, e t c. )

.3

- 1



### 3. 0 Incinerato r Fee d S t rea m Descri p tions

3. 1 General

Veoli a t reat s a broa d rang e o f waste s a n d thu s th e in d i vidua l stream s th a t m a y mak e u p

th e incinerato r o v er a ll fee d a t an y give n tim e ca n var y greatly

, d ependin g o n generato r

pr o ductio n an d s hippin g sche d ules

. Prio r to schedulin g waste s fo r shi p men t t o th e f a cilit y

, th e

wast e stream s ar e characterize d b y th e gene r ato r and reviewe d b y Veoli a st a f f

. A Wast e Pr o f

il e

Numbe r u n iquel y ide n tifi e s eac h differ e n t wast e stre a m

. T h is assure s tha t o nl y pre

- approve d

waste s a r e handle d a t th e facilit y an d th a t al l nec e ssar y regu l a t o r y

, handling, safet y an d o the r

impo r tan t inform a t io n are availa b l e t o O peration s pe r sonnel

. Org a ni c Hazardou s Ai r Pollutants

(HAPs ) measure d o r e x pecte d (base d o n proces s know l edge ) t o b e presen t i n a s ourc e wast e a t

o r above approxim a tel y 0. 1 % b y wei gh t ar e liste d i n th e table s i n t h i s s e c t io n

. Organi c HAP S

n o t liste d a

r e

, base d on proces s knowledge

, beli e v e d t o b e eithe r completel y a b sen t o r pres e n t i n

th e wast e a t les s tha n 0. 1 % b y weight.

I n ad d itio n t o th e i n formati o n belo w th a t s ummarize s th e to p volum e wast e stream s

processe d a t Veolia

, Table 3

- 1 provide s a summar y o f th e majo r HAP s processe d a t th e fac i l i ty

. Veolia will provide EPA with waste profiles and chemical compositions of the anticipated wastes

to be burned during the CPTs about one m onth prior to testing. Note that waste streams may be

added or removed from this packet by test time. Th e tes t re p or t w i l l inc l ud e th e was t e profile s fe d

d u rin g th e testi n g with th e an a lytica l resul t s fo r th e sampl e s obtaine d d u rin g test s fo r heatin g v a lu e,

ash

, SVM

, L V M

, merc u ry

, an d t o ta l chlorine.

3. 2 Hi g h V ol u m e W astes

3.2. 1 Liq u i d W astes

Liqui d waste s ar e receive d a t th e Saug e t facilit y i n tan k truck s an d d r um s an d ar e

eithe r direc t fe d throug h a dedicate d lin e o r ar e blend e d with o t he r c ompati b l e w a st e stream s

i n t o th e tan k fa

r m

. Ta b l e 3

- 2 provide s a summar y o f th e to p volum e liq u i d s t re a m s th a t h a v e

bee n processe d i n th e la s t year

. L i qui d waste s ca n b e processe d i n an y on e o f th e thre e

incin e rators

. Thes e stream s ca n b e organic

, a queou s o r a mixtu re.

3.2. 2 Bu l k S o li d s

Tabl e 3

- 3 pr o v ide s a summar y o f th e to p bul k soli d str e am s handle d a t th e Saug e t

facility in the last year

. Bul k solid s can includ e stre a m s lik e co n t a minate d soil s

, wastewate r

s ludge s o r m a nufacturin g p r oces s solids

. Thes e wastes ar e receive d a t th e sit e primaril y i n 2 0

t o 4 0 cubi c yar d roll

- o f

f cont ai ner s o r othe r simila r b u l k t r ansport vehicles.3

- 2

3.2. 3 Co n ta i n e ri z e d W aste

Tabl e 3

- 4 pr o v ide s a summar y o f th e to p conta i nerize d wast e stream s handle d a t Sauget

in the last year

. Cont ainerized waste s ar e r e ceive d i n dr u m s an d smalle r cartons

, b o xe s o r p ail s

a n d ca n inclu d e mate r i al s s u c h a s labor a tory waste

, spe n t carbon

, proces s residues.

3.2. 4 Ga s eo u s W astes

Smal l volum e s o f compresse d gase s ar e processe d i n Uni t 4 howeve r thes e ar e minima l

i n c o mpariso n t o the othe r wast e type s th a t ar e t r eated.

3. 3 Auxilia ry F uels

Natura l ga s is use d a s auxiliar y fuel t o sta r t

- u p a n d obt a i n desi r e d temperatu r e s i n the

incinerators

. A t t

h i s tim e

, a l l inciner a t or s us e natura l g a s a s th e i r primar y fossi l f u el

. T ypica l

c o mpositio n o f the natural gas i s p rovide d i n T a ble 3

- 5

.

Tabl e 3

- 1. S u mma ry o f M a jo r HAP s Pr o cessed

HAP CAS Number Annual Pounds Received

Toluene 108

- 88

- 3 1,413,638

Styrene 100

- 42

- 5 816,986

Methanol 67

- 56

- 1 779,318

Acetonitrile 75

- 05

- 8 766,568

o

- Xylene 95

- 47

- 6 506,286

Ethylbenzene 100

- 41

- 4 438,753

Atrazine 1912

- 24

- 9 356,148

Methyl Isobutyl Ketone 108

- 10

- 1 347,681

Triethylamine 121

- 44

- 8 212,270

Pyridine 110

- 86

- 1 115,8353

- 3 T able 3

- 2. T o p V o l u m e L iqui d Wast e Streams

Profile W aste Name Annual Pounds Received

397628 DE175

- IPA Wash & Filtrate Wash 4,649,673

388522 Mother Liquor Residue 2,246,160

076148 Formulation Aqueous W ith or W ithout Sevin 2,096,319

388955 1.51B Waste Organics/MKH Sencor FOE/GAU 1,723,519

388521 Upper Phase (May have cyanide) 1,530,146

697847 1.5B3/B4 Aqueous Waste (Sencor/FOE) 1,405,346

351071 Bulked Liquid for Incin (CWDTWILIQ) 1,345,870

131663 MDU

- SIB Recycle Oil 1,299,755

857617 Amine and Water Mixture 1,216,946

097250 Tank Rinsate Aqueous Non

- Haz 915,950

Tabl e 3

- 3

. T o p Bul k Soli d Wast e Stre a m s

Profile Waste Name Annual Pounds Received

156453 Unused Medication 151,439

393836 Hazardous Contaminated Soil 80,768

410031 Bulked Liq for Incin (CWDTWILIQ) 43,099

175684 Soil Contaminated with Xyl ene 38,318

251059 Metal Equipment for Cleanout 29,322

360856 Sludge

- AG Chemical Hazardous 24,740

208526 Bromoxynil Octanoate; Atrazine 19,992

272684 Exchanger Pad Debris 13,328

076872 Demilitarized BDU

- PPE 13,328

197763 Serfene 121 Solids 12,4953

- 4 T abl e 3

- 4

. T o p Contain e rize d S o li d W a st e Stre a m s

Profile Waste Name Annual Pounds Received

SOL003 Solid Neutral BTU > 5000, Halogen <25% 1,285,211

LOP001 Flammable Loose Pack 821,421

597419 Toxic Solids 724,418

076154 Lab Waste (COM) 679,895

BB1445 PLC

- Direct Charge 658,253

LOP003 Non Reg Material

- Loose Pack 534,886

387332 Residues (Plastic Bags PPEET) 479,225

502988 Centrum Vitamin Tablet Production Waste 372,184

534022 Centrum Multi

- Vitamin 357,357

LIQ003 Liquid BTU 5000

- 10000 Halogen, 10% 346, 820

Tabl e 3

- 5

. T y pica l Proper t ie s fo r Natu r a l Gas

Component Units Value Component Units Value

Methane mol e % 94.428 Heptanes mol e % 0.019

Ethane mol e % 3.081 Octanes mol e % 0.005

Propa n e mol e % 0.582 Nitrogen mol e % 0.703

Isobutane mol e % 0.087 Carbo n Dioxide mol e % 0.824

N

- butane mol e % 0.129 Helium mol e % 0.014

Isopentane mol e % 0.040 Hydrogen mol e % 0

. 0 2 3

N

- pentane mol e % 0.032 Argon mol e % 0.0

Hexanes mol e % 0.029 Oxygen mol e % 0.004

Parameter Uni t s Value Parameter Uni t s Value

Hea t Conte n t, gross

, dry Btu / CF 1040.5 Relativ e Den s ity

- 0.592

Hea t Conte n t, gross

, sa t

. Btu / CF 1023.6 Wobb e Ind e x

- 13304

- 1



### 4. 0 Performanc e Tes t Protocol

4. 1 Genera l Description

Thi s CPT Pl a n ha s bee n d esigne d t o d e m onstrat e compliance with all of the applicable

st andards of the HWC MACT and t o esta b lis h OPLs whil e d e monstratin g c o mpliance with

ap p licabl e , and targeted, HW C MA C T emission s standa r ds.

Durin g th e testin g

, Veoli a wil l b e seek i n g t o establis h n e w Operatin g Parameter L imit s

(OPLs) fo r Un i t 4

. Du e t o t h i s

, Veo l i a w i ll adjus t th e limit s a t whic h th e AWFC O s yste m

activ a t e s

, excep t fo r c arbo n monoxide

. A t th e e n d o f eac h d a y of testin g

, curren t AWFC O limit s

wil l b e rei n state d bac k t o currentl y e s tablishe d limit s

.

4. 2 Per f or m a nc e Stand a r d s

Th is te s t p l a n fo r Unit 4 at Sauget h a s bee n desig n e d t o demon s trat e complia n c e with the

performanc e standard s o f th e HWC MACT for all of the applicable emission standards including :

Carbon M onoxide: 100 ppmv, dry

, corrected to 7% O 2 ;

Total H ydrocarbons: 10 ppmv, dry, cor rected to 7% O 2 ;

Dioxins/F urans: 0. 4 0 ng TEQ/dscm, corrected to 7% O 2 ;

Particulate M atter (PM): 0.013 grains/dscf, corrected to 7% O 2 ;

Mercury: 130 g/dscm

, corrected to 7% O 2 ;

Semivolatile M etals (SVM) (Cd and Pb combined): 230 g /dscm

, corrected to 7%

O 2 ;

Low V olatil ity M etals (LVM) (As, Be and Cr combined): 92 g /dscm

, corrected to

7% O 2 ; and

Hydrogen C hloride/ C hlorine (HCl/Cl 2 ): 32 ppmv as Cl

equivalent, dry

, corrected to

7% O 2

.

A performance evaluation test of the Continuous Monitoring System (CMS ) will be performed in

association with the CPT (see Appendix A). And a Relative Accuracy Test Audit (RATA) for the

CO and O 2 Continuous Emissions Monitoring Systems (CEMS) will be performed to coincide

with the CPT (i.e., within 60 days of the CPT )

.4

- 2

4

. 3 Tes t Cond i tion s [4 0 CF R § 63.1207(f)(1)(vi ) an d (vii)]

The All testing i s de s igne d t o demonstr a t e complianc e with targeted HWC MACT

emission s standar d s while establishing OPLs required in association with the targeted standard,

or standards

. There will be one test condition , and one set of OPLs will be established. In the

first part of the test, compliance will be demonstrated with the emission standards for PM and

HCl/Cl 2 , and the OPLs required in association with these emission standards will be

devel oped. In the second part of the test, compliance will be demonstrated with the emission

standards for dioxins and furans, LVM, SVM, mercury, and THC, and the OPLs required in

association with these emission standards will be developed. There will be thr ee test runs

performed at the one test condition. Section 4.11 and Table 4

- 5 present an anticipated daily

schedule for the conduct of the subsequent CPT.

4.3.1 Maximum Feedrate of Metals and Chlorine

This t est is designed to demonstrate compliance with the emission limits and to

establish OPLs for the Final Replacement Standards of the HWC MACT for LVM, SVM, and

mercury.

Uni t 4 wil l b e operate d a t norm a l combust i o n zon e temperature s durin g this conditio n

with norma l wast e fee d rate s

. T h e flu e ga s fl o w rat e a n d chlorin e fee d r a t e wil l b e m a ximized

. The

baghous e inl e t temper a t

ur e wil l b e m a xi mi zed

. Th e tar g e t fee d rate s and operating conditions fo r

this test of the CPT a

re summarize d i n Ta

b l e 4

- 1 a n d th e propo s e d operatin g limit s ar e

summarize d i n T a bl e 4

- 2

. T he feedrate of ash will be at normal (or higher) levels. Ta bl e 4

- 1

presents th e wast e fe e d s an d spike d fee d m a terial s th a t ar e pl a nne d to be fe d durin g th e te s t in g

al o n g with anticip a t e d f

e e d rate s fo r e ach

. I n th e e ven t th a t sele c te d wast e fee d mate r ia ls c ontain

a n appr e ciable quantit y o f chlorine

, LVM

, SVM

, o r mercury

, th e m e t a l s o r chlorin e spiking rat e s

ma y b e a d j u ste d to achiev e th e o v eral l desire d fee d r a te

.

4

. 3. 1 2 Maximum Feedrate of Ash and Chlorine

, M inimum S orbent and C arrier F luid

F lowrates to th e SDA

This part of the CPT t est is designed to demonstrate compliance with the emission limits

and to establish OPLs for the Final Replacement Standards of the HWC MACT for PM and

HCl/Cl 2

.

Unit 4 wil l b e operate d a t norm a l combust i o n zon e temperature s with norma l wast e

fee d rate s

. T h e flu e ga s fl o w rat e a n d the chlorin e and ash fee d r a t e s wil l b e m a ximized

. Th e tar g e t

waste and component fee d rate s and operating conditions fo r this portion t est of the CPT a re

summarize d i n Ta

b l e 4

- 1 a n d th e propo s e d operatin g l imit s ar e summarize d i n T a bl e 4

- 2

. Target

operating conditions for this portion of the test are:4

- 3 Maximum Feedrate of Ash

Maximum Feedrate of Chlorine

Maximum Stack Gas Flowrate

M inimum Sorbent Flowrate to the SDA

M inimum Carrier Fluid Flowrate to the SDA

Ta bl e 4

- 1 presents th e wast e fe e d s an d spike d fee d m a terial s th a t ar e pl a nne d to be fe d

durin g th e te s t in g al o n g with anticip a t e d f e e d rate s fo r e ach

. I n th e e ven t th a t sele c te d wast e fee d

mate r ia ls contain a n appr e ciable quantit y o f ash and chlorine

, the ash o r chlorin e spiking rat e s

ma y b e a d j u ste d to achiev e th e o v eral l desire d fee d r a te

.

Sampling for this portion of the test include:

Stack

– PM

Stack

– HCl/Cl 2

Stack

– CO, O 2

Chlorine Spiking Material

Waste Feeds

– Ash, Chlorine, Moisture, Heating Value

, and Density and

Vis c osity (Liquids)

The OPLs associated with the emission standards for PM and HCl/Cl 2 will be

developed from this portion of the test using process data collected during the collection of the

Method 5/26A sampling train.

4.3. 2 Maximum Feedrate of Metals and Chlorine , Maximum Waste Feedrates,

Minimum Temperatures in the Rotary Kiln and SCC, Minimum Carbon

Feedrate

This part of the t est is designed to demonstrate compliance with the emission limits and

to establish OPLs for the Final Repl acement Standards of the HWC MACT for LVM, SVM,

mercury , dioxins and furans, and THC

.

Uni t 4 wil l b e operate d a t maximum hazardous waste feedrates and minimum combust i o n

zon e temperature s . The feedrates of SVM, LVM, and Hg will be maximized, and t h e flu e ga s

fl o w rat e a n d chlorin e fee d r a t e wil l b e m a ximized

. The feedrate of carbon will be maximized,

and the baghous e inl e t temper a tur e wil l b e m aximized

. The feedrate of ash will be at normal (or

higher) levels. Th e tar g e t fee d rate s and operating conditions fo r this portion of the CPT a re

summarize d i n Ta

b l e 4

- 1 a n d th e propo s e d operatin g limit s ar e summarize d i n T a bl e 4

- 2 . Target

operating conditions for this portion of the test are:

Maximum Pumpable Hazardous Waste F eedrate to the Rotary Kiln4

- 4 Maximum Pumpabl e Hazardous Waste F eedrate to the SCC

Maximum Total Hazardous Waste Feedrate

Minimum Rotary Kiln Temperature

Minimum SCC Temperature

Maximum Stack Gas Flowrate

Maximum Feedrate of Pumpable LV M

Maximum Feedrate of Total LVM

Maximum Feedrate of SVM

Maximum Feedrate of Mercury

Maximum Feedrate of Chlorine

Minimum Carbon Feedrate

M aximum Baghouse Inlet Temperature

Ta bl e 4

- 1 presents th e wast e fe e d s an d spike d fee d m a terial s th a t ar e pl a nne d to be fe d

durin g th e te s t in g al o n g with anticip a t e d f e e d rate s fo r e ach

. I n th e e ven t th a t sele c te d wast e fee d

mate r ia ls contain a n appr e ciable quantit y o f chlorine

, LVM

, SVM

, o r mercury

, th e m e t a l s o r

chlorin e spiking rat e s ma y b e a d j u ste d to achiev e th e o v era l l desire d fee d r a te

. Sampling for this

portion of the test include:

Stack

– Dioxins/Furans

Stack

– LVM, SVM, and Hg

Stack

– CO, O 2

Stack

- THC

Cr, Pb, Hg, and Chlorine Spiking Materials

Waste Feeds

– Metals (LVM

– As, Be, Cr; SVM

– Pb, Cd; Hg), Ash, Chlo rine,

Moisture, Heating Value, and Density and Viscosity (Liquids)

Operation of Unit 4 will remain consistent throughout the collection of the Method 29

and Method 0023A sampling trains. The OPLs associated with the emission standards for

LVM, SVM, Hg, d ioxins/furans, and THC will be developed using process data gathered

during the collection of the Method 29 and Method 0023A sampling trains. The second part of

the t est is expected to be completed with the completion of sampling of the Method 0023A

sampl ing train. The Method 0023A sampling train is the longer running sampling train, and

should be the last one completed.4

- 5 Tabl e 4

- 1. Targe t Fee d ra te s an d O peratin g Co n diti o ns

Parameter Units Current OPL

in NOC Expected F e edrate or

Op er ating Conditi o n to b e

Demonstrated During the CPT

Pumpab l e Waste F e ed to the Primary Combustion Chamber l b / h r ≤ 3,291 3,000

- 4,000

Pumpab l e Waste F e ed to the Secondary Combustion Chamber l b / h r ≤ 1,176 800

– 1,500

Solids Waste F e ed l b / h r 7,500

– 10,000

Total W a ste Feed t o the Primary Combustion Chamber l b / h r ≤ 12,897 12,000

– 15,000

Total W a ste Feed to the Secondary Combustion Chamber l b / h r ≤ 1,176 800 1,500

Stack Gas Flowrate acfm ≤ 37,432 35,000

– 40,000

Temperature in the Primary Combustion Chamber o F ≥ 1,499 1,500

– 1,700

Temperature in the Secondary Combustion Chamber o F ≥ 1,886 1,800

– 1,900

Lead Spike 1 lb / h r 60

- 65

SemiVolatile Metals Feedrate lb / h r ≤ 64 60

- 65

Chrom i um Spike 1 lb / h r 40

- 45

Pumpable Low Volatility Metals Feedrate lb / h r ≤ 47 40

- 45

Total Low Volatility Metals Feedrate lb / h r ≤ 50 40

- 45

Mercury Spike 1 lb / h r 0.02

– 0.06

Mercury Feedrate lb / h r ≤ 0.026 0.0 2

– 0.06

Chl o rin e Spike 1 lb / h r 200

- 250

Chlorine Feedrate lb / h r ≤ 229 200

- 250

Ash Feedrate lb / h r ≤ 6,444 5,500

– 6,500

F a bri c F i l t e r In l et Temperature o F ≤ 400 390

- 425

Carbon Injection Feedrate lb / h r 6.2 6

- 8

Sorbent Feedrate lb /lb Cl 2 ≥ 2.25 2.0

– 2.5

Carrier Fluid Flowrate gal/lb Cl 2 ≥ 3.10 3.0

– 3.5

1 Ra t e s m a y b e m o di f

i e d b a s e d o n c o n c e nt

r at io n s i n t h e nat i v e w a s t e f e d d u r i n g t h e CPT

.4

- 6 Tabl e 4

- 2

. HWC MACT OPLS t o b e Esta b lis h e d Durin g t h e Comprehensive Performance Test

Proces s Pa r ameter Units A v eraging

Peri o d H o w Li mi t

Established Expecte d Limit

Maximum Pumpab l e Waste F e ed to the Primary Combustion Chamber 1 l b / h r 1

- hr Averag e o f maximum

HRA s fo r ea c h run 3,000

– 4,000

Maximum Pumpab l e Waste F e ed to the Secondary Combustion Chamber 1 l b / h r 1

- hr Averag e o f maximum

HRA s fo r ea c h run 800

– 1,500

Maximum Total W a ste Feed to the Primary Combustion Chamber 1 l b / h r 1

- hr Aver ag e o f maximum

HRA s fo r ea c h run 12,000

– 15,000

Maximum Total W a ste Feed to the Secondary Combustion Chamber 1 l b / h r 1

- hr Averag e o f maximum

HRA s fo r ea c h run 800

- 1,500

Maxim u m F l u e Ga s Flowr a te 1 acfm 1

- hr Averag e o f maximum

HRA s fo r ea c h run 35,000

– 40,000

Minimum Temperature in the Primary Combustion Chamber 1 o F 1

- hr Averag e o f t h e te s t ru n

averages 1,500

– 1,700

Minimum Temperature in the Secondary Combustion Chamber 1 o F 1

- hr Averag e o f t h e te s t ru n

averages 1,800

– 1,900

Maxim u m Total L o w Vol a t i lity M e tals (LVM ) Fee dr ate lb/hr 12

- hr Averag e o f t h e averag e HRA s

for eac h run 40

– 45

Maxim u m Pumpable LV M Fe e dr a te lb/hr 12

- hr Averag e o f t h e averag e HRA s

for eac h run 40

– 45

Maxim u m S e mivol a t i l e M e tals (SVM ) Fee dr ate lb/hr 12

- hr Averag e o f t h e av erag e HRA s

for eac h run 60

– 65

Maxim u m T o ta l Mercur y F e edrate lb/h r 12

- hr Averag e o f t h e te s t ru n

averages 0.0 2

– 0.06

Maxim u m Ch l orine/Chloride Fee dr ate 2 lb/hr 12

- hr Averag e o f t h e te s t ru n

averages 200

– 250

Maximum Ash Feedrate lb/hr 12

- hr Averag e o f t h e average HRAs

for each run 5,500

– 6,500

Maxim u m F a bri c Fi l t e r In l et Temperature o F 1

- hr Averag e o f t h e te s t ru n

averages 39 0

– 435

Minimum Carbon Feedrate lb /hr 1

- hr Averag e o f t h e te s t ru n

averages 6

– 8

Minimum Sorbent Feedrate lb /lb Cl 2 1

- hr A verag e o f t h e te s t ru n

averages 2.0

– 2.5

Minimum Carrier Fluid Flowrate gal/lb Cl 2 1

- hr Averag e o f t h e te s t ru n

averages 3.0

– 3.5

1 Per 40 CFR 63.1209(i), the most stringent limit derived from independent performance tests (i.e., Data in lieu from the January 1993 RCRA Trial Burn and the

subsequent CPT applies.

2 Per 40 CFR 63.1209(i), the most stringent limit derived from independent performance tests (i.e., the two portions of the subsequent CPT ) applies.4

- 7

4.3.3 Maximum Waste Feedrates and Minimum Co mbustion Temperatures

This t est is designed to demonstrate compliance with the emission limits and to

establish OPLs for the Final Replacement Standards of the HWC MACT for dioxins/furans

and THC.

Unit 4 wil l b e operate d a t minimum combustion chamber temp erature in the kiln (i.e.,

the primary combustion chamber ) , minimum combustion chamber temperature in the SCC

, maximum flue gas flowrate, maximum pumpable hazardous waste feedrate to the kiln

, maximum pumpable hazardous waste feedrate to the SCC, maximum t otal waste feedrate to

the kiln, and maximum waste feedrate to the SCC

. Th e tar g e t fee d rate s and operating conditions

fo r this t est of the CPT a

re summarize d i n Ta

b l e 4

- 1 a n d th e propo s e d operatin g limit s ar e

summarize d i n T a bl e 4

- 2

. The feedrate of chlor ine will be at normal (or higher) levels. Ta bl e 4

- 1

presents th e wast e fe e d s th a t ar e pl a nne d to be fe d durin g th e te s t in g al o n g with anticip a t e d

f e e d rate s fo r e ach. No spiking of waste streams is planned for the dioxins/furans tests.

4.4 Establishing Op erating Parameter Limits

An objective of the subsequent CPT for the Final Replacement Standards is to establish

limits for a number of operating parameters while simultaneously demonstrating compliance

with the performance standards and emission limits of the HWC MACT. Operating parameter

limits established as required by the HWC MACT from the results of the CPT will limit

emissions of the regulated parameters, and will ensure compliance with these standards during

future operations. Table 4

- 3 identifies ea ch emission standard and the operating parameter to be

monitored to ensure future compliance. The HWC MACT requires operating parameters be

established. The operating limit is set as the average of the three runs during the applicable

portion of the CPT an d the 199 5 RCRA Trial Burn , as appropriate per manufacturer

specification, or by rule.4

- 8 Table 4

- 3. Emission Standards versus Operating Parameters

Operating Parameter

Carbon Monoxide Stack CO CEMS concentration

Dioxins/ Furans PCC temp erature

SCC temperature

Flue gas flowrate

Total waste feedrate

Pumpable waste fe e drate

Baghouse i nlet t emperature

Carbon f eedrate

DRE PCC temperature

SCC temperature

Flue gas flowrate

Total waste feedrate

Pumpable waste fe e drate

Total Hydrocarbons (THC) PCC temperature

SCC temperature

Flue gas flowrate

Total waste feedrate

Pumpable waste fe e drate

Mercury Mercury fe e drate

Carbon fe e drate

Particulate Matter Flue gas flowrate

Ash fe e drate

Semivolatile Metals

Low Volatility Metals Flue gas flowrate

SVM fe edrate

LVM feedrate (total and pumpable)

Total chlorine and chloride fe e drate

Baghouse i nlet t emperature

HCl/Cl 2 Flue gas flowrate

Total chlorine and chloride feedrate

Sorbent feedrate

Carrier f luid f lowrate

The following operating conditions will be established for the HWC MACT :

Limits on the Combustion Units

The carbon monoxide (CO) concentration is established by rule

. The HRA limit is 100

ppmv, dry basis, corrected to 7% oxygen , and will be demonstrated during all testing performed.

T he total hy drocarbon (THC) concentration is established by rule. The limit for THC

of 10 ppmv, dry basis, corrected to 7% oxygen will be demonstrated during the dioxins/furans

portion of the CPT.4

- 9

Minimum combustion chamber temperatures in the kiln (i.e., the primary combustion

chamber) and in the secondary combustion chamber (SCC) will be established during the CPT

. The hourly rolling average (HRA) limits are the average of the test run averages from the

dioxins/furans tests or the limits set during the 199 5 RCRA Tri al Burn , whichever is more

stringent since DRE is being demonstrated using test results from the 199 5 trial burn.

Fugitive emissions are controlled by maintaining a negative pressure on the combustion

system and b y maintaining totally sealed combustion ch ambers. The pressure of both the kiln

and SCC are monitored.

The maximum flue gas flowrate , measured as the stack gas flowrate, will be established

during the CPT

. Flue gas flowrate is an OPL required by standards to be demonstrated during all

testing per formed. The HRA limit is the average of the maximum hourly rolling averages for

each run , and will be established from data from all tests conducted during the CPT or based on

the 199 5 RCRA Trial Burn , whichever is mo st stringent since DRE is being demonst rated using

test results from the 199 5 trial burn.

Limits on the Feedstreams

The maximum total hazardous waste feedrate s to the incinerator (both the kiln and

SCC) will be established during the dioxins/furans portion of the CPT

. The HRA limit is the

aver age of the maximum hourly rolling averages for each run or the limit set during the 199 5

RCRA Trial Burn, whichever is more stringent since DRE is being demonstrated using test

results from the 199 5 trial burn.

The maximum pumpable hazardous waste feedrat es to the incinerator (both the kiln

and SCC) will be established during the dioxins/furans portion of the CPT

. The HRA limit is the

average of the maximum hourly rolling averages for each run during or the limit set during the

199 5 RCRA Trial Burn , whiche ver is more stringent since DRE is being demonstrated using test

results from the 199 5 trial burn

.

The maximum feedrate of mercury will be established during the metals portion of the

CPT

. The 12

- hour rolling average limit is the average of the test run a verages

. The limit

demonstrated during the CPT can be extended by extrapolating the measured total feedrate of

mercury and the measured emission concentration of mercury up to 75% of the HWC MACT

standard of 130 g/dscm or three time s th e s pike d fee d r a t e d urin g th e testing

.

The maximum feedrate of semivolatile metals (SVM) (Pb and Cd combined) will be

established during the metals portion of the CPT

. The 12

- hour rolling average limit is the

average of the test run averages with the demonstration of maximum feedrate of SVM along with4

- 10

demonstration of higher maximum flue gas flue rate and other associated operating parameter

limits

. Feedrates for SVM and LVM will be established concurrently

. The feedrate of total

chlorine/chloride will be maximized as SVM and LVM are demonstrated

. A feedrate of total

chlorine/chloride will be developed in conjunction with the feedrates of SVM and LVM as an

OPL for SVM

. The feedrate limit for SVM can be extended by extrapolating the measured total

feedrate of SVM and the measur ed emission concentration of SVM up to 7 5% of the HWC

MACT standard of 230 g/dscm or 3 time s th e s pike d fee d r a t e durin g th e testing

.

The maximum feedrate of low volatility metals (LVM) (As, Be, and Cr combined) will

be established during the metals porti on of the CPT

. Feedrate limits will be established for

feedrate of LVM in all feedstreams (i.e., total in nonpumpable and pumpable streams) and for

feedrate in all pumpable feedstreams

. The 12

- hour rolling average limits are the averages of the

test run av erages with the demonstration of maximum feedrate of LVM along with

demonstration of higher maximum flue gas fl ow rate and other associated operating parameter

limits

. Feedrates for SVM and LVM will be established concurrently

. The feedrate of total

chlorin e/chloride will be maximized as SVM and LVM are demonstrated

. A feedrate of total

chlorine/chloride will be developed in conjunction with the feedrates of SVM and LVM as an

OPL for LVM

. The feedrate limit for LVM can be extended by extrapolating measured t otal

feedrate of LVM and the measured emission concentration of LVM up to 75% of the HWC

MACT standard of 92 g/dscm or 3 time s th e s pike d fee d r a t e durin g th e testing

.

A maximum feedrate of total chlorine and chloride is established during the CPT in

asso ciation with the establishment of feedrate limits for SVM and LVM, and with demonstration

of the emission limit for HCl/Cl 2

. The 12

- hour rolling average limit is the average of the test run

averages during the metals portion or the HCl/Cl 2 portion of the C PT, whichever is more

stringent

.

A maximum feedrate of ash is established during the PM portion of the CPT with

demonstration of the emission limit for PM

. The 12

- hour rolling average limit is the average of

the test run averages during the PM portion of the CPT

.

Limits on the Spray Dryer Absorber s and Baghouse

The HWC MACT requires that operating parameter limits be established in association

with standards for identified parameters

. The air pollution control system of Unit 4 includes

spray dryer absorb er s and a baghouse. The spray dryer absorber s are designed and operated for

control of acid gases

. The regulated constituents of the HWC MACT for the spray dryer

absorbers are HCl/Cl 2

. The baghouse is designed and operated for control of entrained solids

. The regulated constituents of the HWC MACT for the baghouse are PM, SVM, LVM , and

dioxins/furans. Operating parameter limits will be established for components of the air pollution4

- 11

control system in association with the regulated parameters.

A maximum in let temperature to dry particulate matter control device (i.e., the

baghouse) is required in association with the standards for SVM and LVM, and dioxins/furans,

and will be established during the CPT in association with the establishment of feedrate limits

for SVM and LVM, and with demonstration of the emission limit for dioxins/furans

. The HRA

limit is the average of the test run averages during the SVM and LVM portion or the

dioxins/furans portion of the CPT, whichever is more stringent

.

The minimum car bon feedrate to the baghouse is required in association with the

standard s for dioxins/furans and mercury and will be established during the HCl/Cl 2 portion of

the CPT

. The HRA limit is the average of the test run averages during the metals portion or the

dioxins/furans portion of the CPT, whichever is more stringent

.

The minimum sorbent feedrate to the absorbers is required in association with the

standard for HCl/Cl 2 , and will be established during the HCl/Cl 2 portion of the CPT

. The HRA

limit is the av erage of the test run averages.

The minimum carrier fluid flowrate to the absorbers is required in association with the

standard for HCl/Cl 2 , and will be established during the HCl/Cl 2 portion of the CPT

. The HRA

limit is the average of the test run aver ages.

4. 5 Was t e F e e d Spik i ng

I n orde r t o d e monstrat e th e require d pe r formanc e crit e ri a fo r thi s pr o gram

, i t wil l b e

necessar y t o spik e th e incinerat o r feed s w i th select o r gani c an d in o rgani c const i tuents

. Th e s pikin g

l e vel s a n d approac h propose d for th e CPT h a v e bee n use d s u ccessfull y i n th e pas t fo r t e stin g a t no t

o n l y Ve o li a, bu t fo r testin g a t othe r hazard o u s wast e combust i o n facilitie s a s well.

Eac h spike d materia l wil l b e prepare d t o a know n specifi c a t io n an d confirmed verifie d b y a

c e rtificat e o f an a lysis

. These material s wil l b e prepare d a n d fe d i n a manne r th a t assure s a ve r y

c onsisten t fee d rate

. Fee d r a te s o f each spike d compoun d ar e t o b e wel l abov e e x pecte d l e vel s i n

n ativ e waste s such th a t th e spike d constitu e n t i s expected to be th e dominan t fee d of the selected

parameter. Waste feeds will be sampled during the test and analyzed

. The amounts of the selected

parameters in the waste streams will contribute to the OPL for the waste feedrate of that constituent

.

Spikin g r a te s a

r e als o sele c t e d base d o n h i storica l pe r fo r m anc e t o assur e th a t e mission s ca n

be detecte d an d actua l results

, versu s non

- d etec t resul t s

, ar e use d i n the c alculatio n of system

remova l efficiencies (SREs).4

- 12

A Standard Operating Procedure (SOP) for the preparation of the spi king materials by

Veolia is included in the QAPjP

.

4. 5

. 1 In o r g a ni c Constit u ents

Severa l m e ta

l s wil l b e sp i k e d t o th e s y s t e m t o establish OPLs for the select constituents and

calculate S R E s

. Regulate d met a l s ma y b e fe d a t som e l e ve l i n th e n a tiv e wast e m a terial s t o b e use d

du r in g th e test

. However

, th e s e nativ e concentration s may no t b e hig h e noug h t o achiev e th e

desi r e d fee d rat e limit s t o b e s e t fo r th e s y stem

. Ther e f ore

, during the metals portion of the CPT,

Veoli a plan s to spik e thre e surrogat e m e tal s a t highe r t h a n norma l rate s t o ensur e tha t s u fficien t

metal s ar e f

e d t o achi e v e measurabl e e mission s i n t h e stac k emissions.

Tabl e 4

- 4 pr o v ide s a n o v e r al l summa r y o f inform a t io n r eleva n t t o th e metal s emissions

testin g

. This table shows that at conservati ve method detection limits for the stack sampling

method that will be used to measure metals in the stack gas (i.e., EPA Method 29) and the spiking

rates of these metals

, a SRE can be calculated greater than SRE measured in previou s t e s t progra m s

of Unit 4

. These calculations show that the metals spiking rates w il l resu l t i n measurable

concentrations in the stack gas and e mi ssio n rates. This ta b l e is onl y use d a s a predictiv e t o ol

, a n d

OPLs will be developed using actu a l result s o f the CPT

. Tw o oth e r poi n t s ar e w ort h n o tin g with

regar d t o T a bl e 4

- 4 :

The spiked amount for a given metal will be the diff erence between the desired feed rate

limit and the native quantity expected to be fed during the test; and

Surrogate metals will represent the whole group (in t he case of LVM and SVM) and

test results for the spiked of these two metals categories will be used to extrapolat e to

the OPL for the metal feed rate.

Th e thre e m e tal s t o b e spike d ar e repre s entativ e o f th e thre e classe s o f m e ta l v o latilit y of the HWC

MAC T, an d ther e for e ca n be use d t o se t limit s fo r the HWC MACT metal s n o t spiked.

4. 5

. 2 Sp i kin g fo r th e LV M C a teg o ry

Th e LV M c ategor y fo r inci n erator s inclu d e s arsenic

, b e rylliu m an d c h romium

. Veoli a plan s

t o spik e chromium a t 40

- 45 l b /h r during a l l th r e e metals te s t runs

. Th e SR E d e monstrate d d urin g

th e CPT fo r chromiu m wil l b e use d t o estab l is h the fee d rat e l i m i t s for total and pumpable LVM,

using extrapolation (see Section 4.6)

.

Chromiu m wi l l b e spike d a s chromi c aci d (unless another compound of chrom ium is used,

based on availability, and approved by USEPA Region 5) throug h a l i qu i d fee d i n jecto r vi a a

pum p i n g st a t io n th a t wil l mon i tor th e fee d rat e

. Wast e chromi c aci d i s treate d a t Ve o li a a n d thu s

, spikin g chromi c a c i d durin g th e CPT i s repres e ntativ e o f no r ma l oper a t io n s

.4

- 134

- 14 Tabl e 4

- 4

. M etal s E v alua t i o n Plan

Lead Chromium Mercury

Detection Limit (μg) 0.45

(0.2+0.25) 1 0.50

(0.25+0.25) 1 1.79

(0.14+0.87+0.085+0.47+0.22) 2

Sample Volume Collected (dscf) 45 45 45

Stack Detection Limit (μg/m 3 ) 0.35 0.39 1.40

Stack Flowrate (acfm / dscfm at 12% O 2 ) 37,432 / 15,056 37,432 / 15,056 37,432 / 15,056

Emission Rate at Detection Limit (lb/hr) 2.0 x 10

- 5 2.2 x 10

- 5 7.9 x 10

- 5

Target Spiking Rate (lb/hr) 60

– 65 40

- 45 0.0 2

– 0.06

SRE at Detection Limit (%) 3 99.999987 99.999986 98.49776

Historical SRE (%) 4 99.99824 99.99919 95.38

Stack Gas Concentration at Expected SRE and

Mid

- Range of Target Spiking Rate (μg/m 3 at 7%

O 2 ) 30 9.5 51

1 Detection Limit in Probe and Nozzle Rinse + Acidic Peroxide Impingers of EPA Method 29.

2 Detection Limit in Probe and Nozzle Rinse + Acidic Peroxide Impingers + Empty Impinger +

Acidic Permanganate Impinger + HCl Rinse of EPA Method 29.

3 Based on the low end target spiking rate

.

4 T h is SRE is an ave r a g e of the res u lts f rom the August/September 2008 test program s

.

4. 5

. 3 Sp i kin g fo r th e SV M C a teg o ry

Th e SV M categor y fo r inci n erator s inclu d e s cadmiu m a n d lea d

. Veoli a plan s t o spik e lea d

a t 60

- 6 5 l b /h r duri n g th e CPT t o e s t a blis h a SR E fo r al l thre e metals test r u ns

. Th e SR E

demonstrate d durin g th e CPT fo r lea d wil l b e use d t o e s tablis h a SV M fee d r a t e limit , using

extrapolation (see Section 4.6)

.

Lea d wil l b e spike d a s lea d nitr a t e (unless another compound of lead is used, based on

availability, and approved by USEPA R egion 5) and fed to the incinerator i n s m a ll

, pre

- measure d

plasti c ba g gie s a t regul a r intervals alon g with o t h e r soli d wast e feed s durin g th e pe r forma n c e test

.

Lea d containin g wast e s tha t ar e n ormally treate d a t V e oli a ar e pred o minantl y bul k o r containe r i z e d

solid s an d thus

, t

h i s spikin g approac h durin g the CPT i s representativ e o f no r ma l oper a t io n s

.

4. 5

. 4 Sp i kin g fo r M e r c ury

M ercury is th e onl y h i g h volatil ity met a l of the HWC MACT. Veoli a plan s t o spik e

mercury a t approximat e l y 0

. 0 2

– 0

. 0 6 l b /h r during a l l th r e e metals te s t runs

. Th e SR E demonstrate d

durin g th e CPT fo r mercury wil l b e use d t o e s tablis h a mercury fee d r a t e limit , using extrapolation

(see Section 4.6)

.4

- 15

Mercur y w i l l b e fe d a s a mercuri c nitr a t e sol u tio n (unless another compound of mercury

i s used, based on availability, and approved by USEPA Region 5) contained in vials fed with solids

to the incinerator, and will be fed placing a vial in solids fed to the incinerator a t r egula r i n terv al s

durin g th e p erformanc e t e st

. Mercury i s predomin a ntl y prese n t i n soli d feed s p r ocesse d a t Veoli a

an d usi n g a liqu id sol u tio n fo r spiki n g wil l pr o v ide a n easil y vol a tilize d for m f e d alon g with

o the r soli d fee d s i n a manne r th a t i s repre s entativ e o f n o rmal operations.

4. 5

. 5 Sp i kin g fo r Ch l orin e L o adi n g

Pursu an t t o 4 0 CF R §63.1 2 0 9 (n ) (4) and 4 0 CF R §63.1 2 0 9 ( o ) ( 1 )

, V e oli a wil l b e

e s tablishin g a maximu m tot a l chlorin e an d chlorid e feedrat e durin g t h e CPT. The maximum

chlorine feedrate is an OPL to be established in association with the HWC MACT standards for

LVM and SVM, and HCl/Cl 2

. I n additio n t o th e chlorin e bei n g fe d t o th e i n cinerato r fro m th e

n a tiv e w a stes

, chlorine fee d t o th e in c i nerato r wil l b e supp l eme n te d during the HCl/Cl 2 portion and

the SVM and LVM portion of the CPT b y th e spi k in g o f h e xachloroethan e (unless another

chlorinated compound is used, based on availability, and approved by USEPA Region 5)

. T h e

hexachlo r oethan e wil l b e delivere d i n s m all

, pre

- me a sure d plasti c baggie s a t r e gu l a r i n terv a l s alon g

with o the r soli d wast e feed s duri n g th e pe r form a n c e test

. Th e s pikin g wil l b e adjuste d bas e d o n th e

total chlorine/ chlorid e conte n t o f th e n a tiv e wastes.

Veoli a believ e s th a t th e nativ e waste s wil l contai n suffi c ien t chlorine cont e n t t o compl y

with th e requi r emen t i n 40 CF R §63.12 0 7 (g ) (1)(A ) f o r fee d i n g no r ma l (o r highe r ) l e vel s o f

chlorine durin g th e test for dioxins/furans

. I f th e n ativ e waste s tha t ar e goin g t o b e fe d du r in g th e

testin g d o no t cont ai n a s u fficien t chlorine conten t to achieve the targeted feedrate

, Ve o li a ma y

nee d t o spik e chlorine d

uring the dioxins/furans tests

. The average feedrate of chlorine from

December

January 2012 through May 2013 June 2012 was 82 86 lb/hr.

4. 5

. 6 Sp i kin g fo r As h L o ad in g

Pursuan t t o 4 0 CF R §63.1 2 0 9 (m ) (3)

, V e oli a wil l b e e s tablishin g a maximu m ash feedrat e

durin g t h e CPT

. The maximum ash fe e drate is an OPL to be established in association with the

HWC MACT standard for PM. I n additio n t o th e ash bei n g fe d t o th e i n cinerato r fro m th e n a tiv e

w a stes

, the ash feedrate t o th e in c i nerato r may b e supp l eme n te d during the PM portion of the CPT

if the ash content of the wastes d o no t cont ai n a s u fficien t ash conten t to mee t th e targeted

feedrate.4

- 16

Veoli a believ e s th a t th e nativ e waste s wil l contai n suffi c ien t as h cont e n t t o compl y with

th e requi r emen t i n 40 CF R §63.12 0 7 ( g ) (1)(B ) f o r fee d in g no r ma l (o r highe r ) l e vel s o f as h

durin g th e SV M an d LV M performance tests

. I f th e n ativ e waste s tha t ar e goin g t o b e fe d du r in g

th e testin g d o no t cont ai n a s u fficien t as h conten t to mee t thi s re q uirement

, Ve o li a ma y nee d t o

spik e a h ig h as h m a teria l int o th e solid s feeds. The average feedrate of ash from

December

January 2012 through May 2013 June 2012 was 949 1,355 lb/hr.

4. 6 Metal s Extrapolat i o n Method

A s st a t e d pr e v iousl y i n thi s section

, chromium ( L VM)

, lea d (SVM)

, an d mercur y wil l b e

spike d i n t o th e wast e fe e d s t o achiev e t h e desire d f e e d rate s o f e a c h met a l s category

. Veolia plan s t o

e x tr a polat e t o hig h e r fee d rat e limit s tha n actu all y fe d du r in g th e tes t usin g th e SREs determined

during the test

. Thi s i s appropriat e sinc e i t i s gen e r all y agree d t h a t SRE s a t highe r fee d rat e s woul d

b e at leas t a s goo d a s thos e obs e rve d a t th e l o we r lev e l

. A ny e xtrapol a t i o n performe d wil l tak e int o

c onsideration th e HWC MAC T s t a ndard s t o ensur e f u l l compliance

. Ba s e d o n previou s discussion s

with EP A Re gi o n 5

, the followin g app r oac h wil l b e u sed.

The average feedrate s of mercury, LVM, and SVM to Unit 4 from December 2012

through May 2013 w ere:

Mercury LVM SVM

(lbs/hr) (lbs/hr) (lbs/hr)

Unit 4 0.00492 2.64 2.67

The maximum feedrate s of mercur y, LVM, and SVM to Unit 4 from mid

- February to mid

- June

2013 w ere:

Mercury LVM SVM

(lbs/hr) (lbs/hr) (lbs/hr)

Unit 4 0.0209 22.6 22.2

Th e averag e SR E for the spiked compound fo r th e t h re e run s will b e calcul a t e d fro m th e fe e d an d

e missi o n rate s fo r e a c h ru n

. A fee d r a t e limi t will th e n b e calcul a t e d fo r eac h m e ta l catego r y b y

divi d i n g the maximum emission rate determined using 7 5 % o f th e emissi o n standar d fo r th a t

categor y b y 1 minus th e SR E (as a percentage) fo r th e spike d compoun d representin g t h at category

.

A s imila r approac h will b e fo l lowe d fo r LVM (total and pumpable), SV M (cadmiu m an d lead ), an d

mercury

. T o fu r ther assur e tha t th i s metho d i s p r ote c tiv e

, Veoli a propose s t o limi t th e maximu m

feedrat e fo r an y on e categor y to 3 time s th e s pike d fee d r a t e durin g th e testing . The OPLs for

feedrates of the metals will be established as 12

- HRAs

. Exam p l e calculation s ar e sho w n below

.4

- 17

Maxim u m E mission R ate for E xtrap o lation (lb/hr)

= (e m i s sio n s t an d ar d ( μ g/ m 3 @ 7 % O 2 ) * 0

. 7 5 * Q sta c k ( d sc f m @ 7 % O 2 ) *

0

. 0 28 3 m 3 /ft 3 * 6 0 mi n

/ h r ) / ( 4 53. 6 g /l b * 1 0 6 μ g / g )

Where

Em i s sio n s t an d ar d ( μ g/ m 3 @ 7 % O 2 )

= A pplicable HWC MACT emission standard;

0

. 7 5

= 75% of the applicable HWC MACT emission

standard;

Q sta c k ( d sc f

m @ 7 % O 2 )

= A verage stack gas flowrate using the stack gas

flowrate from each run normalized to 7%

oxygen using the measured oxygen

concentration from that run;

0

. 0 28 3 m 3 /ft 3

= C onversion from cubic feet to cubic meters;

6 0 mi n / h r = C onversion from minutes to hours; and

4 53. 6 g /l b * 1 0 6 μ g / g = C onversio n from micrograms to pounds.

Ex trapolated Fe e d r ate (lb/hr)

= Maximu m E m issio n R at e / ( 1

– ( SR E /100))

During the comprehensive performance testing, Veolia will spike metals at feedrates that

are at the extreme range of normal. Veolia will feed metals at or above Veolia‘s defined NOC

rates which are well above the average feed over the last five years. These demonstrated

feedrates will be incorporated in the subsequent NOC. Veolia will discuss with the Agency any

further requirements that may be necessa ry, such as varied carbon feed rates during mercury and

dioxins/furans testing, before extrapolation is requested. Any additional information or testing

requirements for extrapolation purposes will be done outside of the CPT to not only satisfy the

Agency , but also to avoid conflicts between HWC MACT testing requirements and extrapolation

requirements.

4. 7 Descr i p tion

, P r eparatio n an d Delive r y o f Fee d s fo r t h e CPT

[40 CF R § 63

. 120 7 (f)(1)(vi ) an d (vii)]

T o th e e x te n t possibl e (an d with th e exc e ptio n o f t h e s p ike d constitu e nt s n o te d ab o ve)

, onl y

n orma l waste material s processe d a t th e facilit y wil l b e fe d t o th e inci n erato r durin g th e te s t

progr a m

. Wast e m a terial s wil l be stockpile d t o mee t th e obj e ctive s fo r th e targe t tes t pa r ameters

.

Th e s e waste s wil l b e characterize d in advanc e o f th e te s t an d k e p t u n ti l need e d

. Al l wast e mat e rial s

wil l b e delivere d t o th e facilit y i n accordance with ro u t in e o peratio n an d currentl y pe r mitte d4

- 18

pro c e d ure s a s describe d elsewher e i n t h i s doc u m ent.

4. 8 Testing During Cleani ng Cycles

40 CFR 63.1207(g)(1)(i)(C) requires that tests for PM, SVM, LVM, mercury, and

dioxins/furans include a normal cleaning cycle of the PM control device. The baghouse is the

unit of the air pollution control train that is designed and operated to co ntrol particulate matter

.

T esting for PM, SVM, LVM, mercury, and dioxins/furans will be performed during a cleaning

cycle of the fabric filter (i.e., baghouse)

. Testing in all three runs of all tests conducted will

include a cleaning cycle of the baghouse.

As discussed in Section 2.5.1 of this plan, jet s o f ai r are used t o clea n th e fi l te r bags of the

baghouse

. Per i odically

, th e c l eaning sequenc e is in i t i a te d, either a t th e en d o f a 4

- h ou r time d c y c l e

,

whe n th e d i ffere n t i a l pressur e acr o s s th e filte r r e ac he s a pre d etermine d se t poin t o f appr o x im a tel y

7.0 ‖ w.c.

, o r whe n th e oper a t or initiate s a c y cle

. Veolia will ensure that the baghouse undergoes a

cleaning cycle during each run of the CPT

.

4.9 Condit i on i n g T i m e Neede d t o Reac h Stead y Stat e

[4 0 CF R § 63 .1207(f)(1)(xii)]

Sinc e ther e a

r e n o recircul a tin g scrubbe r f l ow s (th e lim e slurr y t o th e spra y d r ye r i s once

through)

, the conditioni n g tim e prio r t o samplin g fo r th e Ve o li a unit s i s governe d primaril y b y th e

ga s residenc e tim e fro m the fee d p o in t t o th e samplin g locations

. T h i s residenc e tim e i s

approximately 7.1 seconds (see Section 2.3.4)

. Th e incinerato r will b e operate d fo r 30 1 5 minute s a t

th e desir e d fee d rate s a n d operatin g condition s b e for e samplin g begin s fo r a give n conditi o n o f th e

testi n g

. Thi s wil l a s sur e al l operatin g paramet e r s ar e stabili z e d a t th e desire d setting s to achiev e

s t ea d y s t at e , and that the feedrates of spiking materials have stabilized, before sampling begins.

Thi s wil l a s sur e al l operatin g paramet e r s ar e stabili z e d a t th e desi re d setting s to achiev e s t ea d y s t at e

b e for e samplin g

.

4. 10 AWFCO System During the CPT

The CPT will be conducted at operating conditions at the extreme range of normal

. A

primary objective of the test is to establish limits for operating parameters that e nsure compliance

with the emission standards during subsequent operations

. The HWC MACT, at 40 CFR

63.1207(h)(1) and (2), waives the OPLs during subsequent performance testing and pretesting

under an approved test plan.4

- 19

One of the objectives of the subse quent CPT is to establish certain HWC MACT limits at

or near the limits in the current NOC

. To accomplish operation near current OPLs, Veolia will

disable the OPLs in the current NOC during the subsequent CPT

.

Veolia currently does not envision pre

- testi ng of Unit 4 prior to the CPT. If pre

- testing is

deemed to be necessary prior to the CPT, Veolia will request a and for the 720

- hour shakedown

period ( i.e

. , pretesting) in which OPLs would be disengaged. Veolia will notify EPA Region 5 if

pretesting is t o be conducted

.

4. 11 An ti c ip a te d T es t S c h e dule

The subsequent CPT of Unit 4 will be performed at one test condition (i.e., one

mode of operation ) , and one set of OPLs will be developed. There are two portions to the test

condition. In the first part of the test, Veolia will demonstrate compliance with the particulate

matter and HCl/Cl 2 standards of the HWC MACT while the plant is operating to establish the

maximum ash feedrate, maximum chlorine feedrate, maximum combustion gas flowrate, and

other applic able OPLs as required by the HWC MACT for the particulate matter and HCl/Cl 2

standards. In the second part of the test, Veolia will demonstrate compliance , and develop OPLs,

with the dioxins/furans, THC

, CO, LVM, SVM, and mercury standards of the HWC MACT

while the plant is operating to establish maximum total hazardous waste feedrate, maximum

pumpable hazardous waste feedrate, minimum primary combustion chamber (PCC) temperature,

minimum secondary combustion chamber (SCC) temperature

, maximum LVM, SVM, a nd Hg

fe e drates, maximum chlorine feedrate, maximum combustion gas flowrate, and maximum inlet

temperature to the baghouse.

Both parts of the test condition will include three test runs, or test periods. An individual

run of the CPT will be performed over three successive days with the testing for the two portions of

the single test condition performed back

- to

- back on each of the three days. For the first part of the

test, target operating conditions (i.e., normal waste feedrates, maximum ash and chlo rine feedrates,

maximum stack gas flowrate, and minimum sorbent and carrier fluid flowrates to the SDA) will be

established and maintained, and chlorine will be spiked for 30 minutes prior to the start of testing.

Once steady

- state operations have been ac hieved, stack testing for PM and HCl/Cl 2 will begin

along with the sampling of waste feeds. The sampling time of a Method 5/26A run for PM and

HCl/Cl 2 will be one hour. I t i s anticipa t e d tha t a Method 5/26A run for PM/HCl/Cl 2 w il l require

appr o x imatel y o ne and one

- half to two hour s to complete. The amount of time needed to complete

stack sampling for PM and HCl/Cl 2 will determine the length of the first part of the test condition.

The collection of samples of the waste feeds, and the collection of the ch lorine spiking material,

will be coordinated with the Method 5/26A stack sampling for PM and HCl/Cl 2 (i.e., at the

beginning, at port change, and at completion stack sampling).4

- 20

Following completion of testing for the first part of the test, the operation of Unit 4 will be

adjusted to the target operating conditions for the second portion of the test condition (i.e., maximum

waste feedrates, minimum temperatures in the PCC and SCC, maximum chlorine feedrate, maximum

stack gas flowrate, and normal or higher ash feedrate. Steady

- state operation will be established

and maintained, and Cr, Pb, Hg, and chlorine will be spiked for 30 minutes prior to the start of

testing. Once steady

- state operations have been achieved, stack testing for LVM, SVM, and Hg

and for dioxins and furans and THC will begin concurrently along with sampling of waste feeds.

The sampling time of a Method 29 run for LVM, SVM, and Hg will be two hours. I t i s anticipa t e d

tha t a Method 29 run for metals w il l require appr o x imatel y two and one

- half to three hour s to

complete. The sampling time of a Method 0023A run for dioxins and furans will be three hours, and

the amount of time to complete a Method 0023A run for dioxins/furans is expected to be

appr o x imatel y three and one

- half to four hour s

. The collection of samples of the waste feeds will

be coordinated with the Method 0023A stack sampling for dioxins/furans (i.e., at the beginning, at

port change, and at completion stack sampling). While spiking of Cr, Pb, Hg, and chlorine will

continue throughout the second portion of the test, sampling of the spiking materials for Cr, Pb,

Hg, and chlorine will be coordinated with the Method 29 stack sampling for LVM, SVM, and Hg

(i.e., at the beginning, at port change, and at completion stack sampling) . The three individual

samples of the liquid spiking solutions of Cr and Hg will be analyzed. The individual samples of

the solid spiking materials for Pb and chlorine will be archived. A fourth set of samples of the Cr,

Pb, Hg, and chlorine spiking so lutions and materials will be collected at the completion of the

Method 0023A sampling train for dioxins/furans. This fourth sample of the spiking solutions and

materials will be archived.

Table 4

- 5 presents a schedule for the conduct of the subsequent CPT of Unit 4

.4

- 21 Table 4

- 5 . Daily Schedule for the Su bsequent CPT of Unit 4

Day Start Stop Activity

1 8:00 17:00 On

- Site Mobilization

2 6:00 8:00 Unit Line Out

– Run 1 , First Part of the Test Condition

7:30 Begin Spiking of Chlorine

8:00 10:00 Run 1, First Part of the Test Condition

- Stack Testing for PM/HCl

- Cl

2

- Waste Feed Sampling (3 Samples)

 First Sample at Start of PM/HCl

- Cl

2 Sampling

 Second Sample at Port Change of PM/HCl

- Cl

2 Sampling Train

 Third Sample at Completion of PM/HCl

- Cl

2 Sampling

- Chlor ine Spike Sampling

 Taken from the Solid Waste Feed Container Collected at the

Beginning, Mid

- Point, and Completion of PM/HCl

- Cl

2 Sampling Train

10:00 11:00 Unit Line Out, Second Part of the Test Condition

10:30 Begin Spiking of Chromium, Lead, Mercury , and Chlorine

11:00 14:00 Run 1, Second Part of the Test Condition

- Stack Testing for LVM, SVM, and Hg

- Waste Feed Sampling (3 Samples; Composited)

 First Sample at Start of Metals and Dioxins/Furans Sampling

 Second Sample at Port Change of Dioxins/Furans Sampling Train

 Third Sample at Completion of Dioxins/Furans Sampling

- Cr, Pb, Hg, Chlorine Spike Sampling (3 Samples Collected and Analyzed; 1

Sample Archived

 First Sample at Start of Metals and Dioxins/Furans Sampling

 Second Sample at Port Change of Meta ls Sampling Train

 Third Sample at Completion of Metals Sampling

 Fourth Sample at Completion of Dioxins/Furans Sampling (Archived)

11:00 15:00 Run 1, Second Part of the Test Condition

- Stack Testing for Dioxins/Furans, THC

- Waste Feed Sampling (3 Samples; C omposited)

 First Sample at Start of Metals and Dioxins/Furans Sampling

 Second Sample at Port Change of Dioxins/Furans Sampling Train

 Third Sample at Completion of Dioxins/Furans Sampling

- Cr, Pb, Hg, Chlorine Spike Sampling (3 Samples Collected and Analyzed ; 1

Sample Archived

 First Sample at Start of Metals and Dioxins/Furans Sampling

 Second Sample at Port Change of Metals Sampling Train

 Third Sample at Completion of Metals Sampling

 Fourth Sample at Completion of Dioxins/Furans Sampling (Archived)

15:00 1 7:00 Sample Recovery4

- 22

Table 4

- 5 . Daily Schedule for the Su bsequent CPT of Unit 4 (continued)

3 6:00 8:00 Unit Line Out

– Run 2 , First Part of the Test Condition

7:30 Begin Spiking of Chlorine

8:00 10:00 Run 2, First Part of the Test Condition

- Stack T esting for PM/HCl

- Cl

2

- Waste Feed Sampling (3 Samples)

 First Sample at Start of PM/HCl

- Cl

2 Sampling

 Second Sample at Port Change of PM/HCl

- Cl

2 Sampling Train

 Third Sample at Completion of PM/HCl

- Cl

2 Sampling

- Chlorine Spike Sampling

 Taken from the Solid Wast e Feed Container Collected at the

Beginning, Mid

- Point, and Completion of PM/HCl

- Cl

2 Sampling Train

10:00 11:00 Unit Line Out, Second Part of the Test Condition

10:30 Begin Spiking of Chromium, Lead, Mercury, and Chlorine

11:00 14:00 Run 2, Second P art of the Test Condition

- Stack Testing for LVM, SVM, and Hg

- Waste Feed Sampling (3 Samples; Composited)

 First Sample at Start of Metals and Dioxins/Furans Sampling

 Second Sample at Port Change of Dioxins/Furans Sampling Train

 Third Sample at Completion of Dioxins/Furans Sampling

- Cr, Pb, Hg and Chlorine Spike Sampling (3 Samples Collected and Analyzed;

1 Sample Archived

 First Sample at Start of Metals and Dioxins/Furans Sampling

 Second Sample at Port Change of Metals Sampling Train

 Third Sample at Completi on of Metals Sampling

 Fourth Sample at Completion of Dioxins/Furans Sampling (Archived)

11:00 15:00 Run 2, Second Part of the Test Condition

- Stack Testing for Dioxins/Furans, THC

- Waste Feed Sampling (3 Samples; Composited)

 First Sample at Start of Metals and Dioxins/Furans Sampling

 Second Sample at Port Change of Dioxins/Furans Sampling Train

 Third Sample at Completion of Dioxins/Furans Sampling

- Cr, Pb, Hg and Chlorine Spike Sampling (3 Samples Collected and Analyzed;

1 Sample Archived

 First Sample at Sta rt of Metals and Dioxins/Furans Sampling

 Second Sample at Port Change of Metals Sampling Train

 Third Sample at Completion of Metals Sampling

 Fourth Sample at Completion of Dioxins/Furans Sampling (Archived)

15:00 17:00 Sample Recovery4

- 23

Table 4

- 5 . Da ily Schedule for the Su bsequent CPT of Unit 4 (continued)

4 6:00 8:00 Unit Line Out

– Run 3 , First Part of the Test Condition

7:30 Begin Spiking of Chlorine

8:00 10:00 Run 3, First Part of the Test Condition

- Stack Testing for PM/HCl

- Cl

2

- Waste Feed Sam pling (3 Samples)

 First Sample at Start of PM/HCl

- Cl2 Sampling

 Second Sample at Port Change of PM/HCl

- Cl

2 Sampling Train

 Third Sample at Completion of PM/HCl

- Cl

2 Sampling

- Chlorine Spike Sampling

 Taken from the Solid Waste Feed Container Collected at the

Be ginning, Mid

- Point, and Completion of PM/HCl

- Cl

2 Sampling Train

10:00 11:00 Unit Line Out, Second Part of the Test Condition

10:30 Begin Spiking of Chromium, Lead, Mercury, and Chlorine

11:00 14:00 Run 3, Second Part of the Test Condition

- Stack Test ing for LVM, SVM, and Hg

- Waste Feed Sampling (3 Samples; Composited)

 First Sample at Start of Metals and Dioxins/Furans Sampling

 Second Sample at Port Change of Dioxins/Furans Sampling Train

 Third Sample at Completion of Dioxins/Furans Sampling

- Cr, Pb, Hg, Chlorine Spike Sampling (3 Samples Collected and Analyzed; 1

Sample Archived

 First Sample at Start of Metals and Dioxins/Furans Sampling

 Second Sample at Port Change of Metals Sampling Train

 Third Sample at Completion of Metals Sampling

 Fourth Sample at Completion of Dioxins/Furans Sampling (Archived)

11:00 15:00 Run 3, Second Part of the Test Condition

- Stack Testing for Dioxins/Furans, THC

- Waste Feed Sampling (3 Samples; Composited)

 First Sample at Start of Metals and Dioxins/Furans Sampling

 Second Sam ple at Port Change of Dioxins/Furans Sampling Train

 Third Sample at Completion of Dioxins/Furans Sampling

- Cr, Pb, Hg, Chlorine Spike Sampling (3 Samples Collected and Analyzed; 1

Sample Archived

 First Sample at Start of Metals and Dioxins/Furans Sampling

 S econd Sample at Port Change of Metals Sampling Train

 Third Sample at Completion of Metals Sampling

 Fourth Sample at Completion of Dioxins/Furans Sampling (Archived)

15:00 17:00 Sample Recovery

5 8:00 17:00 Composite Waste Samples, Pack and Ship Samples , Demobilize, Contingency4

- 24

Th e incinerato r will b e operate d fo r 1 5 minute s a t th e desir e d fee d rate s

– including spiking

materials

- a n d operatin g condition s b e for e samplin g begin s fo r a give n conditi o n o f th e testi n g

. I t

i s anticipa t e d tha t the Method 29 run s for metals w il l b e appr o x imatel y two and one

- half to three

hour s i n dur a tion; that the Method 5/26A run s for PM/HCl/Cl 2 w il l b e appr o x imatel y one and one

half to two hour s i n dur a tion; and that the Method 0023A run s for dioxins/furans w il l b e

appr o x im atel y three and one

- half to four hour s i n dur a tion

. These sampling trains will dictate the

times required to complete the sampling for an individual run

.

In August and September of 2008, Veolia conducted tests of Units 2, 3, and 4 required

by the informa tion collection requests from USEPA Region 5 dated June 5, 2008 and

September 12, 2008. These tests were designed to demonstrate compliance with the applicable

emission standards of the HWC MACT for metals , and began on August 11, 2008 for Unit 2,

August 5 , 2008 for Unit 3, and August 21, 2008 for Unit 4

. The initial C omprehensive

P erformance T est s of Units 2, 3, and 4 commenced on December 8, 2009 for Unit 2; on

December 1, 2009 for Unit 3; and on December 16, 2009 for Unit 4. The HWC MACT, at 40

CF R § 63 .1207(d), states “The date of commencement of the initial comprehensive

performance test is the basis for establishing the deadline to commence the initial confirmatory

performance test and the next comprehensive performance test. You may conduct performan ce

testing at any time prior to the required date. The deadline for commencing subsequent

confirmatory and comprehensive performance testing is based on the date of commencement of

the previous comprehensive performance test.” Veolia Sauget understands th at EPA Region

5‘s position regarding commencement of the subsequent CPTs is based on the initiation of the

metals tests performed in 2008, stating in a letter dated August 3, 2012 ―Veolia must submit to

EPA a notification of intent to conduct a CPT and a s ite

- specific test plan for the CPT at least

one year before the performance test. 40 CF R § 63. 1 2 07 ( e )( 1)(i)...by September 5, 2012‖.

Veolia is submitt ed ing to EPA its notification of intent and site

- specific test plan for the

subsequent CPT on September 5, 2 012 by this date

.

4. 12 Report i ng

A Notification of Compliance (NOC) and test rep o r t of the subsequent CPT of Unit 4 wil l b e

pre p are d as separate documents and submitted to EPA Region 5 and Illinois EPA n o late r t h a n 9 0

d a y s f r o m compl e ti o n o f th e fi e l d te s t program

. The test report w i l l provid e a complete, concis e

pr e sentatio n o f the t e s t result s an d wil l includ e al l necessary supportin g d o cumentation

.

A n e x ampl e o utlin e o f th e NOC i s presente d below:

Sectio n 1

. 0, Certificati o n Statement

– S t a temen t o f complianc e as required by 40 CFR 63.1210(d)

.

Sectio n 2

. 0, Introduction

– Summa r y o f test program

.

Sectio n 3

. 0, Unit Description

– Brief unit description

.4

- 25

Sectio n 4

. 0, Results of Comprehensive Performance Test

– Summary of the results of the

Comprehensive Performance Test

.

Sectio n 5

. 0, Ope r atin g Parameter Limits

– Listing of the OPLs established from the

Comprehensive Performance Test, and the data, and regulatory requirements, used to establish the

OPLs

.

Sectio n 6

. 0, Bases for Establishment of OPLs

– Summ a r y o f the regulatory requirements of the

HWC MACT, and Veolia‘s approach to address those requirements

.

A n e x ampl e o utlin e o f th e tes t repor t i s presente d below:

Sectio n 1

. 0, Executive Summary

– Summary of the test objectives and results

.

Sectio n 2

. 0, Pr ocess Operations

– Brief description of the unit, and the process operating data from

the test

.

Sectio n 3

. 0, Sampling and Analytical Procedures

Sectio n 4

. 0, Results

– The results of the test

.

Sectio n 5

. 0, Calculated Values

– Values calculated using the res ults, operating data, and spiking

rates.

Sectio n 6

. 0, Quali ty Ass u ranc e / Qu a li t y Cont r o l

– Detaile d discussio n o f sampling an d

analytica l QA/Q C pro c edure s an d r e sults.

APPENDIX A

– CEMS RATA Report

APPENDIX B

– S p ikin g R eport

APPENDIX C

– Process Operat ing Data

APPENDIX D

– CMS Performance Evaluation Test Report

APPENDIX E

– Field Logbook

APPENDIX F

– S a mplin g Documentation

APPENDIX G

– A n alytica l Dat a Reports

APPENDIX H

– Data Quality Assessments

APPENDIX I

– Sampling Equipment/Instrumentation Calibr ation Docum ent5

- 1



### 5.0 Sampling, Analysis, and Monitoring Procedures

The subsequent CPT of Unit 4 will include be performed at one multiple test condition s to

demonstrate system performance and to establish appropriate operating parameter limits (OPLs)

for all of the applicable standards of the HWC MACT. Sections 4.3.1, 4.3.2, and 4.3.3 present

the tests at which the incinerator will be tested. The CPT will include three replicate sampling

runs of at the one test condition each of the set of multiple conditions . T able 5

- 1 summarizes the

parameters that will be measured during the test and the frequency of measurement. URS will

perform all on site sampling activities during the CPT.

5.1 Sampling Locations and Procedures

Samples will be collected of solid, liquid, and gas streams during the CPT. This section

describes the sampling methods that will be employed

. Table 5

- 2 summarizes the sampling

methods for each stream and the param eters that will be determined. Because most of the

proposed methods are standard refer ence methods, only brief, summary type descriptions are

presented

. More detailed descriptions are presented in the indicated reference documents and in

the Quality Assurance Project Plan (QAPjP) for the test.

5.1.1 Liquids Sampling Procedures

Samples of the liquid waste feed and chromium spiking solution will be collected in

amber glass bottles with Teflon cap liners

. The mercury solution samples will remain in the

vials in which the mercuric nitrate solution was fed to the incinerator. Pre

- cleaned bott les

will be purchased and used to collect the samples

. T h e liq u i d waste fee d sample s wil l b e

characterize d fo r ash

, total chlorine, hea t content, metal s (arsen i c

, beryl l ium

, c hromium

,

ca d mium

, lea d

, a n d mercury )

, t o ta l chlorine , a nd moisture, density, and viscosity in the first part

of the test, , as appropriate

. and ash

, total chlorine, hea t content, moisture, density, viscosity, and

metal s (arsen i c

, beryl l ium

, c hromium

, ca d mium

, lea d

, a n d mercury ) in the second part of the

test. URS will be collecting the spike and waste samples.

Three samples of the liquid waste feed, and the chromium and mercury spiking

solutions will be collected in each run. At the beginning, middle (at port change), and end of

the Method 5/26A sampling train of the first part of t he test, approximately 1

- liter samples of

the liquid waste feed stream will be collected. At the beginning, middle (at port change ) , and

end of the Method 0023A sampling train of the second part of the test, approximately 1

- liter

samples of the liquid was te feed stream will be collected. The 1

- liter sub

- samples will be

collected at each designated sampling time, and the collected material (i.e., sub

- sample) will

be transferred into a larger container, producing a composite sample of the liquid waste feed.

The composite liquid waste feed samples from the first part and the second part of the CPT5

- 2

will be analyzed.

Samples of the chromium and mercury spiking solution s will be archived. collected in

each run of the second part of the test. At the beginnin g, middle (at port change), and end of

the Method 29 sampling of the second part of the test, approximately 125

- mL samples of the

chromium spiking solution will be collected. At the same frequency, samples of the mercury

spiking solution will be collected from randomly selected waste feed containers. T he

individual samples of the chromium and mercury spiking solutions collected during each run

of the test will be analyzed for chromium or mercury, respectively. A fourth sample of the

chromium and mercury spiking solutions will be collected at the completion of the Method

0023A sampling train. This fourth sample will be archived.

Liquid waste samples will be collected u p strea m o f a n y meta l spikin g locatio n using the

tap sampling procedure specified in U.S . EPA Method S004, ―Sampling and Analysis Methods

for Hazardous Waste Combustion.‖ The sample tap will be flushed each time by allowing the

sample to flow briefly before the sample is collected

. This will ensure that any stagnant

accumulation of solids, o r other contaminants that may be present in the tap, does not affect the

sample integrity or its representation of the stream being sampled.

Adequate amounts of the samples of the liquid waste feed and the chromium and mercury

spiking solution s will be co llected such that duplicate samples can be made available to EPA

Region 5.

At the beginning, middle (at port change), and end of each test period, approximately

1

- liter samples of each liquid stream will be collected

. The individual samples will be

compos ited on site to provide one sample per test run

.

Samples of the chromium spiking solution will be collected at the beginning and end of

each sampling run.5

- 3 Table 5

- 1. Measurement Frequency

Stream/Parameters Sample Frequency for

the Subsequent CPT

Fir st Part Second Part

Liquid Waste Feed

Ash

Chlorine

Moisture

Heating Value

Viscosity, Density

Metals 3

3

3

3

3 3

3

3

3

3

3 1

Solid Waste Feed

– Containerized and Bulk

Ash

Chlorine

Moisture

Heating Value

Metals 3

3

3

3 3

3

3

3

3 1

Spiking Materials

Mercury Spiking Solution

Lead Solid Spiking Material

Chromium Spiking Solution

Chlorine Solid Spiking Material (if spiked) 3 3

3

3

3

Stack Gas

Metals

Particulate Matter

HCl/Cl 2

Dioxins/Furans

CO 2 , O 2

Total Hydrocarbons

Moisture

CO, O 2 3 3

3

Cont inuous

Concurrent with

isokinetic sampling

Continuous 3 1

3

Continuous 2

Continuous 2

Concurrent with

isokinetic sampling

Continuous

1 Analysis is for As, Be, Cd, Cr, Pb, and Hg.

2 Allowing for hourly calibration of the THC monitor.

3 Plant monitors.

Tab le 5

- 1. Measurement Frequency

Stream/Parameters Sample Frequency for

Each Test Condition5

- 4 Waste Feeds

Ash

Chlorine

Moisture

Heating Value, Viscosity, Density

Metals 3

3

3

3

3 1

Spiking Materials 2

Mercury Spiking Solution

Lead Solid Spiking Material

Chrom ium Spiking Solution

Chlorine Solid Spiking Material (if spiked) 3

3

3

3

Stack Gas

Metals

Particulate Matter

HCl/Cl 2

Dioxins/Furans

CO 2 , O 2

Total Hydrocarbons

Moisture

CO, O 2 4 3 1

3

3

3

Continuous 3

Continuous 3

Concurrent with

isokinetic sampling

Conti nuous

1 Analysis is for As, Be, Cd, Cr, Pb, and Hg.

2 Samples will be archived.

3 Allowing for hourly calibration of the THC monitor.

4 Plant monitors.5

- 5 Table 5

- 2. Sampling Methods

Stream Sampling Method Sampling

Frequency Compositing

Approach Analy tical

Parameters

Liquid Waste

Feed Tap

(Method S004) First part of the test

condition

- Beginning , middle,

and end of Method

5/26A sampling

Second part of the

test condition

- Beginning , middle,

and end of Method

0023A sampling Composite all

subsamples f

rom

each test period Ash

Chlorine

Moisture

Heating Value

Density

Viscosity

Metals 1

Containerized

Solid Waste Feed Grab or Scoop

(Method S007)

– Solids First part of the test

condition

- Beginning , middle,

and end of Method

5/26A sampling

Second part of t he

test condition

- Beginning , middle,

and end of Method

0023A sampling Composite all

subsamples from

each test period Ash

Chlorine

Moisture

Heating Value

Metals 1

Bulk Solid Waste

Feed Grab or Scoop

(Method S007)

– Solids First part of the test

condition

- Beginning , middle,

and end of Method

5/26A sampling

Second part of the

test condition

- Beginning , middle,

and end of Method

0023A sampling Composite all

subsamples from

each test period Ash

Chlorine

Moisture

Heating Value

Metals 1

Chromium

Spiking Solu tion Tap

(Method S004) Second part of the

test condition

- Beginning, middle,

and end of Method

29 sampling

End of Method

0023A sampling Analyze all

subsamples

collected during

Method 29

sampling

Archive

subsample

collected at end of

Method 0023A

sampli ng Chromium5

- 6

Mercury Spiking

Solution Grab Second part of the

test condition

- Beginning, middle,

and end of Method

29 sampling

End of Method

0023A sampling Analyze all

subsamples

collected during

Method 29

sampling

Archive

subsample

collected at end o f

Method 0023A

sampling Mercury

Lead and

Chlorine Spiking

Materials Grab Second part of the

test condition

- Beginning, middle,

and end of Method

29 sampling

End of Method

0023A sampling None

- Archive Archive

Stack Gas EPA Method 2 Concurrent with

is okinetic sampling NR Flow R ate

EPA Method 3 A Concurrent with

isokinetic sampling NR O 2 , CO 2

EPA Method 4 Concurrent with

isokinetic sampling NR Moisture

EPA Method 5

EPA Method 26A 1 + hour collected

isokinetically NR PM

HCl/Cl 2

EPA Method 29 2+ hou r collected

isokinetically NR Metals 1

SW

- 846 Method 0023A 3+ hour collected

isokinetically NR Dioxins/Furans

Plant CEMS Continuous NR CO, O 2

1 Analysis is for As, Be, Cd, Cr, Pb, and Hg only in samples from the second part of the test condition

.

NR = Not Required

Table 5

- 2. Sampling Methods

Stream Sampling Method Sampling

Frequency Compositing

Approach Analytical

Parameters

Waste Feeds Grab or Scoop

(Method S007)

– Solids

Tap

(Method S004)

– Liquids Beginning , middle,

and end of each test

period Com

posite all

subsamples from

each test period Ash

Chlorine

Moisture

Heating Value

Density

Viscosity

Metals 1

Chromium

Spiking Solution Tap

(Method S004) Beginning and end

of each test period None

– Archive Archive

Mercury Spiking

Solution Grab Collect one p acket

from the storage

area each run None

– Archive Archive5

- 7

Lead and

Chlorine Spiking

Materials Grab Collect one packet

from the storage

area each run None

– Archive Archive

Stack Gas EPA Method 2 Concurrent with

isokinetic sampling NR Flow r ate

EPA Met hod 3 A Concurrent with

isokinetic sampling NR O 2 , CO 2

EPA Method 4 Concurrent with

isokinetic sampling NR Moisture

EPA Method 29 2+ hour collected

isokinetically NR Metals 1

EPA Method 5

EPA Method 26A 1 + hour collected

isokinetically NR PM

HCl/Cl 2

SW

- 846 Method 0023A 3+ hour collected

isokinetically NR Dioxins/Furans

Plant CEMS Continuous NR CO, O 2

1 Analysis is for As, Be, Cd, Cr, Pb, and Hg.

NR = Not Required

5.1.2 Solids Sampling Procedures

Solid wastes are fed to Unit 4 containerized and bulk. Fo r the containe r ize d soli d wast e

fee d stream

, a gra

b sampl e fro m a ra n doml y select e d containe r b ein g fe d t o t h e incinerato r wil l b e

collecte d usin g a pre

- cleane d scoo p

. T hre e sub

- sample s from the first part of the test wil l b e

composite d s o th a t th e resul t i s a composit e sampl e for the first part of the test. Likewise, the

thre e sub

- sample s from the second part of the test wil l b e composite d to produce a composit e

sampl e for the second part of the test. URS will be collecting the spike and waste samples.

Samples of bulk solids will be collected f rom the wast e fee d bin s i n t h e B u l k S o lids

Storag e B u ildin g

. G ra

b sampl e s fro m the waste bins wil l b e collecte d usin g a pre

- cleane d scoo p

.

T hre e sub

- sample s from the first part of the test wil l b e composite d s o th a t the resul t i s a

composit e sampl e for t

he first part of the test. Likewise, t hre e sub

- sample s from the second part of

the test wil l b e composite d to produce a composit e sampl e for the second part of the test.

A n a ly s e s wil l b e pe r forme d o n th e composit e s a mple s

. The soli d waste fee d s a mple s

,

c ontainerized and bulk, wil l b e characterize d fo r total chlorine, ash

, moisture, and he a t content in

the samples from the first part of the test, and for total chlorine, ash

, moisture, he a t content

, and

m e tal s (arsenic

, b e ryllium

, chromium

, cadmium, lead

, a n d mercury ) from the second part of the

test

.

The t hree samples of the solid waste feed s, containerized and bulk, will be collected at

the beginning, middle (at port change), and end of the Method 5/26A sampling of the first5

- 8

part of the test

. The t hree samples of the solid waste feed s from the second part of the test will

be collected at the beginning, middle (at port change), and end of the collection of the Method

0023A sampling train

.

Spikes of Pb and chlorine will be added to the containerized sol id waste. S amples of the

chlorine spiking material will be collected in each run of the first part of the test , and s amples of

the lead and chlorine spiking materials will be collected in each run of the second part of the

test. Th ree grab samples of the chlorine spiking material will be collected at the beginning,

middle (at port change), and end of the Method 5/26A sampling of the first part of the test

.

G rab samples of the lead and chlorine spiking materials will be collected a t the beginning,

middle (at port change), and end of the Method 29 sampling of the second part of the test . A

fourth sample of the lead and chlorine spiking materials will be collected at the completion of

the Method 0023A sampling train. All samples of the lead and chlorine sp iking materials will

be archived.

Adequate amounts of the samples of the solid waste feed and the lead and chlorine

spiking materials will be collected such that duplicate samples can be made available to EPA

Region 5.

Fo r containe r ize d soli d wast e fee d streams

, a gra b sampl e fro m a ra n doml y select e d containe r

b ein g fe d t o t h e incinerato r wil l b e collecte d usin g a pre

- cleane d scoo p a t th e star t o f eac h run

, a t

p or t chang e

, a n d a t the completio n o f eac h run

. E a c h o f th e thre e sample s wil l b e composite d s o

th a t the resul t i s a si n gl e composit e sampl e pe r r u n

, an d an a ly s e s wil l b e pe r forme d o n thi s

composit e s a mple

. The soli d fee d s a mple s wil l b e characterize d fo r ash

, he a t content

, m e tal s

(arsenic

, b e ryllium

, chromium

, cadmium, lead

, an d mercury ) an d t o t a l c hlorine.

Samples of the chromium (i.e., chromic acid), lead (i.e., lead nitrate), mercury (i.e., solution

of mercuric nitrate), and chlorine (i.e., hexachloroethane) spiking materials will be collected during

each run and archived.

5.1.3 Stack Gas Sampl ing Procedures

The stack gas emissions will be collected for determination of the parameters indicated in

Tables 5

- 1 and 5

- 2

. The methods that will be employed are described below.

5.1.3.1 Sample Port Location

The stack is 100

- feet high and has an insid e diameter of 48 inches

. There are two sets of

two orthogonal ports located at two slightly different levels

. The number of sampling points will

be determined in accordance with EPA Method 1

, and is discussed further in the QAPjP.

5.1.3.2 EPA Methods 2 an d 4 (Flow r ate and Moisture)5

- 9

Concurrent with the performance of the isokinetic sampling train, measurements will be

made to determine gas velocity by 40 CFR Part 60, Appendix A, Method 2, and moisture by

Method 4.

5.1.3.3 EPA Method 29 (Metals)

Samples of the stack gas emissions will be collected isokinetically for the HWC MACT

metals As, Be, Cd, Cr, Pb, and Hg using Method 29 from 40 CFR Part 60, Appendix A.

This method is basically an EPA Method 5 sampling train with some very specific

modifications:

Th e nozzle and probe liner will be glass or quartz. All con nections will be glass or

Teflon;

The filter will be quartz or glass fiber, with a fritted glass or Teflon support;

The first impinger will be empty (optional);

The second and third impingers will c ontain a nitric acid/hydrogen peroxide solution;

The fourth impinger will be empty;

The fifth and sixth impingers will contain acidic potassium permanganate; and

Modified Greenburg

- Smith impinger containing silica gel.

Following sampling, the probe and n ozzle of the sampling train will be recovered using a

brush containing no metal

. The probe and nozzle will be rinsed with 0.1 normal nitric acid.

Sampling will involve collecting samples iso kinetically across both diagonals of the

stack

. The sampling ra te for each train will be between 0.5 and 0.75 dry standard cubic feet per

minute

. A minimum of 45 dry standard cubic feet will be col lected over a minimum sampling

time of 120 minutes.

5.1.3.4 EPA Method 5 (PM) / EPA Method 26A (HCl/Cl 2 )

Samples for the determination of HCl, Cl 2 , and particulate matter (PM) in stack emissions

will be collected using a single sampling train meeting the requirements of both EPA Method

26A and Method 5

. This sample train consists of the following components:

Glass (quartz) nozzle;

Heated, glass (quartz)

- lined probe;

Heated Teflon mat filter with a Teflon filter support;

Optional empty knockout impinger;5

- 10 Greenburg

- Smith impinger containing 100 mL of 0.1 N H 2 SO 4 ;

Greenburg

- Smith impinger containing 100 mL of 0.1 N H 2 SO 4 ;

Modi fied Greenburg

- Smith impinger containing 100 mL of 0.1 N NaOH;

Modified Greenburg

- Smith impinger containing 100 mL of 0.1 N NaOH; and

Modified Greenburg

- Smith impinger containing silica gel.

The procedure specified in EPA Method 5 will be used to determi ne particulate matter

. These procedures require the isokinetic extraction of particulate matter on a filter maintained at a

controlled temperature . In accordance with EPA Method 26A, the filter temperature will be

maintained between 248°F and 273°F

. A Tef lon union will be used to connect the quartz nozzle

to the quartz probe liner

. The particulate mass, which includes all material that condenses at or

above the filtration temperature, is determined gravimetrically, after desiccation.

Sampling will involv e collecting samples iso kinetically across both diagonals of the

stack

. The sampling rate for each train will be between 0.5 and 0.75 dry standard cubic feet per

minute

. A minimum of 3 0 dry standard cubic feet will be col lected over a minimum sampling

ti me of 60 minutes.

Chloride analysis will be performed on the impinger contents using ion chromatography

according to Method 26A.

5.1.3.5 SW

- 846 Method 0023A (Dioxins/Furans)

Stack gas emissions samples will be collected for dioxins/ furans using SW

- 846 Met hod

0023A

. The sampling train consists of a heated probe, heated filter, sorbent module, and

pumping and metering unit

. A gooseneck nozzle of proper size to allow isokinetic sample

collection is attached to the probe

. S

- type pitot differential pressure is monitored to determine the

isokinetic sampling rate.

From the heated filter, sample gas enters the sorbent module

. The sorbent module

consists of a water

- cooled condenser followed by the XAD

- 2 resin trap

. After the resin trap is a

dry modified Greenburg

- S mith impinger that collects the aqueous condensate

. The stem of this

impinger is short to reduce carryover of collected aqueous condensate

. Following the condensate

trap are two impingers containing 100 mL of DI water to collect any mist carryover from the

condensate trap and a final impinger containing a desiccant to dry the sample gas before

metering

. A pump and dry gas meter are used to control and monitor the sample gas flowrate.

Sampling of the stack gases will be conducted in accordance with published protocol.

This will involve collecting samples isokinetically across both diagonals of the stack

. The

sampling rate for each train will be between 0.5 and 0.75 dry standard cubic feet per minute

(dscfm). A minimum of 2.5 dry standard cubic meters (88.3 dr y standard cubic feet ) will be col

-5

- 11

lected over a minimum sampling time of 3 hours.

5.1.3.6 Continuous Emissions Monitoring (THC, CO 2 , CO and O 2 )

CEMs will be used to monitor the concentrations of THC (total hydrocarbons), CO 2 , CO,

and O 2 in the stack gas.

CO and O 2 results will be reported for the stack gases from permanent installation CEMS

of the incinerator facility

. THC, CO 2, and O 2 continuous monitors will be provided by the test

contractor conducting the test.

The concentrations of total hydrocarbons (THC), carbon dioxide (CO 2 ), and oxygen (O 2 )

in the stack gas will be determined by the test contractor conducting the test using EPA Methods

25A and 3A, respectively

. CO 2 and O 2 will be monitored using Method 3A to determine the

stack gas composition (i. e., molecular weight) to determine the flowrate of the stack gas

. Both of

these methods utilize continuous monitors

.

5.2 Analysis Procedures

Samples collected during the Comprehensive Performance Test will be analyzed for the

parameters specified in Table 5

- 3

. This section describes the analytical methods that will be

employed

. Since most of the proposed methods are standard reference methods, only brief

summary type descriptions are presented

. More detailed descriptions can be found in the

indicated refer ence documents and in the QAPjP. All analyses will be performed by Test

America Laboratories in Knoxville, TN

. Analytical results for the waste feed samples will be

reported on an as

- received or wet weight basis. Samples of the waste feed will not be dri ed prior

to analysis.5

- 12 Table 5

- 3

. Summary of Analytical Methods

Parameter Stream Analytical Method

O 2 , CO 2 Stack Gas EPA Method 3 A

Moisture Stack Gas EPA Method 4

Metals Waste Feeds, Stack Gas ICPES

- SW

- 846 Method 6010B

CVAAS

- Hg, SW

- 846 Method

747 0A or 7471A

Particulate Matter Stack Gas Gravimetric

- EPA Method 5

HCl/Cl 2 Stack Gas IC

- EPA Method 26A

Dioxins/Furans Stack Gas HRGC/MS

– SW

- 846 Method 8290

Composition/Physical Parameters Waste Feeds EPA and/or ASTM Standard

Methods

5.2.1 Compos ition and Physical Parameters Analysis

Samples of the waste feeds will be collected for determination of a number of chemical

and physical parameters, including:

Ash;

Total chlorine;

Moisture;

Heating value;

Density; and

Viscosity.

These analyses will be performed using appropriate EPA and/or ASTM standard

methods.

5.2.2 Metals Analysis

Waste feed samples will be analyzed for metals using a trace level inductively coupled

argon plasma emission spectroscopy (ICPES) and atomic absorption spectroscopy

. Samp les will

be prepared for analysis using SW

- 846 Method 3050B. The metals to be analyzed by ICPES

(SW

- 846 Method 6010B) are arsenic (As), beryllium (Be), cadmium (Cd), chromium (Cr), and

lead (Pb). Mercury (Hg) will be analyzed using Method 747 1 A of SW

- 846.

The Method 29 sampling train will be used to collect samples of the stack gas for metals.

The samples will be analyzed using ICPES according to SW

- 846 Method 6010B, and mercury5

- 13

will be analyzed using Method 7470A of SW

- 846

. The metals to be analyzed by I CPES are As,

Be, Cd, Cr, and Pb.

5.2. 3 Particulate Matter Analysis

The particulate matter concentration of the stack gas will be determined following 40

CFR 60, Appendix A, Method 5 protocols

. The wash from the nozzle, probe liner, and glassware

prior to the filter on the sampling train will be evaporated, and the mass determined on an

analytical balance

. The filter will be removed from the sampling train, desiccated, and weighed

to determine the mass of particulate on the filter

. The combined mass from t he filter and the

evaporated wash are then related to the total volume of gas sampled to determine the particulate

loading

.

5.2.4 HCl and Cl 2 Analysis

The sulfuric acid and sodium hydroxide impinger catches from the Method 5/26A

sampling train will be an alyzed for chloride ion concentrations. Chloride analysis will be

performed using EPA Method 26A, an IC technique.

5.2.5 Dioxins/Furans Analysis

Samples of the stack gas collected using SW

- 846 Method 0023A w ill be analyzed for

dioxins/ furans using SW

- 846 M ethod 8290, high resolution gas chromatography (HRGC) with

high resolution mass spectroscopy (HRMS) analytical technique

. The analytical protocol

includes quantitation of all dibenzodioxins and dibenzofurans including four or more chlorine

atoms

. The metho d provides congener class definition for each of the five congener groups

(tetra

- , penta

- , hexa

- , hepta

- , and octa

- )

. In addition, each individual isomer containing the

2,3,7,8

- substitution pattern will be individually quantified.

5.3 Process Monitoring Procedures

The incinerator system is monitored to ensure that it is operating in accordance with the

permitted conditions. During the performance test, the automatic waste feed cutoff system will

be operational; however, AWFCO limits in the current NOC wil l be adjusted or disabled during

the performance testing period, and during a 720

- hour shakedown period prior to the test , if pre

testing is conducted

. Veolia will notify EPA Region 5 if pretesting is to be conducted

.5

- 14

5.4 Quality Assurance/Quality Cont rol Procedures

An effective QA/QC strategy is essential to ensure the usefulness and reliability of data

collected in any source testing effort

. This QA/QC program is documented in a project

- specific

QAPjP. The QAPjP details QA/QC activities for the Compre hensive Performance Test, as well

as specifications for sampling and analysis activities, objectives, and procedures

. The QAPjP

conforms to the requirements detailed in Guidance for Quality Assurance Project Plans (QA/G

5)

. ―Preparation Aid for HWERL‘s Ca tegory II Quality Assurance Project Plans,‖ U.S. EPA,

June 1987 (PA QAPjP

- 0007

- GFS).

The primary objective of the QA/QC effort will be to provide the mechanism whereby

the quality of the measurement data is known and documented and is subject to ongoing

evaluation throughout the course of the project

. To achieve this objective, the QA/QC program

must serve two distinct, interrelated functions

. One function will be that of providing a QC

database which, together with performance audit results, can be used to assess measurement data

quality in terms of precision and accuracy

. Inherent and implied in this assessment function is a

second, parallel function of controlling data quality within prescribed limits of acceptability.

The QAPjP delineates specific sam pling and analytical procedures, calibration

requirements, internal QC checks, data reduction and validation procedures, and sample custody

requirements for each sampling/analytical activity. It also addresses general QA/QC

considerations such as:

Data re cording;

Documentation procedures;

Project organization and responsibilities;

Preventative maintenance operations;

Reporting requirements; and

Corrective action mechanisms.

In addition to these general considerations, the QAPjP specifies schedules for

pe rformance and the duration of sampling (especially for stack gas samples) to provide adequate

method detection limits to demonstrate compliance with the metals emission standard s. The

QAPjP also devotes considerable attention to the internal QC checks that will be used to ensure

that the measurement data meet data quality requirements

. These QC checks include procedures

such as:

Daily calibration of analytical instruments;

Calibration of sampling equipment and apparatus; and5

- 15 Analytical checks using QC stan dards to assess bias and precision.

The following sections present a brief overview of the QA/QC activities that are an

integral part of the stack test program

. Table 5

- 4 lists specific QA/QC activities that will be

performed.5

- 16 Table 5

- 4. Summary of S ampling and Analytical QC Requirements 1

Field

Blank 2 Trip

Blank 3 Break

Through Duplicate

Sample or

Analysis 4,5 MS/

MSD 6 LCS/LCSD Surrogate

Spike

Particulate Matter

Stack Gas 1 1

HCl/Cl 2

Stack Gas 1 1 All 1 1

Dioxins/Furans

Stack Gas 1 1 1 All

Metals

Stack Gas 1 1 1 1

Waste Feeds 1 1 1

Composition

Waste Feeds 1 1 7

1 Table indicates number of QC samples planned for the Comprehensive Performance Test, unless otherwise

indicated.

2 Field blanks for g as samples are recovered from assembled trains that have been leak checked but through

which no gas sample has passed.

3 Trip blanks consist of applicable filters, sorbents, and solutions. These will be analyzed only if necessary based

on field blank ana lysis results.

4 Field duplicates will be collected as duplicate sets of subsamples used to prepare the composite sample.

5 Field duplicate will be collected of the liquid waste only in the CPT of each unit.

6 Matrix spiked samples will be spiked prior to sample preparation (digestion/extraction), except for metals train

samples, which will be spiked following digestion.

7 MS/MSD for chlorine only.

Table 5

- 4. Summary of Matrix Specific QC Sample Requirements 1

Field

Blank 2 Trip

Blank 3 Duplicate Sample

or Analysis 4 MS/

MSD 5 LCS/LCSD Surrogate

Spike

Metals

Stack Gas 1 1 All 1 1

Wastes 1 1 1

Particulate Matter

Stack Gas 1 15

- 17

HCl/Cl 2

Stack Gas 1 1 All 1 1

Dioxins/Furans

Stack Gas 1 1 All

Composition

Wastes 1 1 6

1 Table indicates number of QC samples planned for the Comprehensive Performance Test, unless otherwise

indicated.

2 Field blanks for gas samples are recovered from assembled trains that have been leak checked but through

which no gas sample has passed.

3 Trip blanks consist of applicable filters, sorbents, and solutions. These will be analyzed only if necessary based

on field blank analysis results.

4 Field duplicates of waste feeds will be collected as duplicate sets for subsamples for compositing.

5 Matrix spiked samples will be spiked prior to sample preparation (digestion/extraction), except for metals train

sam ples, which will be spiked following digestion.

6 MS/MSD for chlorine only.

5.4.1 Sampling QA/QC

The QAPjP prescribes QC procedures to be implemented during all sampling activities

and specifies guidelines for:

Equipment calibration;

Sampling protocol; and

Sample handling techniques.

The checkout and calibration of sampling equipment is an important function in

maintaining data quality

. Referenced calibration procedures are prescribed, and the results will

be properly documented and retained. Calibrati ons will be performed prior to field deployment.

Sampling techniques to be used during the Comprehensive Performance Test will be EPA

references. Sample collection will be done in accordance with the methods prescribed in the

QAPjP

. The QA procedure check s will include the use of standard data forms and source

sampling data sheet checklists

. Other checks will include performance of the following:

Visual inspections of sampling systems;

System leak checks before and after sampling;

Heating system checks;

I mpinger ice checks;5

- 18 Isokinetic sampling rate checks; and

Daily data review and calculation checks.

After the samples have been properly obtained in the field, their subsequent handling

during transfer to the analytical laboratories becomes an important f actor in the successful

performance of a stac k test program

. All collected samples will be labeled with adequate

descriptions of the samples to prevent confusion among multiple samples

. Samples will be

inventoried against logbook records before shipment

. A ll sample container closures will be taped

to ensure against sample leakage during shipment

. The frequency of performance of specific

activities for this stack testing is presented in Table 5

- 4.

5.4.2 Procedures for Analytical Quality Control

A regime of analytical QA/QC is specified in the QAPjP

. The procedures will use various

checks to determine the validity of analyses

. These include:

Calibration standards;

Certified standards;

In

- lab standards;

Blanks;

Spikes; and

Replicates.

QA begins with the sam ple log and continues through the reporting of data

. The unique

identifying number assigned in the field and recorded in the sample log facilitates tracking and

identification and prevents mix

- ups during the analysis process

. Chain

- of

- custody reports will be

used to monitor samples through analytical laboratories.

Chemical characterization of emission and process samples will be performed using

standard wet

- chemistry , IC, ICPES, AAS, and GC/MS techniques

. The accuracy and precision of

analyses will be docu mented through the QA/QC programs specified in the QAPjP

. Accuracy

will be evaluated by analyzing standards and blank and spiked samples

. Precision data will be

reported for matrix spike duplicates, analytical duplicate samples, and surrogate spikes.

## Appendix A

Continuous Monitoring System

Performance Evaluation Test Plan