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### DEPARTMENT OF ENVIRONMENTAL QUALITY DMSION OF AIR QUALITY
:-':onnan H. Bangerter Governor. Kenneth L. Alkema ExecutIve Director 1950 West Norm Temole Salt lake C,:y. U:ar, "<eoly:o State 0: L.;tan Dl\fJS10.'"1 of AIr**Q~ailty** F. Burneil Cordner (801) 536·4000 Deoartmem 01 EnVIronmental**Q~a:lry** Director (801) 536-4099 Fax Sal,laKE City. L.;tan 8411 ':-4820
DAQE-4l6-92 April 28, 1992

James R. Van Orman Director of Environmental Hanagement Department of the Air Force Hill A.F.B., Utah 84056-5990

Re: Approval Order for**Indus~rial** Wastewater Treatment Plant Sludge Dryers, Building 577 Davis County CDS Al NA

Dear Hr. Van Orman:

The above-referenced project has been evaluated and found to be consistent with the requirements of the Utah Air Conservation Rules (UACR) and the Utah Air Conservation Act. A 30-day public comment period was held and all comments received were evaluated. The conditions of this Approval Order (AO) reflect any changes to the proposed conditions which resulted from the evaluation of the**commen~s** received. This air quality AO**au~horizes** the project with the following conditions and failure to comply with any of the conditions may constitute a violation of this order: 1. Hill Air Force Base, shall install and operate the Industrial Wastewater Treatment Plant Sludge Dryers in Building 577 according to the information submitted in the Notice of Intent dated September 4, 1991. A copy of this AO shall be posted on site and shall be available to the employees who operate the air emission producing equipment. All employees who operate the air emission producing equipment shall redeive instruction as to their responsibilities in operating the equipment in compliance with all of the relevant conditions.



### 4.2.4-713

# - Mr. Van Orman April 2B, 1992 Page 2

2. The approved inst:allations shall consist of the following equipment: A. Two JWI Metal**Hydrox~de** Sludge Volume Reducers Model: J360G Heat source: Natural gas Burner rating: 400,000 BTU/hr Gas consumption: 400 CFH B. Two JWI single speed wet venturi scrubbers Scrubber water usage: 3 GPM Dry gas: 79.93 SCFM Humidity: 51\ Saturation Temp: IB4°F Discharge Volume: 293 ACFM 3. Emissions to the atmosphere of NOx from the sludge dryer exhaust stacks shall not exceed the following rates and concentrations: A. 200 ppmdv (7\ oxygen, dry) B. 0.47 lb/hr (per st:ack) 4. Stack testing to show compliance with the emission limitations in condition #3 shall be performed as specified below: Emission Point Pollutant Testing Retest Status Dryer exhaust stacks 

## s *** Testing Status (To be applied above) § The stacks shall be tested for NOx emissions compliance within 30 days of start-up using a portable testing instrument approved by the Executive Secretary *** The dryer stacks shall be retest:ed every 30 dryer operating days ± 10 days. The maximum time between tests shall be 35 dryer operating days. 5. Test Procedure Dryer stack emissions testing shall be performed by the following procedure or an approved equivalent. Equivalency shall be determined by the Executive Secretary and approved prior to tests being

.-... conducted. 

### 4.2.4-714","-

Mr. Van Orman April 28, 1992 Page 3

A.

- Sample Port A sampling port shall be installed in each dryer exhaust stack in accordance with 40 CFR 60, Appendix 8, Performance Specification #2 or as approved by the Executive Secretary. The sample ports shall be safely accessible to the tester, operator, or inspector in accordance with OSHA standards. 8.

- Operating Rate The steam production or operating rate during testing shall be performed under three operating rates; 90%, 70\ and 50\ (all ±10\) of the dryers' rated capacities. C.

- Test Instrument The test procedure shall be conducted using a portable testing instrument approved by the Executive Secretary. The testing instrument shall be calibrated on site with a suitable N8S referenced or traceable calibration gas in accordance with the instruction of the test instrument. D.

- Test Procedure The test shall be conducted in the following manner: (1) The dryers shall be: a) operated at the designated production rate .­ Condition #58 b) allowed to stabilize for a minimum of 5 minutes. (2) The gas sample shall be drawn according to the instructions of the test instrument being used. (3) The sample value shall be determined from the test instrument, appropriate calculations made, and the data recorded. E.

- Failed Dryer Status (1 ) If a dryer is unable to attain the emission limitation in Condition #3, at anyone of the operating**~ates** specified in condition #58, the dryer shall be taken out of service until the unit has been repaired or maintenance performed and a successful retest completed. 

### 4.2.4-715Mr. Van Orman April 28, 1992 Page 4

(2 ) Maintenance and repairs of any dryer that fails the periodical test shall be performed within 15 days, or dryer shall be idled. the
a) If a dryer that has failed a test is repaired and successful retest completed according to the limitations of Condition 13 within 15 days, the dryer shall be determined to not have been in violation. a

b) A dryer that fails the retest after repair shall be idled until further repairs are made and a successful retest completed. If the dryer demand requires the dryer to be operated, it shall be base loaded at the rate that will result in the lowest emissions rate possible until the dryer can be repaired and shown in compliance by the above test. c) Operation of a dryer that "retest after repair" may violation of this AO. has failed the above be determined to be a 

# -. F.

- Reports A copy of all test reports containing the test results, any calculations required, and the test instrument calibration data shall be retained by the owner/operator for two years. The reports shall be made available to the Executive Secretary or his agent upon request. An annual summary report of all the test results with a 

## --_..**-~ ~~~** **_c_;_~'_~l** 

## -n----_**e~~"** be submitted to the Executive Secretary no later**~..** _,anuary.)l of each year for the previous calendar year. 6. Visible emissions from any point or fugitive emission source associated with the installation or control facilities in this NOI shall not exceed 10% ooacitv. Opacity observations of emissions from stationary sources shall be conducted in accordance with 40 CFR 60, Appendix A, Method 9. 7. The owner/operator shall use only natural gas as a primary fuel in the two sludge dryers located in Building 577. If any other fuel is to be used, an AO shall be required in accordance with R307-l-3.l, UAC. 8. All records referenced in**~his** AO or in an applicable NSPS or NESHAPS, which are required to be kept by the owner/operator, shall be made available to the Executive Secretary or his representative upon request. 

### 4.2.4-716Mr. Van Orman April 28, 1992 Page 5

9. All installations and facilities authorized by this AO shall be adequately and properly maintained.**~he** owner/operator shall comply with R307-1-3.5 and 4.7, UAC. R307-1-3.5, UAC addresses emission inventory reporting requirements. R307-1-4.7, UAC addresses unavoidable breakdown reporting requirements. The owner/operator shall calculate/estimate the excess emissions whenever a breakdown occurs. The sum total of excess emissions shall be reported to the Executive Secretary for each calendar year no later than January 31 of the following year. le.**Th~ Execu~ive**  Secretary shall be notified in writing upon start-up of the installation, as an initial compliance inspection is required. Eighteen months from the date of this AO the Executive Secretary shall be notified in writing of the status of installation if installation is not completed. At that time the Executive Secretary shall require documentation of the continuous installation of the operation and may revoke the AO in accordance with R307-l-3.l.5, UAC. Any future modifications to the equipment approved by this order must also be approved in accordance with R307-l-3.l.1, UAC. This AO in no way releases the owner or operator from any liability for compliance with all other applicable federal, state, and local regulations including the Utah Air Conservation Rules. Annual emissions for this source (the wastewater treatment plant sludge dryers in building 577) are currently calculated at the following values: A. 1.026 tons/yr for Particulate B. 0.453 tons/yr for PH 10 

### c. 0.002 tons/yr for 502 D. 2.050 tons/yr for NOx E. 1. 328 tons/yr for VOC F. 0.149 tons/yr for CO These calculations are for the purposes of determining the applicability of PSD and**nona~tainment** area major source requirements of the UACR. Sincerely, : ! . 

### \'/;1 1,-: 1 ; r 

### J.**!/~Ll,l;rl** "­
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## l'\ '
" F. Burnell Cordner, Executive Secretary Utah Air Quality Board FBC:HGN:cl

cc: EPA Region VIII, Hike Owens Davis County Health Department 4.2.4-717

### UTAH DIVISION OF AIR QUALITY NEW/MODIFIED SOURCE PLAN REVIEW James R. Van Orman Director of Environmental Management Department of the Air Force Hill A.F.B .• Utah 84056-5990
RE: Industrial Wastewater Treatment Plant Sludge Dryers, Building 577 Davis County CDS Al NA ENGINEER: Herman G. Nellestein DATE: February 12, 1992 NOTICE OF INTENT DATED: September 4, 

### 1991 PLANT CONTACT: Jay Guptc. PHONE NUMBER: (801) 777-6917 PLANT LOCATION: Building 577, Hill Air ?orce Base, Utah FEES: Filing Fee S 1500.00 

### Review Engineer

- XX hours at SSO.OO/hour S 0.00 Modeler

- 00 hours at SSO.OO/hour S 000.00 Computer Usage Fee S 000.00 Notice to Paper S 00.00 Travel

- 00 miles at SO.23/mile S 

### 000.00 Total S 

### 1500.00 APPROVALS: Engineering Unit Manager

# ~~~~/~~_·~\----~~~--~/-·~----~;r--~--~-~------- Applicant Contact Made 

# 81\

1 

### 4.2.4-718T 

## .... NSPS

- NO PSD

- NO**~ESHAPS** -**~O** TOXICS

- NO TITLE V

- NO TOXIC MAJOR

- NO NONATT MAJOR

- NO DESCRIPTION OF PROPOSAL Hill AFB has submitted a Notice of Intent dated September 4, 1991 to replace two electric batch sludge dryers in Building 577. These dryers were not permitted. The replacement dryers are**conti~uous** natural gas fired sludge dryers. The purpose of the sludge dryers is to process the wastewater produced throughout the base, remove the water, and compact the sludge. Sludge from the Industrial Wastewater Treatment Plant Clarifier is pumped to sludge holding tanks in sludge drying Building 577. Raw sludge is treated with lime and pumped to a filter press for dewatering to 70 percent solids. Dewatered sludge is then fed to a sludge dryer feed hopper via a dump trolley. Sludge is dried to 5 - 107. moisture in two JWI Hodel J360G continuous moving belt gas fired sludge dryers at a temperature of about 550°F. Dried granular sludge is emptied into a dumpster via a screw conveyor for disposal. The dried sludge is disposed by an outside vendor at a proper disposal site. Off gas from the dryers is treated in venturi scrubbers before being exhausted to the atmosphere. The scrubbers are 95

- 98% effective in removing emissions. Manufacturers' bulletins on dryers are contained in the NOI. II. EMISSION SUMMARY The emissions from this source (sludge dryers) will be as follows: Total Emissions Particulate 1.026 ton/yr PM 10 0.453 S02 0.002 NO,;: 2.050 CO 0.149 VOC non meth 1.328 VOC meth 0.001 Metals 0.131 III. BEST AVAILABLE CONTROL TECHNOLOGY (BACT) ANALYSIS HAFB has chosen to use natural gas to supply heat in the dryers. The dryers are to be equipped with**~igh** efficiency venturi impactor scrubbers and cyclonic separators. Removal efficiency of 95

- 98% is achieved with 6 - 8 inches water column pressure drop across**:~e** scrubber. Specifications of the scrubbers are as fo:lows: Dry gas: 79.93 SCFM Humidity: 51%
2 4.2.4-719Saturation Temp.: Discharge Volume:
Two stacks each eight inches in diameter will exhaust approximately 300 acfm. The point of discharge is approximately 30 feet above grade. There are no sampling points provided. Normally, dryers are operated during the day shift. However, in the event of sludge back-up, they may be operated in other shifts. All emission calculations were based on 24 hour-per-day operations. No other systems were investigated. The selected system, operating on natural gas and the use of venturi scrubbers is considered BACT by HAFB. The Engineering Section recommends the following limits as BACT: A. 10% opacity B. NOx - ZOO ppm (7% oxygen dry) IV. APPLICABILITY OF FEDERAL AND**UT~q** AIR CONSERVATION RULES (UACRl This Notice of Intent is for a minor modi:ication of a major source. It is not a new major source or a major modification. The following federal regulations and state rules have been examined to determine their applicability to this Notice of Intent: 1. R-446-1-3.1

- Notice of Intent required for a modified source. This rule applies. 2. R-446-1-3.1.7 (a)

- Notice of Intent not required for fuel burning equipment with a rated capacity of less than 5 x 106 BTU per hour using no other fuel than natural gas. This rule does not apply to sludge dryers even if fired by natural gas. 3. R-446-1-3.1.8(A)

- Application of best available control technology (BACT) required at all**emissio~** points. This rule applies. 4. R-446-1-3.1.8(D)

- Enforceable offset of 1.2:1 required for new sources or modifications which would produce an emission increase greater than or equal to 50.00 tons per year of any combination of PM 10 , S02' and NOx ' This is required in Salt Lake, Davis, and Utah Counties and in any area that impacts these three counties as defined in the rule. The effective date is November 15, 1990. This rule will not apply to this NOI. 5. R-446-1-3.1.8(D)

- Enforceable offset of 1:1 required for new sources or modifications which would produce an emission increase greater than or equal to 25.00 tons per year of any combination of PM 10 ' 502' and NOx ' This is required in Salt Lake, Davis, and Utah :ounties and in any area that impacts these three counties as defined in the rule. The effective date is November 15, 1990. This rule will not apply to this NOI. 3 

### 4.2.4-7206. R-446-1-3.1.9

- Rules for relocation of temporary sources. This source is a permanent source. Therefore, this rule does not apply. 7. R-446-1-3.1.12

- Requirement for installation of low-NOx burners on all existing sources whenever existing fuel combustion burners are replaced, unless the replacement is not physically practical or cost effective. The effective date is November 15, 1990. This rule applies.**~owever, ~~sLalla~ion**  may not be COSL effecLive. 8. R-446-1-3.2.1

- Particulate emission limitations for existing sources which are located in a nonattainment area. This rule has been superseded by the PM 10 SIP, except for Weber County. The effective date is August 14, 1991. The sources listed in Weber County are as follows: A. Farmers Grain Coop B. Fife Rock Products C. Interpace Corporation D. Parsons Asphalt Plant E. Pillsbury Company F. Teledyne Incinerator G. Gibbons and Reed Asphal: HAFB is not listed in the SIP. This rule does not apply. 9. R-446-1-3.3.2

- Review requirements for new major sources or major modifications which are located in a nonattainment area or which impact a nonattainment area. This Notice of Intent does not represent a new major source or a major modification. Therefore, this rule will not apply. 10. R-446-1-3.5

- Emission inventory reporting requirements. This rule requires any source which emits 25 tons or more per year of any pollutant to submit an emission inventory to the Division of Air Quality at least every third year or as determined necessary by the Executive Secretary. This source does not emit 25 tons per year of any pollutant. Therefore, HAFB must comply with this rule. 11. R-446-1-3.6.3

- PSD Increment Consumption

- This rule lists the allowable PSD increment consumption. Under the PSD rules, the entire state has been Lriggered for TSP, S02' and NO ' The x allowable increments are 2S**~ollows:** TSP A. Class I areas 1) 5**~g/m3** (annual) 2) 10**~g/m3** (24 hour)

4 4.2.4-721B. Class II areas 1) 19**~g/m3** (annual) 2) 37**~g/m3** (24 hour)

A. Class I areas 1) 2**~g/m3** (annual) 2) 5**~g/m3** (24 hour) 3 ) 25**~g/m3** (3 hour) 

### B. Class II areas 1) 20 f.Lg/m3 (annual) 2) 91 f.Lg/m3 (24 hour) 3 ) 512**~g/m3** (3 hour)

A. Class I areas - 2.5 f.Lg/m3 (annual) B. Class**~I** areas - 25 f.Lg/m3 (annual) There are also Class III increments, which do not apply in Utah. The above increments apply at all locations, unless the area is already nonattainment. The entire increment may not be available at all locations due to previously permitted sources consuming increment. 12. R-446-1-3.6.5(b)

- Prevention of significant deterioration (PSD) review requirements for new major sources or major modifications. This Notice of Intent does not represent a new major source or a major modification under PSD rules. Therefore, this rule does not apply. 13. R-446-1-3.6.6 Increment violations. This rule requires the DACC· to promulgate a plan and implement rules to eliminate any PSD increment violations which occur in the sLate. No known violations have yet occurred. These sludge dryers will consume no increment. They are existing (they are being replaced) but were never approved. 14. R-446-l-3.8

- Stack height rule. This rule limiLS the creditable height of SLacks to that height determined to be good engineering practice. The formulas used to determine good engineering practice are found in 40 CFR 51.100. A deminimus height of 65 meters (213.2 feet) is allowed. Building 577, Hill AFB, has no stacks which exceed 65 meters in height. It is in compliance with this rule.

5 4.2.4-72215. R-446-1-3.11

-**Visibili~y** screening analysis requirements. This rule requires all new major sources or major modifications to undergo a visibility screening analysis to determine visibility impact on any mandatory Class area. This Notice of Intent does**~ot** represent a new major source or a major modification under UACR rules. Therefore, this rule does not apply. 16. R-446-1-4.1.2

- 20% opacity limitation at all emission points unless a more**stringeD~** :imitctiou is required by New Source Performance Standards**(~SPS)** or BACT or National Emission Standards for Hazardous Air Pollutants (NESHAPS). In this case an opacity limitation of 15% is recommended as BACT. 17. R-446-1-4.1.9

- EPA Method 9 to be used for visible emission observations. This rule applies. 18. R-446-1-4.2.1

- Sulfur content limitations in oil and coal used for combustion. This emission point does not use oil or coal for combustion. This rule does not apply. 19. R-446-1-4.6

-**Conti~~ous** Emission Monitoring Systems Program

­ Reporting and technical requirements for continuous emission monitoring systems. :t covers breakdowns and quarterly**repor~s** for continuous monitoring systems. Section 4.6.5 states that this regulation applies to the following: A. Sources required to install CEMS as required by the following documents; 1) NSPS 2) State Implementation Plan 3) Approval Order 4) Consent Decree 5) Administrative Orders and Agreements B. Any source that constructs after the promulgation of this rule two or more emission points, which may interfere with VEO's, shall install an opacity monitor on each stack. 20. R-446-1-4.7

- Unavoidable jreakdown**repor~ing** requirements. This rule applies. Section 4.7.1**disc~sses** repor·:-:, -equirements. A breakdown for any period longer t;-,an 2 hours rr,l..';;

... be reported to the Executive Secretary within 3 hours of the beginning of the breakdown, if reasonable. but ir. no case longer than 18 hours after the beginning of the breakdown. A written report is required within 7 calendar days. The report shall include the estimated quantity of pollutants (total and excess). Section 4.7.2 discusses penalties. 21. R-446-1-4.9

- Review requirements for**vola~i1e** organic compound (VOC) sources located ir. a**r.or.attai~~ent** area for ozone constructed in 1980 or earlier. This process is not covered in
6 

### 4.2.4-723:-- ... _ ........ .. I..:.. 22. R-446-1-5 Emergency episode requirements. This rule applies. 23. R-446-1-7

- Air Pollution Episode Plan

- This plan provides the basis for taking action to prevent air**pollu~ant** concentrations from reaching levels which could endanger the public health. or to abate such concentrations should they occur. All sources in a**:.o:-.c.':.~o.i.u,men'':'** &:-ea 0:- impact.::'

...:, c.**nonat~ainment.** c.l'c.:i ::'l'

... st submit 3. plan outlining what they will do in an emergency episode. This regulation applies to Salt Lake, Davis, and Utah Counties. 24. New Source Performance Standards (NSPS)

- There is no NSPS for this industrial process. 25. National Emission Standards for Hazardous Air Pollutants (NESHAPS)

- There is no NESHAPS for this indust.rial process. 26. National Ambient Air Quality Standards (NAAQS)

- This source is locat.ed in Davis County, which is a nonattainment area for ozone. The Division of Air Quality guidelines do**no~** call for this source to be modeled for any pollutant. The Division has found through experience that, because of the small quantity of emissions involved and the conservative predictions made by modeling, a source or emission point of this small size is very unlikely to cause a new violation of the NAAQS. 27. 40 CFR 60.14, Definition of Modification

- Any physical or operational change to an existing facility which results in an increase in the emission rate to the atmosphere of any pollutant to which an NSPS standard applies. The following are not by themselves considered modifications: 1) Maintenance, repair, and replacement 2) An increase in'production rate of an existing facility, if that increase can be accomplished without a capital expenditure on that facility 3) An increase in the hours of operation 4) Use of an alternative fuel or raw material if, prior t.o the date any standard under this part becomes applicable to that source type, as provided by 60.1, t.he existing facility was designed to accommodate chat alternative use S) The addition or use of any system or device whose primary function is the reduction of air pollutants 6) Relocation or change in ownership Also see Section 1.92, which is the State's definition. It is a 7 

### 4,2.4-72428. 40 CFR 60.15, Definition of Reconstruction

- the replacement of components of an existing facility to such an extent that: 1) The fixed capital cost of the new components exceeds 50% of the fixed capital cost that would be required to construct a comparable entirely new facility and 2) It is technologically and economically feasible to meet the applicable standards set forth in this part This Notice of Intent is not a reconstruction. 29. R-446-1-1.89, Definition of Maior Modification

- It means any physical change in or change in the method of operation of a major source that would result in a significant net emission increase of any pollutant. A net emissions increase that is significant**fo~** VOC shall be considered significant for ozone. A physical change or change in the method of operation shall not include: A. Routine maintenance, repair, or replacement B. Use of an alternative fuel or raw material by reason of an order under Section 2a and b of the ESECA of 1974 or by reason of a natural gas curtailment plan pursuant to the Federal Power Act C. Use of an alternative fuel by reason of an order**unde~** Section 125 of the CAA D. Use of an alternative fuel at a steam generating unit to the extent that the fuel is generated from municipal solid waste E. Use of an alternative fuel or raw material by a source: 1) which the source was capable of accommodating before January 6, 1975, unless such change would be prohibited under any enforceable permit condition 2) which the source is otherwise approved to use F. An increase in the hours of operation or the production**~ate** unless such change woule be prohibited under any enforceable permit condition G. Any change in ownership at a source This Notice of Intent is not a**majo~** modification. V. RECOMMENDED APPROVAL ORDER CONDITIONS

8 

### 4.2.4-725**~. ~~_~~** **nl~ &~~~c** **D~S~, saa~~** **lns~~~~** ana**op~ra~~ ~Ll~**  Industrial Wastewater Treatment Plant Sludge Dryers in Building 577 according to the information submitted in the Notice of Intent dated September 4, 1991. A copy of this Approval Order shall be posted on site and shall be available to the employees who operate the air emission producing equipment. All employees who operate the air emission**projuci~.g** eq'.lip:ne::.t shaLe :",,-<::':-v,,,**~~,,;~ru-..:~_v** .. as to their responsibilities in operating the equipment in compliance with all of the relevant conditions. 2. The approved installations shall consist of the following equipment: A. Two JWI Metal Hydroxide Sludge Volume Reducers Model: J360G Heat source: Natural gas Burner rating: 400,000 BTU Gas consumption: 400 

### CFH B. Two JWI single speed wet venturi scrubbers Scrubber water usage: 3 GPM Dry gas: 79.93 

## scm Humidity: 51% Saturation Temp: 184 of Discharge Volume: 293 ACFM 3. Emissions to the atmosphere of NO from the sludge dryer x exhaust stacks shall not exceed the following rates and concentrations: A. 200 ppmdv (7% oxygen. dry) B. 0.47 lb/hr 4. Stack testing to show compliance with the emission limitations of condition 83 shall be performed as specified below: Emission Point Pollutant Testing Retest Status Dryer exhaust stacks § 

### *** Testing Status (To be applied above) § The stack shall be tested for NOx emissions compliance within 30 days of start-up using a portable testing instrument approved by the
9 

### 4.2.4-726Executive Secretary 

## *** The dryer stack shall be retested every 30 dryer operating days ± 10 days. The maximum time between tests shall be 35 dryer operation days. 5. Test Procedure**~ryer s~ack**  emissions testing shall be perrormed by**t~e** following procedure or an approved equivalent. Equivalency shall be determined by the Executive Secretary and approved prior to tests being conducted. A.

- Sample Port A sampling port shall be installed in each dryer exhaust stack in accordance with 40 CFR 60, Appendix B, Performance Specification #2 or as approved by the Executive Secretary. The sample port shall be safely accessible to the tester, operator or inspector**i~** accordance with OSHA standards. B.

- Operating Rate The steam production or operating rate during testing shall be performed under three operating rates; 90Z, 70Z and 50Z (all ±lOZ) of the dryer's rated capacity. C.

- Test Instrument The test procedure shall be conducted using a portable testing instrument approved by the Executive Secretary. The testing instrument shall be calibrated on site with a suitable NBS referenced or traceable calibration gas in accordance with the instruction of the test instrument. 

### D.

- Test Procedure The test shall be conducted in the following manner: (1) The dryer shall be: a) operated at the designated production rate in Condition S.B b) allowed to stabilize for a minimum of 5 minutes. (2) The gas sample shall be drawn according to the instructions of the test instrument being used. (3) The sample value shall be determined from the test instrument, appropriate calculations made, 10 

### 4.2.4-727and the daca recorded. E.

- Failed Dryer Status (1) If the dryer is unable to attain the emission limitation in Condition 93, at anyone of the operating rates specified in condition 

### sB, the dryer shall be taken out of service until the**~r:~L** has**b~=n** repaired or**mai2~~:~a~** __**~erfo=ms~** and a successful retest completed. (2) Maintenance and repairs of any dryer that fails the periodical test shall be performed within 15 days. or the dryer shall be idled. a) If a dryer that has failed a test is repaired and a successful retest completed according to the limitations of Condition 13 within 15 days, the dryer shall be determined to not have been in violation. b) A dryer thac fails the retesc after repair shall be idled until further repairs are made and a successful retest completed. If the dryer demand requires the dryer co be operated. it shall be base loaded at the rate that will result in the lowest

.. emissions rate possible**u~til** the dryer can be repaired and shown in compliance by the above test. c) Operation of a dryer that has failed the above "retest after repair" may be determined to be a violation of this Approval Order. F.

- Reports A copy of all test reports containing the test results, any calculations required. and che test instrument calibration data shall be retained by the owner/operator for 2 years. The reporcs shall be made available to the Executive Secretary or his agent upon request. An annual summary report of all the test results with a copy of the periodical reports shall be submitted to the Executive Secretary no later than January 31 of each year for the previous calendar year. 6. Visible emissions from any point or fugitive emission source associated with the installation or concrol facilities in**~his** NOI shall not exceed 10% opacicy. Opacicy observacions of emissions from stationary sources shall be conducted in 11 

### 4.2.4-728

### accordance with 40 CFR 60, Appendix A, Method 9. 7. The owner/operator shall use only natural gas as a primary fuel in the two sludge dryers located in Building 577. If any other fuel is to be used, an Approval Order shall be required in accordance with R446-1-3.1, UAC. 

### B. All records referenced in this Approval Order or in an the owner/operator, shall be made available to the Executive Secretary or his representative upon request. 9. All installations and facilities authorized by this Approval Order shall be adequately and properly maintained. 10. 

### The owner/operator shall comply with R446-1-3.5, UAC. Section 3.5 addresses emission inventory reporting requirements. 11. The owner/operator shall comply with R446-1-4.7, UAC. Section 4.7 addresses unavoidable breakdown reporting requirements. The owner/operator shall calculate/estimate the excess emissions whenever a breakdown occurs. The sum total of excess emissions shall be reported to the Executive Secretary for each calendar year**~o** 

### later than January 31 of the following year. 12. The Executive Secretary shall be notified in writing upon start-up of the installation, as an initial compliance inspection is required. Eighteen months from the date of this Approval Order the Executive Secretary shall be notified in writing of the status of installation if installation is not completed. At that time the Executive Secretary shall require documentation of the continuous installation of the operation and may revoke the Approval Order in accordance with R-446-l-3.1.5, UAC. Any future modifications to the equipment approved by this order must also be approved in accordance with R-446-1-3.1.1, UAC. This Approval Order in no way releases the owner or operator from any liability for compliance with all other applicable federal. state, and local regulations including the Utah Air Conservation Rules. Annual emissions for this source (the wastewater treatment plant sludge dryers in building 577) are currently calculated at the following values: A. 1.026 tons/yr for Particulate B. 0.453 

### tons/yr for PM 10 

## c. 0.002 tons/yr for S02 D. 2.050 

### tons/yr for NOx 

### 12 4.2.4-729

### E. 1.328 tons/yr for VOC F. 0.149 

### tons/yr for CO These calculations are for the purposes of determining the**applicabil~ty** 

### of PSD and nonattainment area major source requirements of the UACR. K:\

...\DUTCH\WP\HILL577A.RVW**o~**

13 

### 4.2.4-730

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### 4.2.4-733i**c~\** DEPARTMENT OF THE AIR FORCE RECEIVED HEADQUARTERS OGDEN AIR LOGISTICS CENTER (AFLCl HILL AIR FORCE BASE, UTAH 84056-5990 

## SEP 'O,6J991 4 SEP 1991

# Al~~;' J Mr 

### F. Burnell Cordner, Executive Secretary Department of Environmental Quality Division of Air Quality 1950 W North Temple Salt Lake City UT 84114-4820**Re~** 

### Notice of Intent to Construct Industrial Wastewater Treatment Plant Sludge Dryers, Bldg 577 Dear Mr Cordner Building 577 had two electric batch sludge dryers. These sources were not permitted. We replaced these electric dryers with continuous gas fired sludge dryers. Technical information and emission rates from these dryers is attached. If this office can provide additional information, please cfeel free to contact Jay Gupta at 777 6917.



### JAMES R. VAN ORMAN 1 Atch 

### Director 01 Environmental Management Notice of Intent to Construct

4.2.4-734 

# A:::'C- COMBAT STRENGTH THROUGH LOGISTICS

### NOTICE OF INTENT TO CONSTRUCT 

### 1. PROJECT DESCRIPTION: Sludge from the Industrial Wastewater Treatment Plant Clarifier is pumped to sludge holding tanks in sludge drying building 577. Raw sludge is treated with lime and pumped to filter press for dewatering to 70 percent solids. Dewatered sludge is then fed to sludge dryers feed hoppers via a dump trolley. $ludge is dried to 5-10 percent moisture in JWI Model J360G continuous moving belt gas fired sludge dryers at a temperature of about -550°F. Dried granular sludge is emptied into a dumpster via a - sc-rew conveyor for disposal. There are two continuous gas fired sludge dryers. Off gas from the dryers**i~** 

### treated in venturi scrubbers before being exhausted to the atmosphere. Manufacturers' bulletin on dryers is Atch 1. Equipment schematic is Atch 2. 

### Design data and exhaust gas flow rate calculations are as follows: Data Each Dryer (Two Required) : working capacity

- water removal rate

- 188 

### Lbs/hr Heat source
- Gas Heat rate

- 400,000 BTU/hr Natural gas heating value

- 1,000 BTU/SCF Gas consumption

- 400 SCFH Operating temperature

- 550'-600 0

### F Water rate to Venturi Scrubber

- 2-4 

### GPM Water pressure
- 40-50 PSIG Venturi Scrubber pressure drop

- 5-8" 

## w.e. Exhaust Gas Flow Rate and Moisture Balance: Water evaporation rate

- 188 

### Lbs/hr Moisture content of sludge

- 30%

Filter Press Moisture content of sludge

- 5%

exiting dryer Water in wet sludge entering dryer

- 188 X 1.05 

# = 197.4 

### Lbs/hr Bone dry sludge

- 70/30 

### X 197.4 

### 460.6 Lbs/hr Wet sludge entering dryer

- 460.6 +**:97.~** 

### 658 Los**/:-.~** 

### Water in sludge leaving dryer

- 197.4

- 

### 188 9.4 

### Lbs/hr Sludge leaving dryer
- 460.6 + 9.4 = 

### 470 Lbs/hr 

### 4.2.4-735 

## r/

j 

### ::f

### Gas Volume Leaving Dryer: P, atmosphere - 12.42 PSiA Products of combustion from Natural Gas (15% excess air): Standard Volume

- Factor S X MM BTU/hr input X 1/60 Factor S for Natural Gas

- 11,990 Standard volume

- 11,990 X 0.4 X 1/60 

### = 79.93 SCFM Temperature correction

- (460 

### +**550)/~60** + 

### 60) = 1. 

### 942 Pressure correction - 1 + 

### (Altitude/1,000 

### X .0375) 

### - 1 + 

### (4,500/1,000 

### X .0375) 

## = 1.169

. Actual volume

- 79.93 

### X 1.942 

### X 1.169

- 181.4 ACFM @ 550

### o p, 

### 12.42 PSiA Evaporation

- 188 Lbs/hr

- 188 Lbs/hr 

### X Lb Mole/18.02 Lb X 

### 379 SCF/Lb Mole X 

### Hr/60 Min

- 65.9 SCFM Actual Volume

- 65.9 X 1.942 X 1.169 

## = 149.6 ACFM Total gas leaving dryer

- 181.4 + 

### 149.6 

## = 331 ACFM @ 

### 550°F, 12.42 PSiA Gas volume leaving Venturi Scrubber: Dry Gas

- 79.93 SCFM

- 79.93 SCF/Min X Lb Mole/ 379 SCF X 29 Lb/Lb Mole X 60 Min/hr

- 366.9 Lb/hr Inlet gas humidity (H)

- 188/366.9 

## = 0.51 Lb Water Vapor/Lb Dry Air Prom Pschyrometeric Chart 

### @

- 550°F H 

## = 0.51 Dry bulb temp Adiabatic Saturation temp (Tsat) Saturated Volume

- 48 cu ft/Lb dry air

- 48 X 366.9/60 

## = 293.5 ACFM Discharge Volume, each dryer: 293 ACFM @ 

### 184°F 2. AIR EMISSIONS: The plume comprises mostly of water vapor eV2.por2.'t.ed**=~Ol':\** 

### wet sludge. Some particulate**a~d** 

### hydrocarbon emissions may also be present. Emissions from natural gas combustion are negligible. Base upon vendor testing of the smaller dryer on metal hydroxide slUdge, a total particulate discharge of**O.O~2** 

### pounds per hour was observed. 4.2.4-736/ 

### Assuming carryover to be 1% of bone dry solids, particulate in air stream entering venturi

- 4.6 

### Lbs/hr Per vendor, venturi impactor scrubber

- 95-98% 

### efficiency Particulate emission rate 4.6 X .05 = 

### 0.23 

### Lb/hr PM-IO emission rate
- 0.1 

### Lb/hr From sludge composition, metals content
- 13% Metals emission rate - .23 X .13 

## = 0.03 

### Lb/hr Hydrocarbon emissions: Some hydrocarbon emissions may be present depending on oil and grease content of wet sludge. 

### A preliminary test of stack gas showed hydrocarbon concentration of approximately 

### 500 PPMV. EXhaust gas from each dryer

- 79.93 

### + 65.9 = 

### 145.83 SCFM 

### Hydrocarbon emission rate

- 500/106 

### X 145.83 = 

### .0729 SCFM 

### Hydrocarbon emissions

- .0729 

### X 16/379 

### X 60 

### (as methane)

- 0.18 

### Lb/hr These emission rates are estimates only. 

### 3. AIR CLEANING DEVICES: 

# r Particulate emissions will be controlled by venturi impactor scrubber and cyclonic separator. Removal efficiency of 95-98% 

### is achieved with 6-8" 

### W.C. 

### pressure drop across the scrubber. 4. 

### EMISSION POINTS: Two stacks each 8" 

### diameter will exhaust approximately 300 

### cubic feet per minute. Point of discharge is approximately 30 

### feet above grade. 5. 

### SAMPLING POINTS: No sampling points are provided. 6. 

### OPERATING SCHEDULE: Normally, dryers are operated during the day shift. However, in the event of sludge back-up, they may be operated in other shifts.

4.2.4-737

# •••••• Continuous J-MatesTM .••• The Final Step .-in Metal Hydroxide Sludge Volume Reduction

The J-Mate, byJWI. has beendesignedtotakeover wherefilter presses, vacuumfilters andcentrifuges leave off. Whilethese mechanical dewatering units can reduce sludgevolume by upto 20: 1, a substantial amount ofwater still remains in the material.TheJ-Mate units use gasorelectric infrared heatfor rapid, effectivewater removal which results in reducedsludgevolume

... changing the materialto a dry. granularform. The result is a furthervolume reduction ofabout 4: 1. Onefourththe wastevolume

... one fourth the handlingand disposal costs. So effective is the J-Mate.that6 month paybacks orepossible (dependingon local disposal costs).



### Features and Benefits: • Paybackwithin 6 months possible." • Designedspecificallyfor metal hydroxidesludge. • Installation flexibility. Simple loadingand unloading.

Noadditional labor required.

r -. '11vautomatic processingcycle. Minimaloperator ,- tion reqUired

. • ess steel construction ofall internalwetted partsin

. trig chamber. All other ports are carborl steel-sand ulasted, and polyurethaneprimedand pointed. • Ruggedly builtfor continuous use and longseNice life. • Sludge volume reduction ranges by a factorofabout

2:1 to.5:1 • Highlyefficient infrared heaters keep energy

costata minimum. • Available in either LP or natural gas.

Smaller modelsavailable in electric. • Extruded filter cakefor maximum weight and volume

reductionwith a minimum of BTU's. • No directflametorching matena/. • No material build uporclogging problems. • Electronic ignition used

... no pilot light. •All models includea stainless steel venturi-type wet

scrubbertomaintain high air quality.

•**A~l,j:::** oerlormonce is 0 fu"'CtlOr"l of IOCOI energy O:lC':: SOOSOi costs ona lnitlOI sludge sallas**co~cenrrOTlon** 

### The J·Press'fContinuousJ-Mate'Combination The J-Mate. used in conjunction with JWl's filter press (or other brand offilter oressesl orovides a caoobil'h;**t~** c-:o::;...::.s ;:; meta, hyoroxiae slurry bya rarlO ot SO: 1. E:ghty barrelsot slurry, fJiterec one dewatered In a tiller cress is redusee ::: 'our carrels offilter caKe. While this represents a substantial reduction In waSTe volume. even greater savings can be realized With a J-Mate Since 60 to80% of rem!";

.... material is still water. These four barrels of dewatered sludge. when proSE' rough theContinuousJ-Mate con befurther redUCed to only one Darrel

.. c- clular, moisturefree materialfor handlinganddisposal.The dumpster aceivingthe filter cakefromthe J-Press can also be usedto transfer and ( Ihe cake into the J-Mate. Ifdesiree. drums can be handled in a similar ",-- .;1. Thus. noadditional labor is neededforwaste disposal. Labor may even :>e reduced dueto thesmallervolumesof end product. one J\M Dewatenng combination

... an80: 1 reduction in your waste disposal :l:oblem c Eighty Borrels Filter Press Four Barrels 

### 4.2.4-739 Receiver Hepper: Includes cakebreaker bars WhiCh facilitates materialcontinually being fea to extruder loodlng System: Three mountinglocatlOf1S available. The optionalhyClraulicallyoperatedloodingsystem is designea to till theJ·Mate receiving hopperbyoufomaticoII, raisingandemptyingdrums ordumpsters. The drums or dumpsters are used to tronsportSludge from ttle mechanical dewatering devices to the ContinuousJ-Mate.

ExtruderSystem: Receives filtercake whiCh hasbeen brOken down bvthe bridge breakerIn fhe receiverhOpper The wIper blades force the sludge through holes In the stamless steeldrum. This prOduces pelleT-likeparticles with moximum surface orea lordrymg. The ex/rudeamatenalfoils onto 0 continuous sTamless steel mesh con· veyorforpassage undera se(Jes ofhighly eftlc/enrmfraredheatdrymg elementsHeaterOptions:Allenergyfordrying in IheJ·Mate comes from infraredhealmg elements. Heating energyopl,ons ore natural orLPgason allmodels wilh elec· Iric availableonModelsJ·120E. J·180EandJ·360E. Ambienfairis drown through thehealchamberbythe ton mountedon the outletatthe wetscruooer. The J-Mate heatcl1amberandscrubberareprotectedfrom higl1 temperalure levels byon exhaustOlftemperature monitor. Infraredheatis known 10 be the mostefficientsource ofheatavailable fordrying applications.

Stolnle$S Sleel Construction: Allinrernol parts In orymg cnomoerexoosed 10 wer sludge areSTeinless sleelforcorrosion res/slonce ona longservice Me.

Discharge System: As Ihe moleflOI reaches Ine deSlreo reduction Idryness}. the ary, granular materialis empTlee mToa oog. :;orrel or(Jumpsler fardtsposal



### Specifications A1r-Hondllno fqulpment: EveryJ·Mate umlis supplied wilh a Single speed, wetscrubber. Ail extloustoir tram the J-Mate enrers the scrubberwhere thepartIculate maNerIS combinedforremoval with onatomiZedstream atwoter. Thescruooer uses nomOying parts andutiliZes tl1e classic high-energy ventufl type scrubber design.**Stojnle~** steelconsfTucfion anO Slfr,ple design contlibules lolong·term. highlyreliobleseNlCe. A 1-2 GPMblawdownstream is over98% efficient! The blower. mountedon lop ofthe scrubber



## , 'AlOnc.,t'\Q cooocr.-.- ­ 

# ... 'NOter Rem?vOl ROle :It. remoyes solids 10 tl1e waste treormenlSYSTem. The scruboer package. provides0/1 atthe alfmovementthrough Ihe entireJ-Mote svstem Unit Includes:. HQPPel'. CakeBleaker • Extruder. Drive Gearmotor• Wet SCrubber [eXhaust ducting not included). Control Panel. Prewired with allOperational Controls. Infrared HeatChamber Mountedon Rugged Frome • Dried Sludge UnloadingChute. One(1) Copy ofon InstaliationlOperationlMaintenance Mon· ual .• Moving Stainless Steel Grating Type Ben Optional Equipment:. Dumpsters. Barrel Loader. DumpsterLooder. OneWay Disposable Bags. Optional Hydraulic Dumping Mechanismfor Dumpster. Special Hopper Designs andSizes • Custom Support Structures Availableto Elevate Filter Press for Direct Disposal intoJ-Mate.

J120G J12GE :::-'·:.,Gas : ..... .....eo· SOurce Gas ConlTol COnsole: Provides finger-tip controlatall J·Mote tunctions: includingextruderteedrate. dryingchaml:>erl:>eftrote, svstem on-offandmain disconnect.

Power ReoulremenTS

­**I~Clvall'~** Dump ur:·

'30\,306OCY 20A**:.~,,»** eo"'Y DUty, long lifeMotor: TE;C IncJuslflolmolor L8Qv 30 60CY lOA**~~~** :lOA

..**~:** :;. " , '" 65A 'ovldes years ofmomtenonce tree operalion.**::\~~ICHe-ol** ""IIO"

...**O~** 31.5KW Gas 5

..**Jfne~** Rcrilng 125.000fffiJ . 200.000 BTU



### .**..:'~** -.'

........ "200CfH ':;**.~CfH** Gcs**CO-.SoJ~OflOI"l lOO~**  14GPH ,,, UGI'H.· _.:3USPH



### -----. I SPIol Scruooer Drel;'"! 170" 170" 46" 46" 73' 78"**~Ig:"l~** ($:'1IDprng)**~Ncmc~LJ::)** 10.7 cu. ft. lO.7cu.ll 

### g.::.,;.**':""~~** 175 175**··';"~·i·** ·70" "78"**f,:'<~~tls.** r'--··- ..•.

MCllenciS 01 ConslfUC1<Cn' 304 SS CortlOn Slee\. PotY\l,etnone Mntsn J·Mote One Barrel

• $eMce 10 De eJe1f!rm.ne<1 OV lacel elecmcol coae reQulremenrs, "50sea on us"'g 2125 BTU 10 r.",ove 110 01 H,O BTU reoultemenrmeyvcryWirn mOlenaIS 

### 4.2.4-740 HOT:**.Io'OC'~9CZ5comD()"lelY5"COf':'l:-"MmFUOf'I(JlRrflliOUl1e.'NIf'7lS**

## __Figure your disposal costs and savings with these charts.



# _______________-=--

__

# 0

Annual Generation (Tons) $200.,.--,

## ----...------------,------r-------,
2:1

- l); $1**001-----+-----t---:7"!-:....---::::OO~__::7'<J/!!::--~,.;....:~---_:** 

### 8.. Weight 

## 6 Reduction Ratio ro ;:e**S50+-----~l""S~~;..rc::::-----+-----+-----i** C < 

### O+------I-------+----f------+------I 

### o S20 $40 $60 $80 $100 Annual Savings (SOOO)


# =-JII 

# r=z::n- - ,--.':

4.2.4-741 JWI, Inc. J2155 112th Ave. Holland, Michigan 49424 U.S.A. 616·m·9011 JFAX 61&-n2-4516 Printed In U.S.A. 1-800-245-3006 JWI 01 51905M 1200 1000 800 Use lOP figure to determine Annual Disoosal Costs. Bottom figure will show your annual savings with a J-Mat",.

600 Annual Disposal Costs

400 200 $250**H;-\--\--J~-~-:lk_----+----'------i---~** c $200**+-+-\--'\-l~....--~-~.---__+-----'------+-------1** iii o (,) $150**+-+-4----Jk--~*__+-....3oo",.---__+~...."...-----_+_-------"** ro III o lir $1 00**+-_-\--_~-~.,__~~-=** 

### __-+_-..=-d_---==-..l----.....; 

### o**$300rT..:.r,,:.....rT-r-T-..:r--....,..--------,---~---,..----- ')O+-----+----~----___+---,,£:-l--~---**  3:1 4:1 5:1

# --

RECOUUENDED EQJJST VENT USE 6" Ov... PIPE WITH

, 00- RECOUUENDED lDlGTIi Of" RUN. WIlH OPTlOH ONLY. (PIPE BY**CUSTO~ER** TO FURNISH SERVlCE IN ACCORDANCE APPUCf<.BLE lOCAl N-lD CODES. 

# j PIPING INSTAUATION

SCRUBBrn

OTHERS)

ELECTRICAL

WTTH NATIONAL 

## 1--------

----­ 10a.00



# '\J



# -

- 

# \ 

# I I**~~ ~~** 



# - - 1------------- 

# ­ 110..00­ 

## MODEL A 

## B C 

## D 

## E 

## F WORJOHG C!oPN:lr( fT.3

### /HR HOPPER \IOf...lJWE: (CUBIC Fm) 0f'1l0fW... HOPf'£R VOlJJWE wecHT (UlS.) 120**~.oo** 25.00 .'.00 31.00**~.OO** 30.00 1 - 1.5 10.7 24.7 3000 '180 52.00 31.00 47.00 37.00**~.OO** 311.00 1.5 - 3 13 2e 3700 3llO 52.00 48.00 102.00 SS.OO 

### eg.oo 54.00 3 - 6 17 33 4400


### 4.2.4-742

### ..J 

# I I**~O ~C~~,\'** **n.~!'!..f'Oott..V"-' .~"....,**  ..... ­ vv..... I t:R OR e.-AA£L WI'ni ONE OF THREE UOUIffiNG POSlTlONS AVAlL'BLE • NOTE: R)GHf twlO DU1lP

LOCATION HOT**AV~u:.** ON WOO€l. J-UATES.



### rs:

• MODElS J-120, J-1aO, &: J-360 8..ECTRlCAL CONSUMTlON (GAS FIRED) []RlV£ MOTORS 2.wJ.3PH.**~OV.** 3PH. 120 20AMPS 10Al,lPS UODEl...= 180 20AMPS 1 OAMPS 360 30AMPS 1SAMPS
El.£CTRIC HEAT MODELS (+SOV. 3PH.)

MODEL: 120: SOAMPS 180: 65AMPS**~INIMUM** CPS REQUIREMENTS (GAS FlRm ONLY) NATIJRAL GAS SUPPLY 0 

# r -2f!' W.C.

MODEl..; 120: 125 

## crn (125.000**EmJ~** 180: 200 CFH (200.000 BW 360: 400 CFH (4D0.000 BTU PROPANE CPS SUPPLY:

MODEl..; 120: 42 

## ern. 1.1 GPH lao: 68 CFH, 1.9 GPH 

### :':'C. ; 35 ":Fi-i. ...).1 CPH

114.00 llc.OO

-----;.--- IQ.OO**--~**

CONTlNUOUS J-
.... UE G.A. 

### 4.2.4-743 J-MATE 

### 9/89 10 

## AT£U-2