Veolia ES Technical Solutions MACT Performance Test Plan 

Revision: 0 

Date: May2008 

Section: Appendices 

Appendix C 

Isokinetic Sampling Train Setup and Recovery Schematics 

O:\mw97\PVq^\10002022Weotia Performance Test Plan U3 R2_052108.doc 

V E S 002629 
• \ 

iii i AECOM 

SAMPLE TRAIN SETUP 

MULTIMETALS 

(as Per EPA Method 29 / 0060) 

IMPINGERS -

1st empty * 

2nd - 100 mL 5% HN0 3 /10% H 2 O z 

3rd - 100 mL 5% HN0 3 /10% H 2 O z 

4th - empty 

5th - 100mL10%H 2 S O 4 /4%KMnO 4 

6th - 100 mL 10% H 2 S 0 4 / 4% KMnO„ 

7th Silica Gel 

FIELD BLANKS - (Exact Volumes Specified by Method) 

0.1 N HN03 - 300 mL 

5% HNOa /10% H 2 0 2 - 200 mL 

10% H 2 S 0 4 / 4% KMn04 - 100 mL 

Dl Water - 100 mL 

8 N HCI - 25 mL 

(added to 200 mL water) 

Filter - One unused filter 

* optional - used for high moisture stacks 

Q:taiw9nPrajertsU0002022lApperidi)i Call unils\[selupM60 xlsJHIMOIST 

V E S 002630 
AECOM 

NOZZLE 

Brush; 

0.1 N 

f-25r 

Rinse 

HNO 3 

nl) 3X 

PROBE 

Brush/ 

0.1 N 

f-50n 

Rinse 

HNO3 

nL(3X 

FRONT HALF 

FILTER HOUSING 

FILTER 

Brush/Rinse 

0.1 N HNO 3 

(~ 25 mL) 3X 

Carefully remove filter 

from support with Tefloncoated tweezers and place 

in petri dish 

250 mL Amber 

1 1 

Brush loose f. 

peti 

>articulate onto 

i dish 

FH - HNO3 

(2) 

Container 3 Seal petri dish with 

tape 

Notel: Exactly 100 mL of 0.1 N HN03 used 

for rinsing nozzle, probe and FH filter 

housing. 

Note 2: Nozzle, probe and FH filter housing 

are rinsed with water followed by acetone 

after the nitric acid rinse. The water and 

acetone are then discarded. 

Filter 

(D 

Container 1 

METHOD 29 (METALS) RECOVERY SCHEMATIC FRONT HALF RECOVERY 

Page 1 of 2 

J:\Air_Tox\Schematics\Recovery\M29FH.doc 

V ES 002631 
ENSR AECOM 

IMPINGERS 

FILTER SUPPORT AND 

BACK HALF OF 

FILTER HOUSING 

Rinse Three Times 

with 0.1 N Nitric Acid 

(Empty) 

(Optional) 

Measure Volume 

Empty the 

into Cc 

Contents 

ntainer 

Rinse Th 

with 0.1 N 

ree Times 

Nitric Acid 

Note: Exactly 100 mL of 

nitric acid is used to rinse 

all components up 

through impingers 1-3. 

2

n d

 and 3 M 

(HN03 /H2 02 ) 

Measure Volume 

Empty the 

Into Co 

Contents 

rtainer 

Rinse Thr 

with 0.1 N 

ae Times 

Nitric Acid 

• 

95Q mL 

BH 

(Container 4) 

4

m

 (Empty) 

5

th

 and 6"1 (KMn04) 

Measure Volume 

Empty the 

No. 4 Con 

Conti 

Impinger 

tents Into 

alner 

Rinse wit 

0.1 N 

h 100 mL 

HN03 

• 

250 mL 

0.1 N HNO 3 

(Container 5A) 

7 * 

(Silica Gel) 

Weigh for Moisture Discard 

Empty the Impinger 

Nos. 5 and 6 Contents 

into Container 

Rinse Three Times with 

Permanganate Reagent, (100 

mL total) then with Water 

(100 mL total) 

500 mL 

KMn04 

(Container 5B) 

Remove Any 

Residue with 25 

mL 8N HCI 

Solution 

250 mL 

8 N HCI 

(Container 5C) 

J:\Air Tox\Schematics\Recoverv\M29BH.doc METHO D 29 (METALS) RECOVER Y SCHEMATI C - BAC K HAL F RECOVER Y 

Page 2 of 2 
V E S 002633 
Prepared for 

Veolia ES Technical Solutions 

7 Mobile Avenue 

Sauget, IL 62201 

Metals Performance Test Plan Prepared 

for the Rotary Kiln Incinerator 

Number 4 in Accordance with 

40 CFR § 63 Subpart EEE 

ENSR Corporation 

May 2008 

Document No.: 10002-022 

ENSR 
Prepared for. 

Veolia ES Technical Solutions 

7 Mobile Avenue 

Sauget IL 62201 

Metals Performance Test Plan Prepared 

for the Rotary Kiln Incinerator 

Number 4 in Accordance with 

40 CFR § 63 Subpart EEE 

Reviewed By Craig Doolittle 

ENSR Corporation 

May 2008 

Document No.: 10002-022 

ENSR 
Revision: 0 

Date: May 2008 

Section: Table of Contents 

Veolia ES Technical Solutions Unit 4 HWC MACT Performance Test Plan Pageiofvi 

Contents 

1.0 Introduction 1 

1.1 Program Summary [40 CF R § 63.1207(f) and § 63.7(c)(2)(i)] 1 

1.2 Facility/Unit Identification 1 

1.2.1 General 1 

1.2.2 Facility ID, Mailing Address, and Primary Contacts 1 

1.2.3 Incinerator Overview 1 

1.3 Purpose and Objectives of the Performance Test 2 

1.3.1 General 2 

1.4 Performance Test Plan Organization 2 

2.0 Engineering Description - 1 

2.1 Process Overview 1 

2.2 Waste Feed Systems [40 CFR § 63.1207(f)(1)(ii)(c) and (f)(1XHi)(D) and (E)] 1 

2.2.1 Unit 4 Liquid Waste Feed System and Blending Operations 1 

2.3 Manufacturer, Make and Model of the Incinerator [40 CF R § 63.1207(f)(1)(iii)(A)] 2 

2.3.1 Combustion Chamber and Burners [40 CFR §63.1207(f)(1 p)(B) and (C) 2 

2.3.2 Secondary Combustion Chamber (SCC) 3 

2.3.3 Location of Combustion Zone Temperature Device [40 CFR §63.1207(f)(1 )(xix)] 4 

2.3.4 Hazardous Waste Residence Time [40 CFR §63.1207(f)( 1 )(ix)] 4 

2.3.5 Combustion System Leak 4 

2.3.6 Emergency Safety Vent 4 

2.4 Procedures for Rapidly Stopping Hazardous Waste Feed During Equipment Malfunction [40 CFR 

§63.1207(f)(1)(viii)] 5 

2.5 Air Pollution Control Equipment [40 CFR §63.1207(f)(1 )(iii)(G)] 5 

2.5.1 Air Pollution Control Systems Descriptions 5 

2.6 Stack Emissions Monitoring [40 CFR §63.1207(f){1)(iii)(H)] 8 

2.6.1 CE M System Description 8 

2.7 Process Monitoring and Control 9 

2.8 Automatic Waste Feed Cut-off System [40 CFR §63.1207(f)(1 )(ili)(F)] 9 

2.8.1 AWFCO System Testing 10 

2.9 Air Pollution Control Equipment Maintenance Practices [40 CF R §63.1207(f)(1)(iii)(G)] 10 

2.9.1 Program Overview 10 

2.9.2 Test Program Preparation Activities 11 

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3.0 Incinerator Feed Stream Descriptions „ : 1 

3.1 General , '. 1 

3.2 High Volume Wastes 1 

3.2.1 Liquid Wastes , - 1 

3.2.2 Bulk Solids '. 1 

3.2.3 Containerized Waste 1 

3.3 Auxiliary fuels 1 

4.0 Performance Test Protocol — « ~ 1 

4.1 General Description 1 

4.2 Performance Standards 1 

4.3 TestCondifions[40CFR§63.1207(f)(1)(vi)and(vii)] '. 1 

4.4 Waste Feed Spiking 1 

4.4.1 Inorganic Constituents 2 

4.4.2 Spiking for the LVM Category 2 

4.4.3 Spiking for the SVM Category 2 

4.4.4 Spiking for Mercury 2 

4.5 Metals Extrapolation Method '. 3 

4.6 Description, Preparation and Delivery of Feeds for the Performance Test [40 CFR § 63.1207 

(f)(1)(vi) and (vii)] 3 

4.7 Conditioning Time Needed to Reach Steady State [40 CFR§63.1207(f)(1)(xii)] 3 

4.8 Anticipated Test Schedule 3 

4.9 Performance Test Reporting : -, 4 

5.0 Sampling and Analytical Program Quality Assurance/Quality Control 1 

5.1 Title Page 2 

5.1.1 Project Title 2 

5.1.2 Expected Performance Test Date 2 

5.1.3 Project Approvals t 2 

5.2 Table of Contents 3 

5.3 Project Description 3 

5.4 Project Organization •• 3 

5.4.1 QA Officer's Responsibilities 3 

5.4.2 Laboratory Coordinator Responsibilities 3 

5.5 QA/QC Program Objectives 4 

5.5.1 Precision, Accuracy and Completeness , 4 

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Veolia ES Technical Solutions Unit 4 HWC MACT Performance Test Plan Page Si of vi 

5.5.2 Representativeness and Comparability 4 

5.5.3 Method Detection Limit (MDL) Determinations 5 

5.6 Sampling and Monitoring Procedures 5 

5.6.1 Reid Program Description 5 

5.6.2 Pre-sampling Activities 5 

5.6.3 Sampling Locations 7 

5.6.4 Waste Feed Stream Sampling Procedures 7 

5.6.5 Stack Sampling Methodologies *. 7 

5.7 Sample Handling, Traceability and Holding Times '. 8 

5.8 Analytical Methods and Calibration Procedures 9 

5.8.1 Analysis of Waste Feed Streams 9 

5.8.2 Analysis of Stack Gas Samples 9 

5.9 Internal QA Program 10 

5.9.1 Data Collection and Sampling Q C Procedures 10 

5.9.2 Analytical QC Procedures for Samples to be Analyzed in the Laboratory 11 

5.10 Data Reduction, Verification and Data Reporting 11 

5.10.1 Field Data Reduction 11 

5.10.2 Laboratory Analysis Data Reduction 12 

5.10.3 Data Verification •• 12 

5.10.4 Rnal Data Reporting 13 

5.11 Routine Maintenance Procedures and Schedules .-. 13 

5.11.1 Held Sampling Equipment 14 

5.11.2 Facility Equipment and Instrumentation 14 

5.12 QA/QC Assessment Procedures 14 

5.12.1 Accuracy 14 

5.12.2 Precision : , 15 

5.12.3 Completeness 15 

5.13 External QA Program 15 

5.13.1 Performance Audits 16 

5.13.2 Corrective Action 16 

5.13.3 Quality Assurance Reports to Management 17 

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Veolia ES Technical Solutions Unit 4HWC MACT Performance Test Plan Pageivofvi 

List of Appendices 

Appendix A Unit 4 Process Flow Diagram 

Appendix B Reid Data Sample Collection Forms 

Appendix C Isokinetic Sampling Train Setup and Recovery Schematics 

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Veolia ES Technical Solutions Unit 4 HWC MACT Performance Test Plan Page v of vi 

List of Tables 

Table 1-1 Summary of Applicable MACT Emission Standards 3 

Table 1 -2 Cross Reference of Perfonnance Test Requirements .'. -4 

Table 2-1 Veolia ES Technical Solutions - Continuous Emissions Monitors 8 

Table 2-2 Technical Information Summary on Incinerator No. 4 : ; 12 

Table 2-3 Current AWFCO Parameters and Limits for Incinerator No. 4 13 

Table 3-1 Top Volume Liquid Waste Streams .-. 2 

Table 3-2 Top Bulk Solid Waste Streams 2 

Table 3-3 Top Containerized Solid Waste Streams : 3 

Table 3-4 Summary of Major HAPs Processed : , 3 

Table 3-5 Typical Properties for Supplemental Fuel Oil 4 

Table 3-6 Typical Properties for Natural Gas 4 

Table 4-1 MACT OPLs to be Established During the Performance Test 5 

Table 4-2 Metals Evaluation Plan 6 

Table 4-3 Anticipated Metals Performance Test Schedule 7 

Table 5-1 General Sampling and Analytical Program Overview (Stack Exhaust) 19 

Table 5-2 QA Objectives for Field Measurements 20 

Table 5-3 Overall Summary of Perfomiance Test Stack Gas Sampling and Analysis Program 21 

Table 5-4 Traverse Point Locations 22 

Table 5-5 Sample Preservation and Holding Time Requirements 23 

Table 5-6 QA Requirements for Metals in Stack Gas by ICAP or ICP-MS 24 

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Section: Table of Contents 

Veolia ES Technical Solutions Unit 4 HWC MACT Perfonnance Test Plan Pageviofvi 

List of Figures 

Rgure 5-1 Stack Sampling Locations . : 25 

Rgure 5-2 Example Sample Packing List ; , 26 

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Section: 1.0 

Veolia ES Technical Solutions Unit 4 HWC MACT Performance Test Plan Page 1 of 5 

1.0 Introduction 

1.1 Program Summary [40 CFR § 63.1207(f) and § 63.7(c)(2)(i)] 

This document is the Metals Performance Test Plan for the rotary kiln Incinerator Number 4 operated by Veolia 

ES Technical Solutions (Veolia) at its Sauget, Illinois facility. Since the Veolia incinerator treats certain waste 

that are classified as hazardous under state and/or federal regulations, this unit is subject to the requirements 

of the HWC MACT Rule. 

This Plan has been prepared in accordance with requirements initially promulgated in NESHAPS: Final 

Standards for Hazardous Waste Air Pollutants for Hazardous Waste Combustors, (generally referred to 

as the Hazardous Waste Combustor [or "HWC"] MACT Rule). These regulations were initially published by 

US EPA on September 30,1999 in 40 CF R § 63 Subpart EEE. However, these initial regulations were 

vacated based on a DC Circuit Court ruling, were subsequently replaced by "Interim Standards" in February of 

2002 and then re-promulgated again in the Permanent Replacements Standards published in the Federal 

Register on October 12, 2005. 

This document addresses the requirements to develop and submit a Perfonnance Test Plan set forth in 40 

C F R § 63.1207. This Performance Test Plan is written to address all applicable Subpart EE E (and General 

Provisions) requirements incorporated into the regulations through promulgation ofthe Final Replacement 

Standards published in the Federal Register on October 12,2005. 

1.2 Facility/Unit Identification 

1.2.1 General 

As mentioned above, this Performance Test Plan has been developed to evaluate the rotary kiln incinerator 

Number 4 at the Veolia facility in Sauget, IL. This is a commercial hazardous waste incineration facility that 

treats liquid and solid wastes that are classified as both hazardous and non-hazardous. 

1.2.2 Facility ID, Mailing Address, 

The facility address is: 

Veolia ES Technical Solutions 

7 Mobile Avenue 

Sauget, IL 62201 

Facility ID#: ILD098642424 

Primary Contacts 

The facility contact is: 

Mr. Dave Klarich 

Phone: 361-572-2317 

Email: David.Klarich@veoliaes.com 

1.2.3 Incinerator Overview 

This incinerator is a rotary kiln incineration system with primary and secondary combustion chambers that 

treats solid wastes as well as aqueous and organic liquids. The process is monitored and controlled by a 

distributed control system (DCS) capable of continuously monitoring the process to assure all operational 

parameters are within regulatory and pemiit limits while waste is being fed to the unit. In addition, this 

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- Section: 1.0 

Veolia ES Technical Solutions Unit 4 HWC MACT Performance Test Plan Page 2 of 5 

incinerator is equipped with a Continuous Emissions Monitoring System (CEMS) that continuously samples 

the exhaust gases for oxygen and carbon monoxide in the stack gas exhaust stream. 

1.3 Purpose and Objectives of the Performance Test 

1.3.1 General 

The purpose of the performance test is to validate the performance level of the incinerator against the 

requirements in 40 CF R Part 63, Subpart EEE. To this end, the specific objectives of this performance test are 

to: 

• Demonstrate that the metals emissions from the incinerator meet the HWC MACT emission limits 

while treating hazardous waste for the parameters being tested. 

• Collect monitoring data in order to re-establish operating parameter limits (OPLs) or set new OPLs on 

key operating variables that will ensure that the incinerator operates within the HWC MACT emission 

limits while treating hazardous waste. 

• ' Utilize an extrapolation procedure, as appropriate, to establish metals feed rate limits. 

The performance test will include feeding a variety of liquid and solid waste materials to the incinerator, 

sampling and analyzing the feed streams, monitoring certain process parameters and conducting emissions 

testing. The emissions standards that will be evaluated under the HWC MACT regulations are summarized in 

Table 1-1. 

1.4 Performance Test Plan Organization 

This test plan has been organized in a format typically used for compliance demonstration test programs. 

Table 1-2 is included so that the performance test requirements in the HWC MACT rule can be crossreferenced with the sections in this Plan. The remainder ofthe document has been organized as follows: 

• Section 2.0 provides a general physical description of the rotary kiln incineration system and 

associated unit operations (including the air pollution control system) as well as an overview of the 

automatic waste feed cutoff (AWFCO) system and maintenance procedures. 

• Section 3.0 presents a brief discussion of the wastes to be treated in terms of physical and chemical 

parameters which impact thermal oxidation and summarizes the hazardous air pollutants presently 

identified in the waste streams. 

• Section 4.0 presents the Test Protocol including planned feed and test conditions, rationale for the 

test design, anticipated test schedule and final report format. 

• Section 5.0 fully describes all sampling and analysis procedures and associated QA/QC protocols 

following the latest EPA guidance. This section essentially serves as the Quality Assurance Project 

Plan (QAPP) for this project. 

The Appendices contain Process Flow Diagrams (Appendix A), examples of performance test field data 

sheets and test equipment calibration (Appendix B); and isokinetic sample train setup and recovery forms 

(Appendix C). 

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Table 1-1 Summary of Applicable MACT Emission Standards 

Emissions Parameter Limit Citation 

Mercury S 130 ug/dscm 40 CF R § 63.1219(a)(2) 

Semivolatile Metals (SVM) 

(Cadmium and Lead) 

< 230 (ig/dscm 40 CF R § 63.1219(a)(3) 

Low Volatile Metals (LVM) 

(Arsenic, Beryllium and Chromium) 

£ 92 ug/dscm 40 CF R § 63.1219(a)(4) 

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

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Table 1-2 Cross Reference of Performance Test Requirements 

Topic Regulatory Citation 

Section No. 

In this 

Document 

Program Summary 40 CFR § 63.1207(f) and § 63.7(c)(2Kf) 1.1 

Test schedule 40 CFR § 63.1207(f), (f)(1)M and 

§63.7(c)(2)(i) 

4.7 

Data Quality Objectives (DQOs) 40 CFR § 63.1207(f) and § 63.7(c)(2)(f) 5.5 

Internal and External Quality Assurance Plan 40 CFR § 63.1207(f) and § 63.7(c)(2)(f) 5.9 & 5.13 

Analysis of feedstreams (as fired) ' 

Heating value, ash content, semi-volatile metals, 

low volatile metals, mercury and total chlorine 

Viscosity 

Identification and quantification of reasonably 

expected HAPs 

40 CFR § 63.1207(f)(1)(f) 

40 CFR § 63.1207(f)(1)(i)(A) 

40 CFR § 63.1207(f)(1Xi)(B) 

40 CFR § 63.1207(f)(1)(ii)(A) & (B) 

3.0 

Detailed engineering description of combustor 

Manutacturer/make/model of HWC 

Type of HWC 

Maximum design capacity 

Feed systems 

Location of combustion zone temperature device 

Hazardous waste AWFCO system 

Design, operation and maintenance of APC 

Justification of alternative gas flow rate 

measurement technique 

Design, operation and maintenance of stack gas 

monitoring systems 

40 CFR § 63.1207(f)(1 )(iii)(A) 

40 CFR § 63.1207(0(1 )(iii)(B) 

40 CFR § 63.1207(0(1)(iii)(C) 

40 CFR § 63.1207(0(1 )(iii)P) & (E) 

40 CFR § 63.1207(0(1)(xix) 

40 CFR § 63.1207(0(1 )(iii)(F) 

40 CFR § 63.1207(f)(f)(iii)(G) 

40 CFR § 63.1207(f)(1)(xvii) 

40 CFR § 63.1207(0(1 )(iii)(H) 

2.0 

22. 

2.2 

2.2 

2.3 

2.2.6 

2.5.1 

2.4.11 

N/A 

2.6 

Description of Waste handling and blending Operations 4OCFR§63.12O7(0(1)(ii)(C) 2.3.5 

Detailed test protocol including: 

Description of sampling, monitoring and analytical 

procedures 

Description of Planned Feed and Operating 

conditions during the Performance Test 

40CFR§63.1207(0(1)(iv) 

40 CFR § 63.1207(0(1 )(vi) & (vii) 

5.6 & 5.8 

4.3,4.4 & 4.5 

Procedures for rapidly stopping hazardous waste feed 

and controlling emissions during malfunction 

40CFR§63.1207(0(1)(viii) 2.3.6 

Determination of hazardous waste residence time 40CFR§63.1207(0(1)(ix) 2.2.7 

Metal feed rate limit extrapolation (if used) 40CFR§63.1207(f)(1)(x) 4.4.2 

Documentation of expected levels of regulated 

constituents in other feed streams that are not analyzed 

40 CFR §63.1207(0(1)(») 3.0 

Documentation of conditioning time needed to reach 

steady state prior to testing 

40CFR§63.1207(0(1)(xii) 4.6 

Alternative monitoring frequency for wet scrubbers (if 

used) 

40 CFR § 63.1207(f)(1 )(xxiii) N/A 

Other information deemed necessary by the agency 40 CFR § 63.1207(0(1)(xxvii) -

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2.0 Engineering Description 

2.1 Process Overview 

Veolia operates 2 Fixed Hearth Dual Chambered Incinerators (Units 2 and 3) and one rotary kiln incinerator 

(Unit 4) at the Sauget, IL facility. The two fixed hearth units are rated at 16 million Btu/hr each. Incineration 

Unit No. 3 is a mirror image of Unit No. 2. Both of these units have their own waste handling systems as 

described in the sections that follow. The only difference being Unit No. 2 is equipped with four (4) baghouse 

modules, while Unit No. 3 is equipped with three (3) baghouse modules. However, each incinerator is 

operated identically with only three baghouse modules in service during operation. Unit 4 is rated at 50 million 

Btu/hr and is equipped with its own tank farm system, drum storage, bulk solids storage and feed systems. 

2.2 Waste Feed Systems [40 CFR § 63.1207(f)(1)(ii)(c) and (f)(1)(iii)(D) and (E)] 

2.2.1 Unit 4 Liquid Waste Feed System an d Blending Operations 

The Unit 4 Rotary Kiln can incinerate any of the waste that Veolia is authorized and permitted to receive. All 

physical forms of wastes will be handled and fed by the system's waste feed devices. Liquids will be fed to 

either the kiln or the Secondary Combustion Chamber (SCC). Bulk solid wastes will be fed to the kiln through 

either the ram feeder. Containerized wastes will be fed to the kiln through the ram feeder or the auxiliary ram 

feeder. This unit can receive any combination of wastes - liquid, semi-solid, or solid — with a heat value of up 

to 50 million Btu/hr. 

Unit 4 is supported by storage tanks located in Tank Farm #3. These tanks are used to store the liquid organic 

waste, aqueous wastes, and pumpable sludges to be fed to the system. Unlike Tank Farm #1, all of the tanks 

in Tank Farm #3 can be used as feed tanks to the incinerator. Several criteria are important in designing a 

blend from received wastes. These include compatibility, proper range of heating value, and permit 

restrictions regarding elemental composition (based on emission limitations). Pumps to transfer these wastes 

to the system are installed in the tank farm. The material is transferred through aboveground pipelines from 

the tank farm to the incinerator. Pipelines used to transfer liquid organic waste and aqueous waste are 

equipped with strainers. 

In compliance with the Benzene NESHAP, all tanks are vented to individual carbon adsorption canisters for 

removal of organics before vapor is discharged to the atmosphere. Each carbon adsorber canister is 

essentially equivalent to a 55 gallon container or greater, if necessary. All tanks are equipped with 

conservation vents, in addition to the carbon canister adsorber. All tanks are grounded, and flame arresters 

are installed between the carbon adsorbers and the tanks. 

2.2.1.1 Organic and Aqueous Liquid Waste Feeds 

The liquid waste injectors used in the combustion chambers are air-atomizing injectors. These are used for 

injection of pumpable sludges, aqueous wastes and organic liquid wastes to the kiln and for injection of 

organic liquid waste to the SCC . Dual fluid injection nozzles will be used for atomization of the waste. Each of 

the injectors is rated at 0-300 gph. The liquid waste feed nozzles are served by parallel redundant pumps and 

recirculation systems with back pressure control. 

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Veolia ES Technical Solutions Unit 4 HWC MACT Performance Test Plan Page 2 of 17 

2.2.12 Packaged and Bulk Solid .'. 

Containers of wastes are sampled and analyzed after receipt in accordance with the facility's Waste Analysis 

Plan. These wastes can then be delivered directly to Unit 4 orrepacked into small combustible containers at 

the facility. Repackaged containers are delivered to, and staged, in the Container Storage Unit No. 6 adjacent 

to the Unit 4 incinerator. When scheduled for feeding to the system, the containers of waste are transferred by 

forWrfts to the feed conveyors serving Unit 4. 

Bulk solids and non-pumpable wastes are delivered and discharged into waste feed, bins in the Bulk Solids 

Storage Building after being received, sampled, and analyzed. A clamshell operating from an overhead crane 

is used to transfer these wastes from the bins to the feed hoppers discharging to the system's ram feeder. 

The weigh hopper is equipped with weigh cells so each charge of waste can be weighed before it is 

discharged into the ram feeder. Fugitive emissions are controlled by a baghouse, cyclone, and carbon 

adsorption system connected to this system. 

The ram feeder is a 25-inch wide by 42 inch high (inside dimensions) rectangular tube operated by a 

hydraulically driven ram. The ram tube is equipped with a vertical, hydraulically operated charge door near the 

kiln end. This door is opened before the ram begins advancing to push a charge into the kiln. After the ram 

has fully retracted, a limit switch triggers the door to close so as to protect the ram feeder from the kiln's 

radiant heat. The ram is capable of operating from 0-30 cycles/hour. 

The top face of the ram feeder has a 2' x 2' opening which receives waste charges from the hopper. The ram 

feeder isolation gate, the charge door, and the ram operate in sequence. At the beginning of a cycle, the ram 

is fully retracted. On a "start" command from the operator or the programmable controller, the ram feeder 

isolation gate opens to receive a charge of waste from the hopper. The gate then closes, the charge door 

opens, and the ram begins its advance. Once the ram reaches its full extension, it begins to retract. When the 

ram is fully retracted, the charge door is closed and the.'cycle can be repeated. This system's sequenced 

operation combined with the negative pressure in the kiln prevent fugitive emissions from escaping the kiln 

ram feeder system. 

The ram feeder also receives containers of wastes delivered by an auxiliary feed system. The auxiliary feed 

conveyor is capable of handling charge weights of 1 to 100 pounds. The system is capable of handling charge 

sizes up to 24 inches in diameter and 24 inches tall. The auxiliary feed conveyor is capable of making 60 

charges an hour or one complete cycle every minute. 

2.2.1.3 Specialty Liquid Feeds 

The Specialty Feed System associated with Incinerator No. 4 is a Direct Inject Liquid Feed System. 

2.3 Manufacturer, Make and Model of the Incinerator [40 CFR § 63.1207(f)(1)(iii)(A)] 

2.3.1 Combustion Chamber and Burners [40 CFR §63.1207(f)(1)(iii)(B) and (C) 

Incinerator No. 4 features a two-stage combustion process. Ignition of waste material takes place in the kiln, 

or primary combustion chamber (PCC). A secondary combustion chamber (SCC) serves as an "after-burner" 

for process gases and is also permitted to incinerate high Btu liquid waste. Ignition of the waste takes place at 

temperatures in excess of 1600 degrees F. The secondary combustion chamber maintains a minimum 

temperature of approximately 1875 degrees F. 

The rotary kiln is fabricated of carbon steel. It has approximate dimensions of 8'8" O.D. X 35' long. It is 

supported on a one-degree slope by two steel tires or riding rings. Each riding ring rides on two pairs of steel 

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trunnions and have an approximate outside diameter of 9 feet 5 inches. The thickness and face width ofthe 

trunnions are approximately 6 inches and 9 inches, respectively. Table 2-2 provides a summary ofthe 

incinerator design specifications. 

The Win is lined with approximately 7 Vzinches of dense abrasion-resistant high-alumina firebrick refractory. 

With this refractory system, the kiln has an inside diameter of approximately 7 feet and a length of 

approximately 35 feet, an integral cross-section area of approximately 38 square feet and an internal volume 

of approximately 1,346 cubic feet 

All kiln feeds will enter through the upper kiln face plate which is located on the feed end of the kiln. The plate 

contains a primary bumer, three liquid feed nozzles (for pumpable sludge, aqueous waste, and high Btu liquid 

waste), a ram feeder and a surge vent 

The primary bumer is equivalent to a North American 'Fuel Directed' burner of 25 MMBtu/hr. and bums No. 2 

fuel oil or natural gas. The burner system is supplied with approximately 4,000 acfm combustion air at a static 

pressure of 20" water column (WC). The pilot for the primary burner will bum natural gas. 

The fuel system for the kiln (and secondary combustion chamber) is controlled by a Factory Mutual approved 

bumer management system complete with interlocks and safety valves. 

2.3.2 Secondary Combustion Chamber (SCC) 

The SC C is a vertical, cylindrical chamber having approximate dimensions of 10'-6" O.D. x 71' high. It is 

fabricated of carbon steel and lined with an inner course (hot face) of approximately six inches of high alumina 

refractory and an outer course of approximately two inches of insulating refractory. With this installed 

refractory, the SC C has an inside diameter of approximately nine feet. The effective length (gas retention 

length) of the chamber is approximately 48' - 6". Consequently, the SC C has a cross-section area of 64 

square feet and an effective volume of approximately 3,084 cubic feet. At maximum combustion gas flows, 

the combustion gas residence time is greater than two seconds. 

Combustion gases from the kiln enter the bottom ofthe SC C through a refractory-lined side duct and exit from 

the top of the SC C through a refractory-lined duct to the tempering chamber. The floor of the chamber is 

sloped to facilitate the removal of ash and solids through a slag tap. 

The SC C is equipped with one burner mounted on the sidewall of the chamber near the bottom, The bumer is 

a Trane Thermal Model, or equivalent, with a design heat release of approximately 30 million Btu/hr. This 

burner is supplied with No. 2 fuel oil or natural gas and combustion air. 

As with the kiln burner, the SC C burner is supplied with atomizing air and is equipped with a burner 

management system. This system controls the ignition and initiates an automatic shutoff when there is a loss 

of flame, combustion air supply, fuel pressure, atomizing air pressure, pilot burner or ID fan. 

The SC C burner is a high-intensity, vortex type unit with a spin vane assembly, located within the windbox to 

impart an intense rotary motion to the combustion air. This rotary motion and the burner design provide 

complete mixing of air and fuel, and recirculation of the gases within the combustion chamber promotes rapid 

combustion and high heat intensity. 

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2.3.3 Location of Combustion Zone Temperature Device [40 CFR §63.1207(f)(1)(xix)] 

The pyrometer that monitors temperature in the rotary kiln is located top-center in the transition section 

between fhe rotary kiln and the SC C about two feet downstream from the exit of the kiln. The thennocouple 

that monitors temperature in the SC C is located on the west side of the chamber near the SC C exit duct 

2.3.4 Hazardous Waste Residence Time [40 CFR §63.1207(f)(1)(ix)] 

The hazardous waste gas residence time for the Unit 4 Rotary Kiln Incinerator is calculated as follows: 

• Rotary Kiln Volume -1346 ft3 

• Secondary Combustion Chamber Volume - 3084 ft3 

• Total Volume - 4430 ft3 

• Maximum Flue Gas Flowrate - 43,000 acfm (717 frJVsec) 

• Total Combustion Zone Residence Time = (4430 ft3)/(717 ft3/sec) = 6.2 sec 

2.3.5 Combustion System Leak 

The kiln itself is equipped with a double seal system that is comprised of overlapping, adjustable, stainless 

steel spring plates on both the feed and discharge ends of the kiln. The sealing edges of each plate are fitted 

with a sintered-metal wear shoe similar to a brake shoe with the inner seal resting on the kiln shell. The 

powdered metal formulation for the seal shoes include graphite granules, which make the shoes selflubricating. The void between the seals and the outer shell of the kiln is pressurized to further prevent fugitive 

emissions. In addition to the kiln seal system, Unit 4 also utilizes an induced draft fan that maintains a vacuum 

of - 0.5 to - 1.0 inches water column while waste is being fired into the system. 

2.3.6 Emergency Safety Vent 

Unit 4 is equipped with two emergency vents, one located at the kiln inlet which acts as an emergency 

pressure relief, the second is located atthe top ofthe SC C as a thermal relief vent. 

The emergency vent at the kiln inlet would only be required for an occunence that overwhelms the ability of 

the ID fan to control the pressure of the kiln. The vent and chute opening is designed such that waste from the 

bulk solids chute would not impede the escaping gas flow. A deflector separates the feed flow from the vent 

opening. The entrainment of solids through the surge vent is minimal. As an extra precaution, the exhaust 

opening of the vent is angled to provide a horizontal exit, thereby minimizing solids entrainment into the air. 

The vent is kept closed by weighted louvers. These louvers will open only if the pressure in the kiln suddenly 

rises beyond the compensating capacity of the ID fan. A limit switch on the louvers will automatically shutoff all 

waste feeds to the kiln and SC C when the vent is opened. 

The incinerator is also equipped with an emergency safety vent (ESV) located at the top of the secondary 

combustion chamber. This ESV is a refractory-lined emergency thermal relief vent (TRV) which is held in the 

closed position by a pneumatic cylinder. The control valve in the line supplying air to the cylinder and the 

cylinder vent valve which opens the TRV are located in the control room for each unit. Valve locks (with keys 

attached) are utilized to deter indiscriminate operation of these valves. Opening of the TRV allows hot 

combustion gas to vent from the combustion system during emergency shutdown events. The purpose of the 

TRV is to protect the downstream APCS from excessive temperature situations. A limit switch on the TRV 

shuts off all waste feeds to the system as it senses that the cap is opening. 

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2.4 Procedures for Rapidly Stopping Hazardous Waste Feed During Equipment 

Malfunction [40 CFR §63.1207(f)(1)(viii)] 

Equipment malfunctions are identified by the control system, observation of process control variables, or by 

regular field inspections. 

In the event of a minor equipment malfunction (e.g. waste feed or scrubber leaks), the control room operator 

will be notified. The control room operator will then close the waste feed valves and disable the waste feed 

pumps. 

In the event of major equipment malfunction (e.g. fire), the emergency stop button located in the control room 

will be pushed. If this button is pushed all equipment will switch to its fail-safe position. 

2.5 Air Pollution Control Equipment [40 CFR §63.1207(f)(1 )(iii)(G)] 

2.5.1 Air Pollution Control Systems Descriptions 

The air pollution control system consists of a tempering chamber, two spray dryer absorbers, and fabric filter 

baghouse modules. The air pollution control system neutralizes acidic compounds and removes particulate 

from the exhaust gas. Two subsystems, the spray dryer absorber and the fabric filter, carry out the chemical 

neutralization and particulate removal functions, respectively. A third subsystem, the lime system, is used to 

prepare and provide lime slurry to the spray dryer absorber for use in the chemical neutralization process. The 

induced draft fan and stack provide the mechanical energy required to transport the flue gas through the 

interconnecting ductwork, to its eventual discharge point to atmosphere. 

2.5.1.1 Tempering Chamber 

The tempering chamber is a vertical, cylindrical unit designed to cool the combustion gases using a series of 

internal dual-fluid (water and air) spray nozzles. The combustion gases enter the top of the chamber, flow 

downward through the spray pattern and exit from the bottom of the chamber. The spray pattern is designed 

to eliminate direct contact of water with refractory, and the chamber is designed to maintain a dry bottom under 

all operating conditions. That is, the injection rate of spray water is controlled so that it is completely vaporized 

and carried out of the chamber in the combustion gases. The tempering chamber is approximately 49' high 

with 11' I.D. and is fabricated of'/ inch nominal plate thickness carbon steel (ASTM A36) and lined with 

refractory. The spray nozzles and extensions are fabricated of 304 SS material. 

The tempering chamber is sized so that a combustion gas retention time of greater than one second will be 

maintained at all gas flows. Because some molten particulate materials in the combustion gases are cooled in 

this process unit to below their fusion point, some solids are generated and collected in the chamber. 

Therefore, the chamber has a cone bottom and a slide gate to facilitate the removal of solids. These solids are 

discharged onto a conveyor system, which transports them to a hopper. 

2.5.1.2 Lime System 

The lime system prepares lime slurry for use in the chemical neutralization process in sufficient supply and 

concentration to maintain continuous flue gas treatment in the spray dryer absorber. The system has been 

designed for batch mixing to provide this service. 

Hydrated lime is stored in a storage bin above the lime preparation area. The storage bin is sized to hold 

enough hydrated lime to maintain several days of system operation at the maximum combustion rate of the 

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incinerator. Lime is discharged through the conical storage bin bottom. The flow of the material from the bin is 

aided by a vibrating live bottom," or bin activator. A variable speed screw feeder is used to meter the 

hydrated lime in the proportions required for batch mixing lime slurry. The lime is mixed with water in a tank 

beneath the lime storage bin. The screw feeder speed and the rate that water is added to the lime slurry tank 

are variable so that the desired lime solids concentration can be achieved in the tank. The variable feed 

adjustments allow water and lime to be added to the lime slurry tank at a rate that will allow a batch mode of 

mixing. An agitator is provided in fhe slurry tank to mix the water and lime and to maintain the suspension of 

lime solids. The mixed lime slurry is pumped at a continuous rate of flow through a recirculation loop to the 

S D A nozzles. 

2.5.1.3 Spray Dry Absorber 

Unit 4 is equipped with two Spray Dryer Absorbers (SDA) located immediately downstream of the Tempering 

Chamber. Each SDA unit is fabricated of 3/8 inch carbon steel. The function of the SDAs is to: 

• Further cool the combustion gases from 600-800°F to 300-500°F, 

• Neutralize and remove HCI and other acids from the combustion gases, 

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

Slurry flow to each spray dryer absorber (SDA) is rnetered by a flow control valve to obtain the proper feed 

concentration to the spray dryer absorber. Manual adjustment to the flow is made as a function of the SDA 

outlet temperature and as a function of the output from a hydrochloric acid (HCI) analyzer in the gas duct 

downstream of the fabric filter. 

The combined units are sized to remove more than 820 Ib/hr. of chlorine from the combustion gases. Each 

SDA is approximately 72' high by 107" in diameter. Each unit includes a head section, and a 60° conical 

hopper. Each SDA chamber has one access door in the upper section. Each hopper has one access door, a 

flanged clean-out port, and a drain connection. The SDA head section consists of a flanged inlet connection 

and a hot gas inlet plenum. The dual-fluid atomizing nozzles include stainless steel housings and stellited 

inserts. The nozzles are assembled to permit field removal from the piping. The two lime slurry piping 

headers have automatic isolation valves. 

Combustion gases enter the top of each of these units, flow downward through a central duct and are 

dispersed symmetrically from this duct into the absorber chamber at a velocity and direction that assures 

optimal contact with the cloud of atomized lime slurry droplets introduced into the chamber by dual-fluid (lime 

slurry and air) nozzles. The gases then flow downward through each absorber chamber and exit through a 

bottom side duct. As the gases contact and pass through the cloud of atomized lime slurry, the water in the 

slurry evaporates, cooling the gases. Simultaneously, the lime in the slurry reacts with the hydrogen chloride 

in the gases to produce calcium salts. Some of the resulting dry material, consisting of calcium salts, fly ash 

and excess lime, falls to the conical bottom of each unit. The dry material from each unit is discharged to a 

conveyor system which transports it to a dump trailer or equivalent type system. 

2.5.1.4 Fabric Filter 

Gas exhausted from the spray dryer absorbers is distributed to two fabric filter modules connected in parallel. 

Each module is divided into three compartments connected in parallel, which contain multiple fabric filter bags 

through which the combustion gases pass to remove particulates. Within each compartment, the gas is 

passed through Teflon-coated fiberglass cloth bags. The gas passes from the outside to the inside of the filter 

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bags. Particulate entrained in the gas stream is mechanically deposited on the outside of the filter bags as the 

gas passes through the cloth. 

Each compartment has a clean air plenum and housing section to contain approximately 308 bags. Each bag 

is approximately 5" in diameter by 5' long. The baghouses are fabricated from 3/16" mild steel plate, of welded 

construction, gas tight and stiffened to withstand the maximum operating negative pressure. Each 

compartment has a tube sheet that supports the bags and provides for top bag/cage removal. Access to the 

clean air plenum is via a bolted access door. Each trailer mounted unit contains the compressed air headers," 

gas inlet and outlet manifolds, and the conveyor. 

The fabric filter cleaning mechanism utilizes jets of air to clean the filter bags. Periodically, the cleaning 

sequence will be initiated. The sequence is started when the differential pressure across the filter reaches a 

predetermined setpoint of approximately 8.0" w.c. or when the operator initiates a cycle. The controller then 

sequences to each row of filter bags in each module, releasing a burst of air opposite to the direction of gas 

flow. The quickly released burst of air dislodges dust cake on the exterior of each bag as it travels from the top 

to the bottom of the bags. Released from the bag, the dust cake falls by gravity into the hopper at the bottom 

ofthe module. From there it is discharged to a conveyor system which transports it to a dump trailer, or 

equivalent type system. 

Treated by the spray dryer absorbers and filtered by the fabric filters, the cleaned flue gas exits the fabric filter 

compartments to an outlet manifold for exhaust. 

2.5.1.5 Carbon Injection 

' The carbon injection system will air inject activated carbon into the plenum immediately upstream of the 

baghouses and allow for a more efficient means of controlling Dioxin/Furan and mercuiy emissions. This 

system will be controlled by an existing PLC which will control the input of activated carbon to the baghouse 

inlet plenum. 2 to 20 pounds per hour of powdered activated carbon will be air injected into this plenum and 

allow for direct contact with the stack gases exiting the SDA's. 

The amount of carbon is dosed in a dust-free manner into a low pressure air stream via pneumatic eduction. 

The eductor uses a blower for the motive air. High and low air pressure switches ensure that the blower is 

operating correctly and that the carbon delivery system is clear from obstruction. The minimum high pressure 

setting is 4 psig and the maximum low pressure setting is 1 inch water column. The carbon/air stream will then 

travel through piping to the injection nozzle into the ductwork. The carbon will contact the gas stream exiting 

the SDA's and allow for the adsorption of any dioxin/furans and mercury that might be present in this stream. 

Adsorption will continue as the stack gases.proceed through the baghouses. The clean stack gas will exit the 

final stack via the induced draft fan and the captured solids will be discharged from the baghouses via the 

screw conveying system into an enclosed dump trailer for disposal at a Subtitle C landfill. 

2.5.1.6 Induced Draft Fan and Stack 

The induced draft fan and stack are located downstream of the fabric filter. Combustion gases are drawn 

through the system by a 400 hp induced draft (ID) fan, rated at 53,000 acfm at 400° F saturated, and 25" water 

column pressure. The induced draft fan provides the mechanism for transporting the incinerator flue gas 

through the spray dryer absorber, fabric filter, and all interconnecting ducts. The ID fan includes an inlet 

volume control damper to be used to control the velocity of the gas within the ducting and treatment devices. 

Treated gases are exhausted from the induced draft fan to the atmosphere through a 100-ft. high stack. The 

stack diameter for Unit 4 is 48 inches I.D. The stack is equipped with instrument sampling ports and a 

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sampling platform for emissions testing. Figure 5-1 provides details on ihe design and sample port locations 

and configurations for the stack. 

2.6 Stack Emissions Monitoring [40 CFR §63.1207(f)(1)(iii)(H)] 

The continuous emissions monitoring (CEM) system consists of sample probes, sample delivery and 

conditioning apparatus, and gas analyzers. Samples are extracted from the transition ducting located between 

the ID fan and the stack. A CEM performance test and quality assurance program has been implemented in 

accordance with Perfonnance Specifications for Continuous Emission Monitoring of Carbon Monoxide 

and Oxygen for Incinerators, Boilers and Industrial Furnaces Burning Hazardous Waste, as defined in 

40 CFR 266, Appendix IX, Section 2.1. 

Responses from each CEM S will be fed to the Control System (CS) where the C O houriy rolling average is 

calculated and interlocked to the waste feed cutoff valves as part of the Automatic Waste Feed Cutoff System 

(AWFCO) discussed in Section 2.8, below. The following provides a brief description of the CEM S 

instruments including the operating range and measurement principal. < 

2.6.1 CEM System Description 

The Continuous Ernissions Monitoring Systems (CEMS) currently being utilized at Incinerator 4 analyzes for 

opacity, carbon monoxide, hydrogen chloride, total hydrocarbons and oxygen. These monitors, except 

opacity, are extractive devices mounted in the ductwork between the ID fan and the stack. The table below 

summarizes the analyzer specifications. 

The opacity monitor continuously measures the stack gas opacity and reports the measurements to an 

indicator and a recorder. An opacity that exceeds a preset limit triggers an alarm and interlock. 

Carbon monoxide and hydrogen chloride are monitored with extractive non-disperse infrared analyzers. Total 

hydrocarbon is monitored with an extractive flame ion detector analyzer. Oxygen is monitored with a 

zirconium oxide cell. 

Stack gas flow rate is continuously monitored using an anubar that sends a 4-20 mA signal to the PLC which 

converts the signal to acfm. 

Table 2-1 Veolia ES Technical Solutions - Continuous Emissions Monitors 

Parameter Current Mfg. Range Principle 

Oxygen COS A 0-25% Electrochemical 

Carbon Monoxide Echochem MC 3 0-200 ppmv 

0-3000 ppmv 

Infrared 

Total hydrocarbons Thermoelectron 0-100 ppmv FID/lnfrared 

Hydrogen chloride Echochem MC 3 0-1000 ppmv Infrared 

Opacity Teledyne 0-100% White light 

Stack gas flow PSE/Rosemount 0-55,000 acfm Pressure drop 

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2.7 Process Monitoring and Control 

The facility is equipped with a state-of-the-art monitoring and control system, which facilitates compliance with 

permit conditions, and otherwise, collects process control information, facilitates efficient operation and detects 

and prevents damage to the facility. The system consists of three major components: 

• A human-machine interface (HMI) system, 

• Programmable logic controller's (PLC's), and 

• A high speed ethernet cable connects all control system components 

The desired control functions are implemented through the HMI system. All digital control and emergency 

interlocks are accomplished by the PLC. 

The control system is capable of monitoring the "operational envelope" of the incinerator and is capable of 

performing a number of activities including: 

• Control room indication of processor sensors located within the incinerator system (such as pressure 

indication of a 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. 

The process control corriputer will continuously control and monitor the operation of the incinerator. When outof-range conditions exist, it will notify the operator of those conditions. The process control computer is 

programmed to shut-down equipment (i.e., bring the system into a safe mode) when designated parameters 

are exceeded, which is a protective mechanism against potential equipment damage, operation outside of 

pennit limits, or conditions that might lead to a release to the environment. 

Continuous monitoring ofthe incinerator and scrubber system is an important aspect of the system design. A 

digital readout of all monitoring instrumentation is displayed on the main control screen. An audible and visual 

alarm alerts the incinerator operator to significant deviations from nonnal operating conditions. This system 

allows an immediate response to adverse conditions by the operator. Automatic waste feed cut-off and 

incineration shutdown mechanisms are also interlocked with the monitoring system at or prior to reaching 

permit limit levels. Monitoring methods and calibration frequencies are listed in Table 2-3. 

The Incinerator has an independent process control computer that interfaces to the Allen-Bradley 

programmable controllers. The process computer is capable of controlling the incinerator in case of a failure in 

a HMI server. This computer runs a RSVIEW HMI control software that provides operator interface to all 

instrumentation and controls. 

2.8 Automatic Waste Feed Cut-off System [40 CFR §63.1207(f)(1 )(iii)(F)] 

The incinerator has an Automatic Waste Feed Cut-Off (AWFCO) System that will shut waste feeds off in the 

event certain operating parameters deviate from allowable set points. The PLC continuously monitors 

operating parameters, making adjustments to the process as needed for proper control. Alarm logic is 

incorporated into the PLC system to automatically initiate an AWFCO. Table 2-3 summarizes the current 

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AWFCO set points. AWFCO limits have been established based on several factors that are summarized , 

below. 

• Reaulatorv/penmit limits - established to comply with existing permits. An example of this type of limit 

is the low temperature limit, below which waste cannot be fed until the proper limit is re-established. 

In addition, the HWC MACT regulations require that the AWFCO system be interlocked with the span 

of each process instrument that is part of the Continuous Monitoring System (CMS). A listing of these 

CMS instruments and their interlocked span setpoints is maintained as part of Veolia's Operating 

Record. 

• Process safety limits - established to assure process equipment is protected and unsafe operating 

conditions do not occur. An example of this is inadequate excess air in the combustion chamber that 

can lead to fuel rich conditions. 

• Utility or Power failure - established to facilitate a controlled shutdown of the process during loss of 

process air, steam, water or electricity. An example of this is the loss of instrument air that is 

necessary for certain types of process instruments to function properly. Wastes will not be reintroduced into the incinerators until proper operation of key instruments is re-established. 

In addition to the AWFCO system, operators can manually shutdown waste feeds or the entire process should 

this be needed. 

2.8.1 AWFCO System Testing 

Veolia tests the AWFCO systems bi-weekly. Instrument calibrations are performed as indicated in Table 2-3. 

In some cases this testing occurs more frequently depending on how often actual AWFCOs occur at the unit 

Per the required frequency, incinerator personnel check the functionality of AWFCO logic that is part of the 

incinerator's PLC system to make sure that should process conditions deviate from allowable limits, the 

computer logic will initiate waste feed shutdowns as required. This is accomplished by manually simulating 

process conditions that are outside allowable limits and observing and documenting when the control or block 

valve software logic on the waste feed line begins to initiate valve closure. Should actual AWFCOs occur 

during a given testing period, these are documented by operating personnel to satisfy regulatory requirements 

for system testing. Results of this testing are documented on a separate AWFCO Testing Log and maintained 

as part of the unit's Operating Record. 

2.9 Air Pollution Control Equipment Maintenance Practices [40 CFR 

§63.1207(f){1)(iii)(G)] 

2.9.1 Program Overview 

Once equipment is installed and operational, Veolia utilizes an extensive preventative maintenance (PM) 

program to keep equipment operational and prevent breakdowns and failures. Based upon the type of 

equipment and historical operations and maintenance experience, schedules for various inspection and PM 

activities are followed. This includes aspects such as documenting detailed maintenance histories on 

equipment, routine inspection and lubrication programs for high wear equipment and non-destructive testing of 

piping and vessels using techniques like ultrasound to assess integrity. The frequency of these activities 

varies depending upon the equipment, PM activity and the incinerator's shutdown schedule. 

For example, frequent (i.e., weekly) instrument and certain mechanical equipment checks are made for critical 

process items. Lubrication, vibration analysis and other mechanical integrity checks are done at longer 

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frequencies like monthly or quarterly. And finally, such items as inspecting refractory brick for wear, are 

typically performed when the entire incinerator is shut down for maintenance. 

2.9.2 Test Program Preparation Activities 

Prior to testing, instrumentation associated with key parameters of the test will be checked, calibrated, or 

replaced, as appropriate, to ensure proper operation ofthe instrumentation during testing (i.e., waste feed 

flowmeters and scales, CEM's, pressure transmitters, thermocouples and pyrometers, stack flowmeters, etc.). 

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Table 2-2 Technical Information Summary on Incinerator No. 4 

• Manufacturer Trade Waste Incineration 

Model No. TWI-2000, Series 2 

Type Rotary Kiln 

Date of Manufacture 1989 

Dimensions Primary Chamber Secondary Chamber 

External Length 35' 48'6" 

External Diameter 8'8" 10'6" 

Internal Diameter 7' 9' 

Cross-sectional area 38 square feet 64 square feet 

Burners Primary Chamber Burner Secondary Chamber Burner 

Manufacturer North American Trane Thermal 

Size 12.0 Million Btu/hr 30 Million Btu/hr 

Fuel Natural Gas Natural Gas 

Primer Mover Induced Draft Fan 4,000 acfm @ 400°F saturated, 20 in. water column 

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Table 2-3 Current AWFCO Parameters and Limits for Incinerator No. 4 

System Device Units Cutoff Limits 

Calibration 

Frequency 

Primary Combustion Chamber 

Temperature 

Pyrometer "F £1,240 (one-minute average) 

<1,507 (HRA1) 

£2,400 (instantaneous) 

Annually 

Secondary Combustion Chamber 

Temperature 

TypeK 

Thermocouple 

"F £1,825 (one-minute average) 

<1,886 (HRA1) 

>2,400 (instantaneous) 

Annually 

Primary Combustion Chamber 

pressure 

Pressure 

transmitter 

in. w.c. 2 atmospheric (instantaneous) Quarterly 

Secondary Combustion Chamber 

pressure 

Pressure 

transmitter 

in. w.c. t atmospheric (instantaneous) Quarterly 

Spray Dryer Adsorber Inlet 

Temperature 

TypeK 

Thennocouple 

°F s 1,200 (one minute average) Annually 

Spray Dryer Adsorber Outlet 

Temperature 

TypeK 

Thermocouple 

"F 5 500 (one minute average) 

>435 (HRA) 

Annually 

Total Pumpable Waste Feedrate Mass flow 

meter/scales 

Ib/hr >4262 (HRA) Annually 

Total Waste Feedrate Mass flow 

meter/scales 

ib/hr >14,802 (HRA) Annually/ 

Quarterly 

LVM Feedrate Mass flow 

meter/scales 

Ib/hr >120 (12 HRA) Annually/ 

Quarterly 

SVM Feedrate Mass flow 

meter/scales 

Ib/hr >117(12HRA) Annually/ 

Quarterly 

Mercury Feedrate Mass flow 

meter/scales 

Ib/hr >0,067(12HRA) Annually/ 

Quarterly 

Chlorine Feedrate Mass flow 

meter/scales 

Ib/hr >274 (12 HRA) Annually/ 

Quarterly 

Ash Feedrate Mass flow 

meter/scales 

Ib/hr >8777 (12 HRA) Annually/ 

Quarterly 

Carbon Feedrate Mass flow 

meter 

Ib/hr >6 (HRA) Quarterly 

Chlorine Feed to Siuny Flow Ratio Flow Meter Ratio >44.4 Annually 

Combustion Gas Flow Rate Anubar acfm > 43,900 (HRA) Annually 

Stack Gas Excess Oxygen Zirconium 

Oxide fuel cell 

% £ 3 (one minute average) Quarterly 

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System Device Units Cutoff Limits 

Calibration 

Frequency 

Stack carbon monoxide Infrared ppmv. 2100 (HRA) 

2500 (one minute average) 

Quarterly 

Stack Hydrocarbon . FID ppmv 210 (one minute average) Quarterly 

Stack gas opacity ~ White Light % 210 (one minute average) Quarterly 

Stack hydrogen chloride Infrared ppmv 2100 (HRA) 

2500 (one minute average) 

Quarterly 

Liquid feedrate Mass flow 

meter 

Ib/hr 2 1,700 Annually 

Sludge feedrate Mass flow 

meter 

Ib/hr 2 1,100 Annually 

Drummed and Bulk Solids 

Feedrate 

Scale Ib/hr > 15,000 Quarterly 

Baghouse low pressure drop Delta P 

transmitter 

in. w.c. £ 2 or £10 (one minute 

average) 

Quarterly 

1

 HRA means "hourly rolling average" as calculated by averaging the previous 60 one-minute average values. 

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3.0 incinerator Feed Stream Descriptions 

3.1 General 

Veolia treats a broad range of wastes and thus the individual streams that may make up the incinerator overall 

feed at any given time can vary greatly, depending on generator production and shipping schedules. Prior to 

scheduling wastes for shipment to the facility, the waste streams are characterized by the generator and 

reviewed by Veolia staff. A Waste Profile Number uniquely identifies each different waste stream. This 

assures that only pre-approved wastes are handled at the facility and that all necessary regulatory, handling, 

safety and other important infonnation is available to Operations personnel. Organic Hazardous Air Pollutants 

(HAPs) measured or expected (based on process knowledge) to be present in a source waste at or above 

approximately 0.1 % by weight are listed in the tables in this Section. Organic HAPS not listed are, based on 

process knowledge, believed to be either completely absent or present in the waste at less than 0.1 % by 

weight 

In addition to the infonnation below that summarizes fhe top volume waste streams processed at Veolia, 

Table 3-1 provides a summary of the major HAPs processed at the facility. 

3.2 High Volume Wastes 

3.2.1 Liquid Wastes 

Liquid wastes are received at the Sauget facility in tank trucks and drums and are either direct fed through a 

dedicated line or are blended with other compatible waste streams into the tank farm. Table 3-1 provides a 

summary of the top volume liquid streams that have been processed in the last year. Liquid wastes can be 

processed in any one of the three incinerators. These streams can be organic, aqueous or a mixture. 

3.2.2 Bulk Solids 

Table 3-2 provides a summary of the top bulk solid streams handled at the Sauget facility. Bulk solids can 

include streams like contaminated soils, wastewater sludges or manufacturing process solids. These wastes 

are received at the site primarily in 20 to 40 cubic yard roll-off containers or other simitar bulk transport 

vehicles. 

3.2.3 Containerized Waste 

Table 3-3 provides a summary of the top containerized waste streams handled at Sauget. Containerized 

wastes are received in drums and smaller cartons, boxes or pails and can include materials such as laboratory 

waste, spent carbon, process residues. 

3.3 Auxiliar y fuel s 

Natural gas or #2 fuel oil can be used as auxiliary fuels to start-up and obtain desired temperatures in the 

incinerators. At this time, all incinerators use natural gas as their primary fossil fuel. Typical composition of 

both fuels is provided in Tables 3-5 and 3-6. 

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Table 3-1 Top Volume Liquid Waste Streams 

Profile Waste Name 

Annual Pounds 

Received 

BZ3328 REFLUX WATER 3,222,363 

388955 1.51B WASTE ORGANICS/MKH 2,897,025 

397628 DE175-IPA WASH & FILTRATE WASH 2,192,832 

346631 SEMICARBAZIDE PROCESS WASTE 1,594,454 

388852 BULK MIXED WASTE LIQUIDS 1,453,766 

393651 PVA PRODUCTION 1,273.063 

410013 DP202 949,035 

296227 RINSE WATER/AG CHEMICAL 815,882 

351071 BULKED LIQUID HIGH BTU >3000 797,682 

BF0568 BULK LIQUIDS LOW BTU <3000 753,595 

Table 3-2 Top Bulk Solid Waste Streams 

Profile Waste Name 

Annual Pounds 

Received 

396871 DOG FOOD 9,682,704 

346603 HYDROCARBON TANK BOTTOMS 3,677,040 

562221 BULK SOLID WASTE BTU >5000 2,638,520 

330548 

HYDROCARBON WASTE FROM 

PETROLE 2,567,400 

396775 WASTEWATER TRASH BOXES-DRY 1,613,940 

351070 CWD BULKED INCINERATION SOLID 1,610,360 

674065 DRUMS & BULK CONTAINING GREASE 1,557,680 

350400 SMALL PAINT CANS 1,380,780 

024042 SURGE TANK CLEAN OUT 1,058,000 

360069 PRIMARY SEPARATOR SLUDGE 956,980 

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Table 3-3 Top Containerized Solid Waste Streams 

Profile Waste Name 

i 

Annual Pounds 

Received 

SOL003 SOLIDS CHLORINE < 25% 1,635,929 

395485 NON-HAZ PRODUCTION WASTE PPE 1,439.513 

CG6944 PILOT PLANT SOLVENTS 1,026;877 

BB1445 REP LAB PACK (DCN) 858,467 

LOP003 LOOSE PACKS O F NON-REGULATED 855,396 

393399 PHARMACEUTICALS (DEA) 771,078 

393758 Q8-6061 SILOXANE DRUMS 648,240 

360169 M865 ROUNDS 646,796 

346662 FLAMMABLE LAB WASTE 579,685 

640004 PHARMACEUTICAL SAMPLES 567,961 

PZLOP4 LOOSE PACKS O F NON-REG USED 548,425 

579751 SHARPS WITH CONSUMER PRODUCTS 547,098 

Table 3-4 Summary of Major HAPs Processed 

HAP C A S Number 

Annual Pounds 

Received 

Toluene 108-88-3 1,692,440 

Methanol 67-56-1 1,534,599 

Acetonitrile 75-05-8 654,939 

Xylene (mixed isomers) 1330-20-7 595,372 

Methyl isobutyl ketone 108-10-1 515,310 

n-Hexane 110-54-3 348,994 

Acrylonitrile 107-13-1 329,248 

Methyt ethyl ketone 78-93-3 201,431 

Methyl tert-butyl ether 1634-04-4 188,219 

Hydrazine 302-01-2 180,238 

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Table 3-5 Typical Properties for Supplemental Fuel Oil 

Parameter Units Value Parameter Units Value 

HeatValue Btu/lb > 17.000 Chromium ppm 2.0 

Ash Content %wt <5.0 Lead ppm <20 

Chloride Content %wt <2.0 Mercury ppm N/A 

Antimony ppm <1.0 Nickel ppm <10 

Arsenic ppm <1.0 Selenium ppm <0.1 

Barium ppm <2.0 Silver ppm <0.1 

Beryllium ppm <2.0 Thallium ppm <0.05 

Cadmium ppm <5.0 

Table 3-6 Typical Properties for Natural Gas 

Component Units Value I Component Units Value 

Methane mole % 94.428 | Heptanes mole % 0.019 

Ethane mole % 3.081 Octanes mole % 0.005 

Propane mole % 0.582 Nitrogen mole % 0.703 

Isobutane mole % 0.087 Carbon Dioxide mole % 0.824 

N-butane mole % 0.129 Helium mole % 0.014 

Isopentane mole % 0.040 Hydrogen mole % 0.023 

N-pentane mole % 0.032 Argon mole % 0.0 

Hexanes mole % 0.029 Oxygen mole % 0.004 

Parameter Units Value Parameter Units Value 

Heat Content, 

gross, dry 

Btu/CF 1040.5 Relative Density - 0.592 

Heat Content, 

gross, sat 

Btu/CF 1023.6 Wobbe Index - 1330 

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4.0 Performance Test Protocol 

4.1 General Description 

This Performance Test Plan has been designed to demonstrate performance under a single test condition 

using a combination of actual and spiked feeds. This test condition will be designed to establish maximum 

metals feed rates while demonstrating conformance with applicable HWC MACT metals emissions standards. 

During the performance test, Veolia will be seeking to establish new Operating Limits for Unit 4. Due to this, 

Veolia will adjust the limits at which the AWFCO system activates except for carbon monoxide. At the end of 

each day of testing, cunent AWFCO limits will be reinstated back to currently established limits. 

4.2 Performance Standards 

The Performance test for the Veolia incinerator has been designed to demonstrate compliance with current 

performance standards ofthe Hazardous Waste MACT rule as follows: 

• Conformance with the mercury emission limit of 130 pg/dscm corrected to 7% oxygen; 

• Conformance with the semivolatile metal (cadmium and lead) emission limit of 230 pg/dscm corrected 

to 7% oxygen; and 

• Conformance with the volatile metal (arsenic, beryllium and chromium) emission limit of 92 pg/dscm 

corrected to 7% oxygen. 

4.3 Test Conditions [40 CFR § 63.1207(f)(1 )(vi) and (vii)] 

The test condition for this performance test is designed to demonstrate compliance with the applicable MACT 

metals emissions standards. Unit 4 will be operated at normal combustion zone temperatures during this 

condition with normal waste feed rates. The flue gas flow rate and chlorine feed rate will be maximized. The 

baghouse inlet temperature will be maximized. The proposed operating limits for the performance test are 

summarized in Table 4-1. 

4.4 Waste Feed Spiking 

In order to demonstrate the required performance criteria for this program, it will be necessary to fortify (spike) 

the incinerator feeds with organic and inorganic constituents. The spiking levels and approach proposed for 

this performance test have been used successfully in the past for testing at not only Veolia but for testing at 

other hazardous waste combustion facilities as well. 

Each spiked material will be prepared to a known specification and verified by a certificate of analysis. These 

materials will be prepared and fed in a manner that assures a very consistent feedrate. Feed rates of each 

spiked compound are chosen to be well above expected levels in native wastes, generally an order of 

magnitude or more higher, so that the spiked constituent is the dominant feed and the native contribution is not 

significant. Spiking rates are also selected based on historical performance to assure that emissions can be 

detected and actual results, versus non-detect results, are used in calculation removal efficiencies. 

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4.4.1 Inorganic Constituents 

Several metals will be spiked to the system to permit calculation of system removal efficiencies (SREs), which 

can then be used to determine appropriate feed rate limits, as necessary! Regulated metals may be fed at 

some level in the native waste materials to be used during the test. However, these native concentrations may 

not be high enough to achieve fhe desired feed rate limits to be set for the system. Therefore, Veolia plans to 

spike three surrogate metals at higher than normal rates to ensure that sufficient metals are fed to achieve 

measurable emissions in the stack emissions. 

Table 4-2 provides an overall summary of information relevant to the metals testing portion of the program. 

S R E data from previous test programs have been used in conjunction with present feed rate limits and present 

MACT emission limits to specify target feed rates that will result in acceptable emission rates. This table is 

only used as a predictive tool, however, and final limits to be imposed will depend on the actual results ofthe 

performance test. Two other points are worth noting with regard to Table 4-2: 

• The spiked amount for a given metal will be the difference between the desired feed rate limit and the 

native quantity expected to fed during the test; and 

• Surrogate metals will represent the whole group (in the case of LVM and SVM) and test results will be 

used to extrapolate up to the applicable MACT standard. 

The three metals to be spiked are representative of the three classes of metal volatility and therefore can be 

used to set limits for any metals not spiked. 

4.4.2 Spiking forthe LV M Category 

The LVM Category for incinerators includes arsenic, beryllium and chromium. Veolia plans to spike chromium 

at 40-45 Ib/hr to establish a SRE for all three test runs. The SR E demonstrated during the performance test 

for chromium will be used to establish a LVM feed rate limit. 

Chromium will be spiked as chromic acid through a liquid feed injector via a pumping station that will monitor 

the feed rate. N Waste chromic acid is treated at Veolia and thus, spiking chromic acid during the performance 

test is representative of nonnal operations. 

4.4.3 Spiking forthe SV M Category 

The SVM category for incinerators includes cadmium and lead. Veolia plans to spike lead at 60-65 Ib/hr during 

the performance test to establish a SRE for all three runs. The SR E demonstrated during the performance test 

for lead will be used to establish a SVM feed rate limit. 

Lead will be spiked as lead nitrate and delivered in small, pre-measured plastic baggies at regular intervals 

along with other solid waste feeds during the performance test. Lead containing waste that are normally 

treated at Veolia are predominantly bulk or containerized solids and thus, this spiking approach during the 

performance test is representative of normal operations. 

4.4.4 Spiking for Mercury 

For mercury, the only high volatile metal, Veolia plans to spike this at approximately 0.01 - 0.02 Ib/hr and will 

follow a similar approach as noted above for the other MACT-regulated metals. Mercury will be fed as a 

mercuric nitrate solution at regular intervals along with other solid feeds during the performance test. Mercury 

is predominantly present in solid feeds processed at Veolia and using a liquid solution for spiking will provide 

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an easily volatilized form fed along with other solid feeds in a manner that is representative of normal 

operations. 

4.5 Metals Extrapolation Method 

Veotia plans to extrapolate to higher feed rate limits than actually fed during the test using the performance test 

-established SREs. This is appropriate since it is generally agreed that SREs at higher feed rates would be at 

least as good as those observed at the lower level. Any extrapolation performed will take into consideration 

the MACT standards to ensure full compliance. Based on previous discussions with EPA Region 5, the 

following approach will be used. 

The average SR E for the three runs would be calculated from the feed and emission rates for each run and an 

average SRE for the performance test. A feed rate limit would then be calculated for each metal category by 

dividing 75% of the emission standard for that category by the SRE for the spiked compound representing that 

category. A similar approach would be followed for SVM (cadmium and lead) and for mercury. To further 

assure that this method is protective, Veolia proposes to limit the maximum feedrate for any one category to 

10 times the spiked feed rate during the performance test. The test program will establish 12-hour feed rate 

limits for the MACT metals. Example calculations are show below: 

Maximum emission rate for extrapolation 

= (emission standard (ug/m3 @ 7% Oz) * 0.75 * ( W (dscfm @ 7% Oz) * 0.0283 m3ffi3* 60 min/hrV(453.6 g/lb * 106 pg/g) 

Maximum extrapolated feed rate 

= Maximum emission rate / (1 - SR E from performance test) 

4.6 Description, Preparation and Delivery of Feeds for the Performance Test [40 

CFR § 63.1207 (f)(1)(vi) and (vii)] 

To the extent possible (and with the exception of the spiked constituents noted above), only nomial waste 

materials processed at the facility will be fed to the incinerator during the test program. Waste materials will be 

stockpiled to meet the objectives for the target performance test parameters. These wastes will be 

characterized in advance of the test and kept until needed. All waste materials will be delivered to the facility 

in accordance with routine operation and currently permitted procedures as described elsewhere in this 

document. 

4.7 Conditioning Time Needed to Reach Steady State [40 CFR § 63.1207(f)(1)(xii)] 

The incinerator will be operated for 15 minutes at the desired feed rates and operating conditions before 

sampling begins for a given condition of the performance test. This will assure all operating parameters are 

stabilized at the desired settings to achieve steady state before sampiing. 

4.8 Anticipated Test Schedule 

The performance test will be performed over a 4-day period using a three-person field crew according to the 

schedule shown in Table 4-3. For this performance test, it is anticipated that all runs will be approximately two 

hours in duration, as dictated by the sample run time required for metals measurements. The performance 

test program for this incinerator is planned to start on or after August 1,2008. 

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4.9 Performance Test Reporting 

The final report will be prepared for submittal no later than 90 days from completion of the field test program. 

This document will provide a concise presentation of performance test results and will include all necessary 

supporting documentation. An example outline ofthe final performance test report is presented below: 

Section 1.0 Certification - Includes project title, statement of compliance and project approval 

signatures 

Section 2.0 Summary of Test Results - Summary of emission results compared to applicable 

standards; interim status operating limits; overview of process operating conditions; 

Section 3.0 Project Overview - Facility and unit description; project background and scope; test 

requirements; test chronology and report organization 

Section 4.0 MACT Notification of Compliance - Regulatory requirements; performance test results and 

compliance determination; area or major source determination; description of air pollution control system; 

and description of process monitoring systems 

Section 5.0 Process Operating Conditions - Overview of test conditions and summary of facility 

process monitoring data 

Section 6.0 Sampling and Analytical Program Overview - Summary of proposed plans and 

discussion of actual activities and any required deviations from plan 

Section 7.0 Test Results - Detailed presentation of waste analysis and stack sampling results including 

tabulated presentation of all data 

Section 8.0 Quality Assurance / Quality Control - Detailed discussion of waste and stack sampling 

and analytical QA/QC procedures and results 

APPENDICES 

A - Facility Process Monitoring Data 

B - Spiking Report 

C - Field Sampling Documentation 

D - Analytical Data Reports 

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Table 4-1 MACT OPLs to be Established During the Performance Test 

Process Parameter Units 

Avg. 

Period 

How Limit 

Established 

Expected 

Limit 

Maximum Flue Gas Flowrate acfm 1-hr Average of maximum 

HRAs for each run 

40,000 - 45,000 

Maximum Low Volatile Metals 

(LVM) Feed Rate 

lb/hr 12-hr Average ofthe average 

HRAs for each run 

400 - 450 

Maximum Total Pumpable LVM 

Feed Rate 

Ib/hr 12-hr Average ofthe average 

HRAs for each run 

400 - 450 

Maximum Semi-Volatile Metals 

(SVM) Feed Rate 

Ib/hr 12-hr Average of the average 

HRAs for each run 

600 - 650 

Carbon Feed Rate Ib/hr 1-hr Average ofthe average 

HRAs for each run 

6-7 

Maximum Chlorine/Chloride 

Feed Rate 

Ib/hr 12-hr Average of the test run 

averages 

250-350 

Maximum Total Mercury Feed 

Rate 

Ib/hr. 12-hr Average of the test run 

averages 

0.1-0.2 

Maximum Fabric Filter Inlet 

Temperature 

°F 1-hr Average ofthe test run 

averages 

400-440 

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Table 4-2 Metals Evaluation Plan 

Metal 

Historical Desired 

Feed Range Feed Rate 

(lb/hr) Limit (Ib/hr) 

• Expected 

Spiked Quantity 

(lb/hr) 

Expected 

Metal 

SRE (%) 

Project© 

Rate att 

FeedR 

(lb/hr) 

d Emission I 

lie Desired 

ate Limit 

ug/m3@ 

7%Oz 

Mercury 0.1 0.02 85.00% 0.002 33 

SVM 600 - 650 60-75 99.9999% 0.001 14.5 

Chromium * 400-450 40-45 99.9999% 0.0005 10.0, 

Assumptions: 

Qs = stack gas flow rate = 18,600 dscfm 

O2-stackoxygen level = 12.0 %vol. 

MACT Standards: 

SVM (Cd and Pb) = 230 pg/m3 

LVM (As, Be and Cr) = 92 pg/m3 

Mercury = 130 ug/m3 

* Surrogate metals to be spiked during the 2008 Performance 

Test 

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Table 4-3 Anticipated Metals Performance Test Schedule 

General Overview of Planned Schedule 

Activity Schedule 

Mobilization, site safety training and set-up Day 1 

Preliminary traverses, Conduct Run 1 and Run 2 Day 2 

Conduct Run 3 Day3 

Equipment removal and depart site Day 4 

Example of Detailed Daily Schedule (Day 2 Above) 

Test Activity Time 

Incinerator lined out on trial bum wastes 07:00 

Begin metal spiking 08:30 

Initiate all stack sampling and waste sampling 08:45 

Approx. end time for sampling runs 15:00 

Recovery of sampling train 15:00-16:30 

Depart Site 17:00 

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5.0 Sampling and Analytical Program Quality Assurance/Quality 

Control 

This section presents the Quality Assurance and Quality Control goals, objectives, and procedures for the 

MACT Performance Test program. The quality assurance/quality control procedures and criteria for this 

program will comply with the requirements of this document and its updates. The analytical work conducted 

will incorporate the QA/QC requirements ofthe approved methods. This document has been prepared using 

available guidance provided ih the following EPA documents: 

• "EPA Requirements for Quality Assurance Project Plans", EP A QA/R-5, November 1999. 

• "Component 2 - How to Review a Quality Assurance Project Plan (including Attachment A - Generic 

Trial Bum QAPP", Hazardous Waste Combustion Unit Permitting Manual, U.S. EPA Region 6, 

January 1998. 

• "Handbook - Quality Assurance/Quality Control (QA/QC) Procedures for Hazardous Waste 

Incineration" (EPA/625/6-89/023 January 1990). 

Quality Assurance Project Plan for Veolia ES Technical MACT Metals Performance Test on the Rotary 

Kiln Incineration Number 4 

Facility ID Number: ILD098642424 

Prepared for: Veolia ES Technical, 7 Mobile Avenue, Sauget, IL 62201 

Prepared by: ENSR Corporation, Westford, MA 01886 

Revision No.: 0 

Date: May 2008 

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5.1 Title Page 

5.1.1 Project Title 

Quality Assurance Project Plan for Veolia ES Technical Solutions HWC MACT Metals Performance Test Plan 

for the Rotary Kiln Incineration System 

5.1.2 Expected Performance Test Date 

On or after August 1,2008. 

5.1.3 Project Approvals 

Veolia Project Manager Date 

ENSR Project Manager Date 

ENSR QA Officer Date 

Maxxam Analytics Lab Services Coordinator Date 

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5.2 Table of Contents | 

A complete table of contents, including listings of tables and figures and acronyms is presented at the 

beginning of this Performance Test Plan and includes all pertinent information applicable to this QAPP section. 

5.3 Project Description 

This project will consist of a comprehensive sampling and analysis program designed to demonstrate 

compliance with the HWC MACT rule requirements. Testing will be performed under one process operating 

condition, entailing triplicate sampling runs. Operating parameter limits (OPLs) associated with metals 

emissions testing will be re-established or modified based on the results ofthe program. The reader is 

referred to Sections 1.3,1.4,2.5.3 and 4.0 for further details on program scope, test objectives and target 

parameters for emission measurements and process monitoring. The remainder of this section outlines the 

detailed measures that will be followed to ensure colleclion of valid data. A brief overview of the 

measurements to be made during the test program is provided in Table 5-1. A more detailed summary ofthe 

sampling and analytical program is provided later in Section 5.6. 

5.4 Project Organization 

The ENSR Project Manager, Mr. Jeffrey Gorman will be responsible forthe overall direction of this program 

and will report to the Veolia Project Manager, Mr. David Klarich. Mr. Gorman will be responsible for project 

design and implementation, communicating with the client, scheduling all activities, reviewing all, project data 

and preparing all reports. He will be assisted in the oversight of Quality Assurance activities by the program 

Quality Assurance Officer (QAO) and each Analytical Laboratory Services Coordinator (LSC). Each contract 

laboratory will have one individual designated as the person responsible for project activities. 

5.4.1 QA Officer's Responsibilities 

Mr. Craig Doolittle will serve as the project Quality Assurance Officer (QAO) and will be responsible for review 

and approval of the Quality Assurance Project Plan presented in this section, as well as any subsequent 

revisions. He will monitor implementation of field and laboratory activities, scheduling performance and/or 

system audits as warranted. The QAO will report to the Project Manager on any conditions noted which may 

adversely affect data quality. 

Mr. Doolittle will provide independent oversight for data verification and data quality assessment activities. He 

will prepare a section for the Final Report summarizing QA/QC activities and provide an overall evaluation of 

data quality. 

5.4.2 Laboratory Coordinator Responsibilities 

Each analytical laboratory will designate a Laboratory Services Coordinator (LSC), who will be the principal 

point of contact for the ENSR Project Manager. The LSC will review QA requirements with all laboratory staff 

to ensure that all required measures are taken to meet data quality objectives. They will monitor the shipment 

and receipt of samples, track analytical progress and review data as reported from the laboratories for 

completeness. Each LSC will be responsible for validation of all data generated by the laboratory for this 

program and will provide all necessary documentation for inclusion in the final report. 

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5.5 QA/QC Program Objectives 

5.5.1 Precision, Accuracy and Completeness 

The collection of data to fully characterize the incinerator waste feed materials and stack gas emissions 

requires that sampling and analysis procedures be conducted with property operated and calibrated equipment 

by trained personnel. QA objectives for measurements made in the field are summarized in Table 5-2. QA 

objectives specific to each analytical methodology performed by the subcontractor laboratories are presented 

later in Section 5.9. The overall program has been designed with consideration of sampling parameters and 

analytical limits to ensure that the achieved MDLs for emissions will be more than adequate for regulatory limit 

decisions. Critical MDL determinations are addressed subsequently in Section 5.5.3. 

Precision is defined as a measurement of mutual agreement among individual measurements made under 

prescribed similar conditions. Precision is expressed in terms of relative percent difference (RPD) between 

dupficate determinations and in terms of relative standard deviation (RSD) when 3 dr more determinations are 

made. Overall precision for analysis of the waste feed streams will be assessed through the analysis of one 

set of duplicate samples for each designated parameter. 

Accuracy is the degree of agreement of a measurement with an accepted reference or true value. Analytical 

accuracy will be measured through the recoveries of matrix spikes, analysis of standard reference materials or 

audit sample analysis. Matrix spike samples for the waste feed will be prepared by spiking known amounts of 

target analytes into a portion of the sample Recoveries are monitored to assess laboratory and method 

accuracy. Laboratory control samples (LCS) will also be used to distinguish between method performance 

and matrix effects on accuracy. LCS and MS spiking solutions will be independent from calibration standards. 

Completeness is a measure of the amount of valid data obtained compared to the amount that was expected 

under normal conditions. The overall program objective is to obtain valid data for three (3) runsifor each test 

condition. For all data considered critical to the investigation, a completeness objective of 100% has been 

established. As a result, critical priority data from each of three (3) runs should achieve the precision and 

accuracy goals established herein. This completeness criterion applies to all permit parameters in emissions 

samples as well as feed/process stream samples. Individual samples for which the critical data points do not 

achieve accuracy and/or precision data quality objectives may require reanalysis. Results for samples where 

matrix interferences preclude meeting objectives for the recoveries of surrogates or spikes will be evaluated for 

potential bias to calculated emission results. In summary, the completeness goals are stated at 100%, since 

three valid runs are necessary to assess operation at any one condition. 

5.5.2 Representativeness and Comparability 

It is recognized that the usefulness ofthe data is also contingent upon meeting the criteria for 

representativeness and comparability. Wherever possible, reference methods and standard sampling 

procedures will be used. The QA objective is that all measurements be representative ofthe matrix and 

operation being evaluated. The detailed requirements for sampling given in the various EPA Reference 

Methods will be followed to ensure representative sampling of flue gases. The sampling of incinerator feed 

streams prior to the performance test will provide representative samples of these matrices. 

The corresponding QA objective is that all data resulting from sampling and analysis be comparable with other 

representative measurements made by the performance test field team, on this or a similar process operating 

under similar conditions. The use of published sampling and analytical methods and standard reporting units 

will aid in ensuring the comparability of the data. 

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5.5.3 Method Detection Limit (MDL) Determinations 

Method Detection Limits (MDLs) for the various analytes to be measured in this program will be determined 

following well-established laboratory procedures in accordance with standard EPA protocols. These are 

described below for those parameters deemed most crucial to the program. 

5.5.3.1 Metals-Methods 6020 and7470A 

Reporting limits for all metals are detennined based on the results ofthe latest MDL studies performed for 

each metal. For this program, the MDL for non-detect values will be detennined by low-level replicate spiking 

of aliquots of the trial bum samples submitted. The reporting limit for non-detectable metals is a chosen whole 

number above the MDL, usually in the range of 1.5-2 times the MDL value. 

5.6 Sampling and Monitoring Procedures 

This section describes the procedures that will be followed during the field sampling program. Throughout the 

overall program, all sampling will be performed using sampling protocols described herein and approved by 

EPA; Regulatory agency approval will be obtained for any deviations from or changes to the approved 

Performance Test Plan which may be warranted prior to program implementation as a result of changes in 

personnel or facility circumstances. If situations occur during the demonstration testing which necessitate 

deviations from the plan, the agency will be notified and onsite approval requested. Any deviations from the 

specified protocols will be fully documented in the final Performance Test Report. 

5.6.1 Field Program Description 

A detailed description of the compliance strategy and test conditions was provided previously in Section 4.0. 

In general, however, the program is presently configured to collect samples during three runs for a single 

process operating condition. Table 5-3 provides a detailed listing of the sampling and analytical parameters 

and methods planned for this program. All sampling will be conducted concurrently at the outlet stack location. 

5.6.2 Pre-sampling Activities 

Pre-sampling activities include equipment calibration, sample media preparation, cleaning of sample train 

glassware, preparation of computer-generated sample labels, and other miscellaneous tasks. Each of these 

activities are described or referenced in the following subsections. Other pre-sampling activities include such 

details as team meetings, equipment packing and shipment, equipment setup, and finalization of all details 

leading up to the coordinated initiation of the sampling program. 

5.6.2.1 Equipment Calibration 

A most important aspect of pre-sampling preparations is the inspection and calibration of all equipment 

planned to be used for the field effort. Equipment is inspected for proper operation and durability prior to 

calibration. Calibration of equipment is conducted in accordance with the procedures outlined in the EPA 

document entitled "Quality Assurance Handbook for Air Pollution Measurement Systems; Volume III— 

Stationary Source Specific Methods" (EPA-600/4-77-027b). Equipment calibration is performed in accordance 

with EPA guidelines and/or manufacturer's recommendations. Documentation of all calibration records will be 

kept in the project file during the field program and will be available for inspection by test observers. Examples 

of field equipment used and typical calibration requirements follows: 

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. • Probe nozzles (OA Handbook Section 3.4.2, pg. 19) - make three measurements ofthe nozzle ID (to 

the nearest 0.001 in.) using different diameters with a micrometer. Difference between the high and 

low values should not exceed 0.004 in. Post-test check - inspect fpr damage. 

• Pitot tubes (QA Handbook Section 3.1.2, pp. 1.-13) - measured for appropriate spacing and 

dimensions or calibrate in a wind tunnel. Rejection criteria given on the calibration sheet. Post-test 

check - inspect for damage. 

• Thermocouples (QA Handbook Section 3.4.2, pp. 15-18) - verify against a mercury-in-glass 

thermometer at two or more points including the anticipated measurement range. Acceptance limits -

impinger *2T ; DGM ±5.4°F; stack ±1.5 percent of stack temperature. 

• Dry gas meters (QA Handbook Section 3.4.2, pp. 1 -12) - calibrate against a wet test meter. 

Acceptance criteria - pretest Yi = Y ± 0.02; post test Y = ± 0.05 Yi. 

• Field barometer (QA Handbook Section 3.4.2, pp. 18-19) - compare against a mercury-in-glass 

barometer or use Airport Station BP and correct for elevation. Acceptance criteria - ± 0.02 in. Hg; 

post-test check - same. 

5.6.2.2 Glassware Preparation 

Sample train glassware and sample containers require specialized pre-cleaning to avoid contamination ofthe 

sample from the collection container or devices. Cleaning/storage procedures for sample train glassware are 

summarized below. Note that all bottle caps are fitted with teflon liners which are cleaned in the same manner 

as the bottles themselves. Sample containers used for waste feed streams are purchased pre-cleaned and 

sealed to specified EPA protocols. 

• EPA Method 29 glassware and containers (metals) - wash with soap and water, rinse with hot tap 

water, rinse three times with reagent water. The glassware is next soaked in a 10% nitpc acid solution 

for a minimum of 4-hours, rinsed three times with reagent water, rinsed a final time with acetone and 

air dried. All glassware openings where contamination can occur will be covered until the sampling 

train is assembled prior to sampling. 

5.6.2.3 Sample Media Preparation 

All reagents will be checked in accordance with ENSR's existing Q C Program to minimize the probability of 

using contaminated solvents. This includes the use ofthe proper grade reagents/solvents as specified in the 

test method, selection of reagents from the same lot and the collection and analysis of the appropriate blanks. 

Sampling media will be procured and prepared in accordance with the appropriate test methods as described 

below: 

• Quartz filters used in the Method 29 sampling train are purchased from Pallflex Products Co. who 

pre-screen filters for metals content. 

5.6.2.4 Other Pre-Sampling Activities 

Sample team meetings will be held to designate responsibilities to each team member. Assignments will be 

based on individual experience and relative importance of the assigned task. Other pre-sampling activities in 

the office will include generation of sample checklists, printing of computer-generated sample labels, and 

proper packing of all equipment. Equipment will then be transported by freight or truck to the sampling 

location. 

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Site setup is the final pre-sampling adrvity. This task will involve moving the equipment to the vicinity ofthe 

sample collection area. A separate office trailer or other suitable onsite facility will be used to serve as a 

sample train setup and recovery area and sample custody area. 

Normally, preliminary tests are conducted at the stack location to verify the presence or absence of cyclonic 

flow conditions and to determine flue gas moisture, temperature and velocity. These measurements facilitate 

determination of nozzle size selection and sample train operation rates for. the isokinetic sampling trains. 

. 5.6.3 Sampling Locations 

5.6.3.1 Waste Feed Streams 

Waste feed materials will be sampled in accordance with the facility's feed stream analysis plan (FSAP) and 

RCRA Waste Analysis Plan (WAP). Waste feed sampling will occur upstream of any metal spiking location. 

Samples will be collected using methodologies described in the FSAP and WAP. 

5.6.3.2 Stack Sampling Location 

Sample test ports in the circular 48-inch inside diameter (ID) stack are located 65.5 feet (16.4 diameters) 

downstream of the induced-draft fan and 26 feet (6.50 diameters) upstream of the stack exit to atmosphere. In 

accordance with EPA Method 1, a 12-point traverse will be performed during testing. One test port level will 

be used to accommodate simultaneous testing of all emissions test parameters. Figure 5-1 provides a 

schematic ofthe stack showing the location ofthe sampling ports. Actual traverse point locations and 

upstream/downstream distances from flow disturbances are shown in Table 5-4. 

5.6.4 Waste Feed Stream Sampling Procedures 

Each waste feed material fed during fhe test will be sampled from taps in the feed lines or other appropriate 

locations, upstream of any metal spiking location. During the testing each waste feed material will be sampled 

at the start of each run, at port change, and at the completion of each run. After testing is completed, the three 

samples that were collected will be composited and analyses will be performed on this composite sample. The 

feed streams will be characterized for ash, heat content, metals (arsenic, beryllium, chromium, cadmium, lead, 

and mercury) and total chlorine. Veolia will be responsible for all waste feed analyses. 

5.6.5 Stack Sampling Methodologies , 

Gases discharged from the exhaust stack will be sampled by ENSR for the following parameters: 

• Flue gas velocity, flow rate, temperature, moisture content and fixed gas (O2 and C0 2 ) composition; 

• MACT Metals - arsenic, beryllium, cadmium, chromium, lead and mercury; 

The following sections provide summaries of the sampling methodologies to be followed. In addition, sample 

field data sheets to be used during the program are provided in Appendix B. Summaries of relevant 

information pertaining to setup and recovery of the EPA Method 29 sampling train are provided in 

Appendix C. 

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5.6.5.1 Gas Stream Velocity, Moisture and Fixed Gases 

Gas stream flowrate, moisture and fixed gas concentration will be determined concurrent with the EPA 

Method 29 isokinetic sampling train. Gas stream velocity will be determined using a pitot tube and water 

manometer in accordance with EPA Method 2. Gas stream temperature will also be determined at each ofthe 

Method 2 traverse points using a Type T C thermocouple and pyrometer. Gas stream moisture will be will be 

determined as specified in EPA Method 4 concurrent with the EPA Method 29 isokinetic sampling train. In this 

procedure the impinger contents are measured or weighed before and after each test run and used in 

conjunction with the metered gas volume to determine the gas stream moisture content. Fixed gases (0 2 and 

C0 2 ) for gas stream molecular weight determination and constituent oxygen conection will be determined in 

accordance with EPA Method 3 (Orsat procedure) during each test run. 

5.6.5.2 Metals 

EPA Method 29 will be utilized for the collection of MACT and other metals including: 

• MACT LVM metals - arsenic, beryllium and chromium; 

• MACT SVM metals - cadmium and lead; and 

• Mercury. 

Specific sampling details for the Method 29 sampling train are as follows: 

• Target sampling rate - 0.75 cfm 

• Sample run time - 2-hr 

• Number of sampling points per stack traverse - 6 

• Total number of sampling points - 12 

• Number of field reagent blank sets collected -1 

5.6.5.3 Continuous Emission Monitoring 

ENSR will provide measurement of oxygen (02 ) and carbon dioxide (C02 ) throughout all test run periods. 

These parameters will be measured using the procedures specified in 40 CFR 60, Appendix A, Method 3 

(Orsat analysis). 

Veolia will provide continuous emission monitoring for carbon monoxide (CO) during all three test runs in 

accordance with the facility's Quality Assurance Plan for their CEMs. 

5.7 Sample Handling, Traceability and Holding Times 

Sample integrity will be maintained throughout all phases of the sampling and analysis program. Samples will 

be held within sight of the samplers or sample custodian, or will be kept in sealed or secured containers at all 

times. Sealed coolers and DOT shipping boxes will be used to ship samples to the designated laboratory via 

Priority 1 overnight FedEx service. 

Preprinted sample identification labels are used by ENSR to ensure that all required information is fully 

documented. When sample batches are shipped to the specified laboratory, a sample packing list (see 

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Figure 5-2) accompanies the shipment This form is based on established laboratory format and will be used 

to document sample transfer in the field and from sampling personnel to the laboratory. 

The ENSR Field Team Leader will coordinate the packing and shipment of all samples. Worksheets 

specifically designed for this program will be generated prior to the field effort. These sheets will assist the 

Field Team Leader in assuring that all samples have been collected, accounted for and shipped under sample 

traceability documentation to the appropriate laboratory. Requirements pertaining to sample preservation and 

recommended holding times are noted in Table 5-5. All materials such as field and laboratory notebooks and 

logbooks, field and laboratory data records, correspondence, reports, sample tags, traceability records and 

instrument printouts will be clearly labeled with the project number and become a permanent part ofthe project 

file. Project samples will be disposed of in an appropriate manner 60 days after acceptance and approval of a 

final report. All project-related documentation at both ENSR and the subcontractor laboratories will be kept on 

file for 2 years following submittal of the final report. 

5.8 Analytical Methods and Calibration Procedures 

This section delineates the analytical protocols that will be used to analyze samples during this performance 

test Samples of waste feed materials and stack gas will be collected and analyzed forthe parameters 

previously discussed using the appropriate laboratory protocols detailed in this section and as outlined 

previously in Table 5-3. 

5.8.1 Analysis of Waste Feed Streams 

5.8.1.1 Chemical and Physical Properties of Waste Feed Streams 

Analyses to determine the chemical and physical properties of the waste feed materials will be performed 

using appropriate ASTM or EPA SW-846 analytical methods as outlined in the Veolia FSAP and WAP. For 

any analytical results that are "non-detect", Veolia will utilize 14 of the detection limit for that parameter in any 

calculation of feed rates. 

5.8.2 Analysis of Stack Ga s Sample s 

5.8.2.1 Metals in Stack Gas Samples 

Analysis - Each sampling train will be prepared and analyzed in accordance with EPA Reference Method 29. 

From each sampling train, seven individual samples are generated for analysis. The first two samples, labeled 

Fractions 1A and 1B consists ofthe digested sample from the front half of the train, consisting ofthe 

particulate filter and the front-half nitric acid probe rinse. Fraction 1A is for ICP analysis and Fraction 1B is for 

mercury analysis. Fractions 2A and 2B consist of digestates from the moisture knock out and HNO3/H2O2 

impingers 1,2, and 3. Fraction 2A is for ICP analysis and Fraction 2B is for mercury analysis. Fractions 3A, 

3B and 3C consist of the impinger contents and rinses from the empty and permanganate impingers 4, 5, 

and 6. These fractions will be analyzed for mercury. 

Analyses for metals other than mercury will be performed using Inductively Coupled Plasma Mass 

Spectroscopy (ICP-MS) as described in EPA Method 6020 (SW-846, 3rd Edition). Mercury analysis will be 

performed using EPA Methods 7470A or 7471A (SW-846,3rd Edition). 

All quality control procedures, including the interference check standard, will be followed as described in the 

respective method. 

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Calibration - Calibration of the ICAP will be performed daily in accordance with the procedures described in 

Melhod 6020 and the manufacturer's instructions. The calibration is verified daily by analysis of an instrument 

check standard prepared from an EPA quality control concentrate or other independent standard. 

QA/QC requirements for the analysis of metals in stack gas samples are summarized in Table 5-6. 

5.9 Internal QA Program 

Quality control checks will be performed to ensure the collection of representative samples and the generation 

of valid analytical results for these samples. These checks will be performed by project participants throughout 

the program under the direction of the Project Manager and the QA Officer. 

5.9.1 Data Collection and Sampling QC Procedures ' 

Q C checks for the process data collection and sampling aspects of this program will include, but not be limited 

to, the following: 

1. Use of standardized data sheets, checklists and field notebooks to ensure completeness, traceability, and 

comparability ofthe process information and samples collected. 

2. Field checking of standardized forms by the Field Team Leader and a second person to ensure accuracy 

and completeness. 

3. Strict adherence to the sample traceability procedures. 

4. Submission of field biased blanks. 

5. Leak checks of sample trains before and after sample collection and during the test, when appropriate. 

5.9.1.1 Sampling Equipment Q C Checks and Frequency 

Calibration of the field sampling equipment will be performed prior to and at the conclusion of the field 

sampling effort. Copies ofthe calibration sheets will be available onsite during the field sampling program for 

inspection, will be kept in the project file and wiil be submitted in the final report. Calibrations will be performed 

as described in the EPA publication "Quality Assurance Handbook for Air Pollution Measurement Systems, 

Volume III, Stationary Source Specific Methods;" Section 4.2.1 presents acceptance limits. 

Leak checks of the sample trains will be conducted in accordance with the protocol called out for each method. 

Leak checks will be conducted prior to and at the end of sample collection and during the test run, when 

appropriate. 

5.9.1.2 Sample Collection QC Checks 

Field-biased blanks of reagents and collection media (deionized water, filters, impinger solutions, etc.) will be 

placed in appropriately cleaned and sized sample containers in the field and handled in the sarne way as 

actual field samples, to provide a Q C check on sample handling. 

For this program, sample collection Q C checks and frequency for samples to be analyzed in the laboratory are 

listed below: 

• One field reagent blank Method 29 sampling train. 

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5.9.2 Analytical QC Procedures for Samples to be Analyzed in the Laboratory 

The Quality Control program for laboratory analysis makes use of a number of different types of QC samples 

to document the validity ofthe generated data. The following types of Q C samples will be used during the 

program. 

5.9.2.1 Quality Control Samples and Blanks 

Method Blanks 

Method blanks contain all the reagents used in the preparation and analysis of samples and are processed 

through the entire analytical scheme to assess spurious contamination arising from reagents, glassware, and 

ofher materials used in the analysis. 

Calibration Check Samples 

One ofthe working calibration standards which is periodically used to check that the original calibration is still 

valid. 

Laboratory Control Samples (LCS) or Blank Spikes 

These samples are generated from spikes prepared independently from the calibration concentrates. The 

LCS are used to establish that an instrument or procedure is in control. An LCS is nonmally carried through 

the entire sample preparation and analysis procedure also. 

Reagents used in the laboratory are normally of analytical reagent grade or higher purity; each lot of acid or 

solvent used is checked for acceptability prior to laboratory use. All reagents are labeled with tiie date ' 

received and date opened. The quality ofthe laboratory deionized water is routinely checked. AH glassware 

used in the sampling and analysis procedures will be pre-cleaned according to the method requirements. 

Standard laboratory practices for laboratoty cleanliness, personnel training and other general procedures are 

used. The results of these quality control procedures will be included in the final report. 

5.10 Data Reduction, Verification and Data Reporting 

Specific QC measures will be used to ensure the generation of reliable data from sampling and analysis 

activities. Proper collection and organization of accurate information followed by clear and concise reporting of 

the data is a primary goal in all such projects. 

5.10.1 Field Data Reduction 

Appendix B of this Performance Test Plan presents the standardized forms that will be used to record field 

sampling data. The Field Team Leader and at least one other field crew member will review the data collected 

from each train in its entirety in the field. Errors or discrepancies will be noted and dealt with accordingly. The 

Field Team Leader has the authority to institute correction actions in the field. The QA officer will also be 

notified for resolution if the situation warrants. At a minimum, the QA officer is apprised of all deviations from 

standard protocol. Field data reduction (checking of valid isokinetic sampling rate and other sampling 

parameters) is done with a laptop computer using standardized Excel spreadsheets. Appendix C provides 

sample train setup and recovery schematics and a description of solutions and reagents to be used in each 

isokinetic train required for the overall program. All sample recovery sheets will be checked for completeness. 

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5.10.2 Laboratory Analysis Data Reduction 

Analytical results will be reduced to appropriate units by the laboratory using the equations given in the 

applicable analytical method. Unless otherwise specified, results from the analysis of waste feed and process 

samples for specific target constituents will be reported in units of mg/kg or % wt Other parameters will be 

reported in standard units such as g/cc, Btu/lb, etc. 

The laboratory typically reports results from the analysis of stack flue gas samples as total mass detected for 

the sample submitted. For those sample fractions where liquid impinger condensate is analyzed, the 

laboratory will measure the total liquid volume submitted and multiply by the measured concentrations of target 

analytes in these samples. The laboratories will generally report data as follows: 

« All metals except mercury - total pg of each metal in the combined front-half and back-half sample 

train fractions 

• Mercury-total pg in each sample train fraction 

Each LS C will be responsible for reviewing all results and calculations and verifying the completjeness of fhe 

data set The laboratory reports submitted by each laboratory will include the following deliverables: 

• Transmittal letter listing all samples and analyses and a case narrative identifying any difficulties 

associated with the analyses and any anomalous QA/QC results 

• Copies of Chain of Custody Forms 

• Sample Report forms with sample field and laboratory identifier, dates of sample preparation and 

analysis, analytical results and detection limits 

• Method Blank results 

• Matrix spike and matrix spike duplicate results (as applicable) 

• Replicate sample analyses (as applicable) 

• Laboratory Control Sample results 

5.10.3 Data Verification 

Data verification is fhe process of reviewing data and accepting, qualifying or rejecting it on the basis of 

method-specific criteria. The independent project QAO will use validation methods and criteria appropriate to 

the type of data and the purpose ofthe measurement. Records of all data will be maintained, even that judged 

to be an "outlying" or spurious value. 

Field sampling data will be validated by the Field Team Leader based on a judgment ofthe representativeness 

of the sample, maintenance and cleanliness of sampling equipment and the adherence to an approved, written 

sample collection procedure. 

Analytical data will be validated by the subcontractor laboratory Q C or supervisory personnel using criteria 

outlined in their laboratory-specific QA Plan and/or written SOPs. Results from field and laboratory method 

blanks, replicate samples and internal Q C samples will be used to further validate analytical results. Analytical 

results on field blanks and replicate field samples are valuable for validation of sample collectiort also. Q C 

personnel will review all subcontractor laboratory raw analytical data to verify calculated results Presented. 

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The following criteria will be used to evaluate the field sampling data: 

• Use of approved test procedures 

• Proper operation of the process being tested 

• Use of property operating and calibrated equipment 

• . Leak checks conducted before and after tests 

• Use of reagents that have conformed to Q C specified criteria 

• Use of NBS traceable CE M calibration gases (as applicable) 

• Proper chain-of-custody maintained 

• All sample trains -check to ensure proper sample gas volume collected 

The criteria listed below will be used to evaluate the analytical data: 

• Use of approved analytical procedures 

• Use of property operating and calibrated instrumentation 

• Precision and accuracy achieved should be comparable to that achieved in previous analytical 

programs and consistent with objectives stated in this document. 

5.10.4 Final Data Reporting 

i 

Stack gas concentrations for each applicable parameter will be calculated from laboratory results and field 

sampling data. The total weight of the analyte detected will be divided by the volume of gas sampled to 

provide emission concentrations. For MACT compliance, all emission concentrations are further corrected to 

7% oxygen for comparison to the published standards. 

A complete Final Report outlining the goals, methods and results for the program will be prepared and any 

deviations from this test plan will be documented. The Final Report will include a section on evaluation and 

discussion of QA/QC results. Results will be compared to expected limits for accuracy, precision and/or 

completeness as targeted in this protocol. The final test report will also include the results of any internal 

audits conducted on the program as well as: 

• All field data sheets showing sampling method, dates, run times, personnel, equipment; sample 

preservation, identification and compositing records. 

• Field equipment calibration data. 

• Analytical lab reports and relevant supporting documentation. 

5.11 Routine Maintenance Procedures and Schedules 

This section provides pertinent information for field sampling equipment as well as a listing of all critical facility 

equipment necessary to maintain permitted operating conditions and to demonstrate continuing permit 

compliance. Information is provided for preventive maintenance and schedules and spare parts for key 

equipment and instrumentation. 

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5.11.1 Field Sampling Equipment 

The field team follows an orderly program of positive actions to prevent the failure of equipment or instruments 

during use. This preventive maintenance and careful calibration helps to ensure accurate measurements and 

minimal field delays. 

All equipment that is scheduled for field use is calibrated as outlined previously in Section 5.6.2.1. Prior to 

each field use for a specific project, the equipment is cleaned and checked to ensure it is in good working 

order. An adequate supply of spare parts and sample train glassware is brought to each site to minimize 

downtime and field sampling delays. Any equipment that does experience problems is appropriately tagged in 

the field to ensure that it is repaired upon return to the office. 

5.11.2 Facility Equipment and Instrumentation 

As stated in Sections V.a.F. and V.b.F. of Veolia's Part B RCRA Permit, each incinerator system undergoes a 

"thorough visual inspection for leaks, spills, fugitive emissions, and sign of tampering at least daily and in 

accordance with the inspection schedule contained in Appendix 6 ofthe approved permit application". Veolia 

utilizes these inspections and additional preventive maintenance activities as proactive measures for 

minimizing the potential for malfunctions. To facilitate proper maintenance, a cold shutdown will occur at least 

once per year for each incinerator system. 

Routine inspection and maintenance activities are scheduled, communicated, and recorded through the use of 

field checklists. Parts of the incinerator systems that are subject to wear (e.g., bearings, O-rings; air/oil filters) 

are replaced based on the schedules indicated on these checklists. These field checklists will also be used to 

document repairs or replacements of incinerator components that may be revealed during inspections. Brief 

procedures/instructions for inspection and maintenance activities are provided on field checklists. 

Continuous monitoring system components are comprised of many instruments including scales, flowmeters, 

thermocouples, pressure transmitters, differential pressure cells, bag leak detectors, and limit switches. All 

components critical for monitoring permitted parameters are audited either on a quarterly or annual basis to 

ensure proper operation. Daily calibration checks are performed on the Unit"s CEM's. 

5.12 QA/QC Assessment Procedures 

The Q A activities implemented in this program will provide a basis for assessing the accuracy and precision of 

the analytical measurements. Section 5.8 of this QAPP discusses the QA activity that will generate the 

accuracy and precision data for each sample type. A generalized form ofthe equations that will be used to 

calculate accuracy, precision and completeness follows. 

5.12.1 Accurac y 

Percent accuracy will be determined using the following equation: 

% Recovery = — ~

 S )

 x 100 

where: 

X = experimentally determined concentration of the spiked sample 

T = true concentration ofthe spike 

S = sample concentration before spiking 

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5.12.2 Precision 

Precision (calculated as percent relative difference) will be determined using the following equation: 

Rc lative Percent Difference 'RPD ) = 

where: 

Di and D2 = results of duplicate measurements or standard deviation relative to the average value 

expressed as relative standard deviation: 

Relative standard deviation will be expressed as follows: 

Relative Standard Deviation (% RSD) = 

x (xi • X.) 

x 100 

where: 

a (n-i) = standard deviation of the sample data 

n = number of replicates 

x<xi..xn) = arithmetic mean of the sample data 

5.12.3 Completeness 

Data completeness is a measure of the extent to which the database resulting from a measurement effort 

fulfills objectives for the amount of data required. For this program, completeness will be defined as the 

percentage of valid data for the total valid tests. Completeness is assessed using the following equation: 

Completeness (%) = 

Dr 

Dc 

x 100 

where: 

Dr = number of samples for which valid results are reported 

D c = number of valid samples that are collected and reach the laboratory for analysis 

The completeness objective will help to evaluate the accuracy and precision of the analytical measurements. 

5.13 External QA Program 

The External Quality Assurance Program includes both performance and system audits as independent 

checks on the quality of data obtained from sampling, analysis, and data gathering activities. Every effort is 

made to have the audit assess the measurement process in normal operation. Either type of audit may show 

the need for corrective action. 

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Veotia ES Technical MACT Unit 4 HWC Performance Test Plan Page 16 of 37 

5.13.1 Performance Audits 

The sampling, analysis, and data handling segments of a project are.checked in performance audits. A 

different operator/analyst prepares and conducts these audit operations to ensure the independence of the 

quantitative results. 

EPA Quality Control concentrates or other standards will be used to assess the analytical work. Results will 

be reviewed by the subcontractor laboratory and Q C personnel. Any additional audit samples presented by 

the regulatory agencies will be analyzed along with program samples, by the appropriate lab and at the same 

time as all other samples. It will, however, be the responsibility of the regulatory agency to obtain these 

samples, and present them to the facility project manager in a form that is amenable and appropriate to the 

analytical methods being utilized. 

If the regulatory agency advises facility program manager that audit results fall outside of acceptable ranges, 

the analytical data will be further reviewed for error in conjunction with the agency, lf a simple, correctable 

error is found (e.g., an arithmetic error), correction will be made and results resubmitted. If no error is found, 

an investigation into other causes of the failure (e.g., lack of sample integrity) will be conducted and results 

evaluated in terms ofthe impact on sample data integrity. 

5.13.2 Corrective Action 

The acceptance limits for the sampling and analyses to be conducted in this program will be those stated in 

the method or defined by the project manager. The corrective actions are likely to be immediate in nature and 

most often will be implemented by the analyst or Project Manager; the corrective action will usually involve 

recalculation, reanalysis, or repeating a sample run. Ongoing conective action policy is described here. 

5.13.2.1 Immediate Corrective Action 

Specific Q C procedures and checklists are designed to help analysts detect the need for corrective action. 

Often the person's experience will be more valuable in alerting the operator to suspicious data or 

malfunctioning equipment. 

If a corrective action can be taken at this point, as part of normal operating procedures, the collection of poor 

quality data can be avoided. Instrument and equipment malfunctions are amenable to this type of action and 

QC procedures include troubleshooting guides and corrective action suggestions. The actions taken should 

be noted in field or laboratory notebooks but no other formal documentation is required, unless further 

corrective action is necessary. These on-the-spot corrective actions are an everyday part of the QA/QC 

sysfem. 

Corrective action during the field sampling portion of a program is most often a result of equipment failure or 

an operator oversight and may require repeating a run. When equipment is discovered to be defective (i.e., 

pre- and post-sampling leak check) it is repaired or replaced and a correction factor is established as per the 

EPA method. If a correction factor is unacceptable the run is repeated. Operator oversight is best avoided by 

having field crew members audit each other's work before and after a test. Every effort is made by the field 

team leader to ensure that all Q C procedures are followed. Economically, it is preferred to repeat a run during 

a particular field trip rather than return at a later date. 

Corrective action for analytical work would include re-calibration of instruments, reanalysis of known Q C 

samples and, if necessary, of actual field samples. 

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Veolia ES Technical MACT Unit 4 HWC Performance Test Plan Page17of37 

If the problem is not solved in this way, more formalized long-term corrective action may be necessary. 

5.13.2.2 Long-Term Corrective Action 

The need for this action may be identified by standard Q C procedures, control charts, performance or system 

audits. Any quality problem which cannot be solved by immediate corrective action falls into the long-term 

category. The condition is reported to a person responsible for correcting it who is part of Ihe closed-loop 

action and follow-up plan: 

The essential steps in the closed-loop corrective action system are: 

• Identify and define the problem. 

• Assign responsibility for investigating the problem. 

• Investigate and detennine the cause of the problem. 

• Detennine a corrective action to eliminate the problem. 

• Assign and accept responsibility for implementing the corrective action. 

• Establish effectiveness of the conective action and implement it 

• Verify that the conective action has eliminated the problem. 

Documentation ofthe problem is important to the system. A Corrective Action Request Form is filled out by 

the person finding the quality problem. This form identifies the problem, possible causes and the person 

responsible for action on the problem. The responsible person may be an analyst, field team leader, 

department Q C coordinator or the QA Director. If no person is identified as responsible for action, the Q A 

Director investigates the situation and determines who is responsible in each case. 

The Corrective Action Request Form includes a description of the corrective action planned and the date it was 

taken, and space for follow-up. The QA Director checks to be sure that initial action has been taken and 

appears effective and, at an appropriate later date, checks again to see if the problem has been fully solved. 

The QA Director receives a copy of all Corrective Action Forms and then enters them in the Corrective Action 

Log. This permanent record aids the QA Director in follow-up and makes any quality problems visible to 

management; the fog may also prove valuable in listing a similar problem and its solution. 

5.13.3 Quality Assuranc e Reports to Management 

5.13.3.1 Internal Reports 

The Laboratory Services Coordinator will prepare a written report on Q C activities associated with this project 

for the Quality Assurance Director. This report will detail the results of quality control procedures, problems 

encountered and any corrective action, which may have been required. 

All Corrective Action Forms are submitted to the QA Officer for initial approval ofthe corrective action planned 

and a copy is provided to the Program Manager. All system audit reports are provided to the Program 

Manager and the Quality Assurance Officer. 

Q:\rr^7\Prcj«te\10002022\Veolia Performance Test Plan U4 R3_052108.doc 

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1

 Date: May 2008 

Section: 5.0 

Veolia ES Technical MACT Unit 4 HWC Performance Test Plan Page 18 of 37 

5.13.3.2 Reports to Client 

The final report will include a section summarizing QA/QC activities during the program. The Project Manager, 

Laboratory Services Coordinators and the QA Officer will participate in preparing this section. This section will 

provide summary QA/QC results for method blanks and laboratory control spike recoveries. This section will 

evaluate overall data quality in terms of accuracy, precision and completeness. Any discrepancies or 

difficulties noted in program work, protocol deviations or documentation gaps will be identified and discussed. 

l 

aVm#7\Prqects\10002022\Vi!oJa Performance Tesl Plan U4 R3_052108.doo 

V E S 002688 
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Veolia ES Technical MACT Unit 4 HWC Perfonnance Test Ptan Page 19 of 37 

Table 5-1 General Sampling and Analytical Program Overview (Stack Exhaust) 

Parameter 

MACT Emission 

Limits (a) Sampling Method Analytical Method 

Flow, Fixed Gases and 

Moisture 

N/A E PA Methods 2,3 

and 4 

N/A 

Mercury 130 ug/dscm EPA Method 29 EPA Method 7471 

CVAAS 

LVM Metais 

(As, Be and Cr) 

92 ug/dscm E PA Method 29 EPA Method 6020 

ICP-MS 

SVM Metals 

(Cd and Pb) 

230 ug/dscm E PA Method 29 EPA Method 6020 

ICP-MS

 1 

t 

I 

Q:\rrw97\ProjectsV10002022\Vedla Performance Tesl Plan IM R3_052108.doc 

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, Section: 5.0 

Veolia ES Technical MACT Unit 4 HWC Performance Test Plan Page 20 of 37 

Table 5-2 Q A Objectives for Field Measurements 

Field Measurement Accuracy Precision Completeness 

Moisture (EPA Method 4) (a) ±20 % 100% 

Carbon Dioxide (EPA Method 3 - Orsat Analysis) - (b) N/A 100% 

Oxygen (EPA Method 3 -r Orsat Analysis) (c) N/A 100% 

(a) Not determinable. 

(b) An accuracy of + 0.2% would be expected if a certified gas audit is performed. Otherwise 

individual readings must be within 0.3 g/g-mole ofthe mean value for three (replicate) readings. 

(c) An accuracy of 20.8% ± 0.5% would be expected if an ambient air audit is performed. 

I 

i 

i 

O:\mw97\Praiects\10002022WeoSa Perfonnance Test Ran U4 R3_052108.doc 

V E S 002690 
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Date: May2008 

Section: 5.0 

Veolia ES Technical MACT Unit 4 HWC Perfonnance TestPIan Page 21 of 37 

Table 5-3 Overall Summary of Performance Test Stack Gas Sampling and Analysis Program 

Sample Matrix and 

Samplinq Method 

Analytical 

Parameters 

Analytical 

Method 

Lab . 

(a) 

Total Samples Analyzed 

Sample Matrix and 

Samplinq Method 

Analytical 

Parameters 

Analytical 

Method 

Lab . 

(a) 

Total 

Runs 

Field 

Blanks Audit 

Lab 

QC 

I 

EPA M 29 Metals (b) EPA M 6010B/6020/7000 MAX 3 1 0 1 

EPA M 3 QzandCOj EPA M 3 (Orsat) ENSR 3 0 0 0 

Facility CEM 02 andCO Facility CEM QA Plan Veolia 3 0 0 0 

(a) ' MAX = Maxxam Analytic 

Veolia = Veolia ES Tech 

(b) Target metals include: a 

al, Burlington, Ontario 

nical Solutions 

rsenic, beryllium, cadmium, chromium, lead and mercury 

a\mw97\Pniiects\10M2022\Veolia Performance Test Plan U4 R3_052108.doc 

V E S 002691 
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Date: May 2008 

Section: 5.0 

Veolia ES Technical MACT Unit 4 HWC Performance Test Plan Page 22 of 37 

Table 5-4 Traverse Point Locations 

STACK INSIDE DIAMETER: 48 inches 

SAMPLING LOCATIONS: 16.4 diameters downstream 

6.50 diameters upstream 

MINIMUM NUMBER OF TRAVERSE POINTS 12 

AS SPECIFIED BY EPA METHOD 1: 

NUMBER OF TRAVERSE POINTS SAMPLED: 12 

Percent of Stack 

Traverse Point Diameter Distance in Inches 

Number From Inside Wall From Inside Wall 

1 95.6 45.9 

2 85.4 41.0 

3 70.4 33.8 

4 29.6 14.2 

5 14.6 7.0 

6 4.4 2.1 

Q:\mw9nProjecls\10002022\Veoia Performance Tesl Plan U4 R3_0521O8.doc 
Veolia ES Technical MACT Unit 4 HWC Performance Test Plan 

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Date: May 2008 

• Section: 5.0 

Page 23 of 37 

Table 5-5 Sample Preservation and Holding Time Requirements 

Stack Gas Samples

 w 

Parameter Matrix Preservation 

Holding 

Time 

Metals (Method 29) 

(except Hg) 

Metals (Method 29) Aqueous Cool,4°C 6 months 

(except Hg) 

Solid /Filter Cool,4°C 6 months 

Mercury (Method 29) Aqueous Cool, 4°C 28 days 

Solid/Filter Cool,4°C 28 days 

(a) Holding times will be calculated from the day of sample collection. 

QArrM97\Proiects\10002022\VBOia Performance Test Plan U4 R3_052108.doc 

V E S 002693 
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Date: May 2008 

Section: 5.0 

Veolia ES Technical MACT Unit 4 HWC Performance Test Plan Page 24 of 37 

Table 5-6 Q A Requirements for Metals in Stack Gas by ICAP or ICP-MS 

Quality 

Parameter, Method Determination Frequency Target Criteria 

Calibration Initial analysis of standards Daffy Analysis of calibration check 

standard within 10% of true value 

Calibration 

Continuing mid-range calibration 

standard 

At least once before and 

after sample analysis 

90-110% 

Calibration 

Continuing calibration blank With continuing calibration 

standard 

Subject to interpretation 

Accuracy - ICV Analysis of calibration check 

standard 

After every initial calibration 90% to 110% of true value 

Accuracy - fitters Analysis of NIST standard reference 

fitters or EPA audit filters, if provided 

Once per test 70% to 130% of reference value 

Accuracy Post-digestion spikes Once per test 70% to 130% recovery 

Precision Post-digestion spikes Once per test RPD < or = 35% 

Blanks Field Reagent Blanks and Method 

Blanks 

One each per test Evaluated on case by case basis | 

RPD = Relative Percent Difference 

ICAP = Inductively Coupled Argon Plasma 

ICP-MS = Inductively Coupled Plasma - Mass Spectrometry 

ICV = Initial Calibration Verification 

a:Vnw97\Prtfe<^\1rXH)2022Vveo!ia Performance Test Plan IM R3_052108.doc 

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Veolia ES Technical MACT Unit 4 HWC Performance Test Plan 

Revision: 0 

Date: May 2008 

Section: 5.0 

Page 25 of 37 

Figure. 5-1 Stack Sampling Locations 

1 

s 

il 

• A 

Traversa 

i 

3 

4 

& 

&*ZKTD3 fciTl • 

a n 

7,01 

4&3B 

* ST 

i 

a\m«a7\Prcjecte\10M2022\Vec*i Performance Test Plan U4 R3_052108.doc 

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Veolia ES Technical MACT Unit 4 HWC Performance Test Plan 

Revision: 0 

Date: May 2008 

Section: 5.0 

Page 26 of 37 

Figure 5-2 Example Sample Packing List 

ENSRAECOM SAMPLE PACKING LIST 

Project Site: Sample Date: Project Location: P.O.# 

Pronram Tvpe: ntate Shipped : 1 ahnratnryProject No.: Cooler No.: 

ENSR Office: WESTFORD DOT Box No.: 

ENSR j .: Contact: Doua Roeck Sianature : FedEx Airbill N j .: 

Sample ID Matrix DescriDtion Analytical Parameters. . 

Instructions 

Fiplrl Nntfis / Comments-

(11 Plpasfi mh im this form with analytical msi firs 

Relinquished by (Print) Date: 

Signature: Time: 

Received by (Print) Date: 

Signature: Time: 

Analytical Laboratory: 

Relinquished by (Print) Date: 

Signature: Time: 

Received by (Print) Date: 

Signature: Time: 

Received by: Date: 

Signature: Time: 

Q:\rr^7lProjecls\10O02022\Veolia Performance Test Plan U4 R3_0521O8.doc 

V E S 002696 
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Date: May 2008 

Veolia ES Technical MACT Unit 4 HWC Performance Test Plan Section: Appendices 

Appendix A 

Unit 4 Process Flow Diagram 

Qtaw97\Projects\10002022\Veolia Performance Test Plan U4 R3 052108.doc 

V E S 002697 
V E S 002698 
Veolia ES Technical MACT Unit 4 HWC Performance Test Ran 

Revision: 0 

Date: May 2008 

Section: Appendices 

Appendix B 

Field Data Sample Collection Forms 

i 

Q:\rnw97\r^,ecls\10002022\VeoSa Performance Test Plan U4 R3_052108.doo 

V E S 002699 
ENSR AECOM EPA ISOKINETIC SAMPLING - FIELD DATA SHEET 

Sampling Train 

Run Number 

. Client 

Facility Location 

Source 

Date | 

Operator 

Stack Dla, - in, 

Stnrt Time 

Stop Time 

Bit ro metric Prcsturc 

Static Pressure {+/-) 

Probe/Pltot Number 

Pltol Coefficient 

Filter Box No. 

Meter Box No. 

Orlllce Coefficient (Y) 

Delta H ® 

Nonlo Stec/No. 

X A D Thermocouple ID: 

Imp Outlet TC IDi 

LEA K CHECK S ln "Hg 

INITIAL VAC , In. CF M 

M ID VAC , tn. CF M 

FINAL VAC . In. CF M 

INIT. PITOT. FINA L PITOT 

FILTER DATA 

lit i J u ' 

< 

m 

w 

o 

o 

ro 

o 

o 
ENSR AECOM 

ORSAT ANALYSIS (EPA METHOD 3) 

PLANT : PRE-LEA K CHECK : 

DATE : POST-LEA K CHECK : 

LOCATION : NOTE: 

Valid Leak Check: Liquid level must not fall 

below bottom of capillary tubing in 4 minutes 

and meniscus must not change by more than 

0.2 mL in 4 minutes. 

SAMPL E TYPE : 

NOTE: 

Valid Leak Check: Liquid level must not fall 

below bottom of capillary tubing in 4 minutes 

and meniscus must not change by more than 

0.2 mL in 4 minutes. 

OPERATOR : 

NOTE: 

Valid Leak Check: Liquid level must not fall 

below bottom of capillary tubing in 4 minutes 

and meniscus must not change by more than 

0.2 mL in 4 minutes. 

NOTES / DATA CRITERIA -

C 0 2 : When greater than 4%, difference between readings shall be 0.3% or less. 

When less than 4%, difference between readings shall be 0.2% or less. 

0 2 : When greater than or equal to 15%, difference between readings shall be 0.2% or less. 

When less than 15%, difference between readings shall be 0.3% or less. 

Test Condition: 

Run: Reading A Reading B Reading C Avg. 

Net 

Volume 

G A S Actual Net Actual Net Actual Net 

Avg. 

Net 

Volume 

co2 

o2 * 

Run: Reading A Reading B Reading C Avg. 

Net 

Vplume 

G A S Actual Net Actual Net Actual Net 

Avg. 

Net 

Vplume 

C 0 2 

• 

i 

0 2 * 

Run: Reading A Reading B . Reading C Avg. 

Net 

Volume 

GAS Actual Net Actual Net Actual Net 

Avg. 

Net 

Volume 

co2 

0 2 * 

* Net 0 2 is actual 0 2 minus actual C0 2 reading. 

Q:\rnw97Vrojeclsi1000202Z\Appendix B_all urals\rOreatAndy3isFc-mi.xis]A 

V E S 002701 
SAMPLE TRAIN MOISTURE RECOVERY DATA SHEET 

Reference Method / Sampling Train : 

Recovered by:' Recovered by: Recovered by: 

Run No. Date: Run No. Date: Run No. Date: 

Filter No.: FQter No.: Filter No.: 

Im pinger No. and Volume Im pinger No. and Volume Im pinger No. and Volume 

No. 

Initial 

(mL) 

. Final 

(mL) 

Rinse 

(mL) No. 

Initial 

(mL) 

Final 

(mL) 

Rinse 

(mL) No. 

Initial 

(mL) 

Final 

(mL) 

Rinse 

(mL) 

1 1 1 

2 2 2 

3 3 3 

4 4 4 

5 5 5 

6 6 6 

7 7 7 

DIFF: DIFF: 

7 

DIFF: 

Totals Totals Totals 

' *- y' ',. 

Initial 

(g) 

Final 

(9) 

initial 

(g) 

Final 

(g) -

Initial 

(g) 

Final 

(g) ' *- y' ',. 

Initial 

(g) 

Final 

(9) DIFF: 

initial 

(g) 

Final 

(g) DIFF: -

Initial 

(g) 

Final 

(g) DIFF: 

Silica 

Gel 

Silica 

Gel 

Silica 

Gel 

Final Net Moisture Gain: Final Net Moisture Gain: Final Net Moisture Gain: 

Q:\mwv97\PTpiecls\10002022\AppendiK Bjall unil5\lM4Recovery.xlsJA 

V E S 002702 
NOZZLE CALIBRATION FORM 

Client: . Project*: 

Date: _ ^ Calibrated by: 

Nozzle ID # D,, in. D2 , in. D3 , in. Delta D, in. D avg , in. 

Where: 

Di^,3 = Nozzle diameter measured on a different diameter to the nearest 0.001 in. 

Delta D = Maximum difference between any two measurements, in. 

Tolerance = 0.004 in. 

D a v g = Average of D, i 2 3 

Q:Vnw97\Projects\10002022\Arjpendix B_all unifca[Noz2leCaKbForm.xls]A 

V E S 002703 
Revision: 0 

Date: May 2008 

Veolia ES Technical MACT Unit 4 HWC Performance Test Plan Section: Appendices 

Appendix C 

Isokinetic Sampling Train Setup and Recovery Schematics 

Q:\mw97TProjecls\10002022\Veofe Performance Tesl Plan IM R3_052108.doc 

V E S 002704 
SAMPLE TRAIN SETUP 

MULTIMETALS 

(as Per EPA Method 29 / 0060) 

IMPINGERS 

1st 

2nd 

3rd 

4th 

5th 

6th 

7th 

empty * 

100 mL 5% HN0 3 / 10% H 2 0 2 

100 mL 5% HNO3 /10% H z O z 

empty 

100 mL 10% H 2S 0 4 7 4 % KMn0 4 

. 100 mL 10% H 2 S 0 4 / 4% KMnO, 

Silica Gel 

FIELD BLANKS (Exact Volumes Specified by Method) 

0.1 N HN03 

5%HNO 3 /10%H 2 O 2 

10%H 2 S O 4 /4%KMnO 4 

Dl Water 

8 N HCI 

Filter 

300 mL 

200 mL 

100 mL 

100 mL 

25 mL 

(added to 200 mL water) 

One unused filter 

optional - used for high moisture stacks 

Q'.toiv»97\Projects\10002022\Appendix Call unils\[selupM60.KlspMOlST 

V E S 002705 
NOZZLE 

Brush/ 

0.1 N 

(~25r 

TCnse 

HN03 

nU3X 

PROBE 

Brush/ 

0.1 N 

(- 50 n 

Rinse 

HNO3 

dU3X 

FRONT HALF 

FILTER HOUSING 

FILTER 

Brush/Rinse 

0.INHNO3 

f~25mLl3X 

Carefully remove filter 

from supporf with Tefloncoated tweezers and place 

in petri dish 

250 mL Amber 

Brush loose particulate onto 

petri dish 

FH-HNOa 

(2) 

Container 3 Seal petri dish with 

tape 

Notel: Exactly 100 mL of 0.1N HN03 used 

for rinsing nozzle, probe and FH filter 

housing. 

Note 2: Nozzle, probe and FH filter housing 

are rinsed with water followed by acetone 

after the nitric acid rinse. The water and 

acetone are then discarded. 

Filter 

(D 

Container 1 

METHOD 29 (METALS) RECOVERY SCHEMATIC FRONT HALF RECOVERY 

Page 1 of 2 

J:\Air_Tox\Schematics\Recovery\M29FH.doc 

V E S 002706 
ENSR AECOM 

IMPINGERS 

FILTER SUPPORT AND 

BACK HALF OF 

FILTER HOUSING 

1

11 

(Empty) 

(Optional) 

Rinse Three Times 

with 0.1 N Nitric Acid 

2"" and 3 M 

(HNO3/H2O2) 

Measure Volume 

Empty the 

into Cc 

Contents 

ntainer 

Rinse Th 

with 0.1 N 

ree Times 

Nitric Acid 

Note: Exactly 100 mL of 

nitric acid is used to rinse 

all component s up 

through impingers 1-3. 

Measure Volume 

Empty the Contents 

into Container 

Rinse Thr 

with 0.1 N 

ee Times 

vlitric Acid 

950 mL 

BH 

(Container 4) 

< 

m 

co 

o 

o 

ro 

--1 

o 

-vl 

4

t h

 (Empty) 

5

l h

 and 6th (KMn04) 

Measure Volume 

Empty the Impinger 

No. 4 Contents into 

Container 

Rinse with 100 mL 

0.1 N HNO3 

250 mL 

0.1 N HNO3 

(Container 5A) 

• 7m 

(Silica Gel) 

Weigh for Moisture Discard 

Empty the Impinger 

Nos. 5 and 6 Contents 

into Container 

Rinse Three Tlmes.wlth 

Permanganate Reagent, (100 

mL total) then with Water 

(100 mL total) 

500 mL 

KMn04 

(Container 5B) 

Remove Any 

Residue with 25 

mL 8N HCI 

Solution 

250 mL 

8 N HCI 

(Container 5C) 

J:\Air Tox\Schematics\Recoverv\M29BH.doc METHO D 29 (METALS) RECOVER Y SCHEMATIC - BAC K HAL F RECOVER Y 

Page 2 of 2