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5465 Miller County Road 64 Texarkana, AR 71854 Dear

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5465 Miller County Road 64 Texarkana, AR 71854 Dear ADEQ ARK ANSAS Department of Environmental Quality October 31, 2013 Dan Crowe Plant Manager Tyson Foods, Inc. (River Valley Animal Foods) 5465 Miller County Road 64 Texarkana, AR 71854 Dear Mr. Crowe: The enclosed Permit No. 1684-AR-8 is your authority to construct, operate, and maintain the equipment and/or control apparatus as set forth in your application initially received on 5/20/2013. After considering the facts and requirements ofAC.A §8-4-101 et seq., and implementing regulations, I have determined that Permit No. 1684-AR-8 for the construction, operation and maintenance of an air pollution control system for Tyson Foods, Inc. (River Valley Animal Foods) to be issued and effective on the date specified in the permit, unless a Commission review has been properly requested under Arkansas Department ofPollution Control & Ecology Commission's Administrative Procedures, Regulation 8, within thirty (30) days after service of this decision. The applicant or permittee and any other person submitting public comments on the record may request an adjudicatory hearing and Commission review ofthe final permitting decisions as provided under Chapter Six ofRegulation No.8, Administrative Procedures, Arkansas Pollution Control and Ecology Commission. Such a request shall be in the form and manner required by Regulation 8.603, including filing a written Request for Hearing with the APC&E Commission Secretary at 101 E. Capitol Ave., Suite 205, Little Rock, Arkansas 72201. Ifyou have any questions about filing the request, please call the Commission at 501-682-7890. Sincerely, Mike Bates Chief, Air Division Enclosure ARKANSAS DEPARTMENT OF ENVIRONMENTAL QUALITY 5301 NORTHSHORE DRIVE / NORTH UTILE ROCK / ARKANSAS 72118-5317 / TELEPHONE 501-682-0744/ FAX501-682-0880 www.adeq.stote.or.us ADEQ MINOR SOURCE AIR PERMIT Permit No.: 1684-AR-8 IS ISSUED TO: Tyson Foods, Inc. (River Valley Animal Foods) 5465 Miller County Road 64 Texarkana, AR 71854 Miller County AFIN: 46-00193 THIS PERMIT IS THE ABOVE REFERENCED PERMITTEE'S AUTHORITY TO CONSTRUCT, MODIFY, OPERATE, AND/OR MAINTAIN THE EQUIPMENT AND/OR FACILITY IN THE MANNER AS SET FORTH IN THE DEPARTMENT'S MINOR SOURCE AIR PERMIT AND THE APPLICATION. THIS PERMIT IS ISSUED PURSUANT TO THE PROVISIONS OF THE ARKANSAS WATER AND AIR POLLUTION CONTROL ACT (ARK. CODE ANN. SEC. 8-4-101 ET SEQ.) AND THE REGULATIONS PROMULGATED THEREUNDER, AND IS SUBJECT TO ALL LIMITS AND CONDITIONS CONTAINED HEREIN. Signed: ~ October 31, 2013 Mike Bates Date Chief, Air Division Tyson Foods, Inc. (River Valley Animal Foods) Permit #: 1684-AR-8 AFIN: 46-00193 Table ofContents Section I: FACILITY INFORMATION 4 Section II: INTRODUCTION 5 Summary ofPermit Activity 5 Process Description 5 Regulations 7 Total Allowable Emissions 8 Section III: PERMIT HISTORY 9 Section IV: EMISSION UNIT INFORMATION 12 Section V: INSIGNIFICANT ACTIVITIES 17 Section VI: GENERAL CONDITIONS 18 APPENDIX A: NSPS-Subpart De - Standards ofPerformance for Small Industrial-Commercial- Institutional Steam Generating Units A-I 2 Tyson Foods, Inc. (River Valley Animal Foods) Permit #: 1684-AR-8 AFIN: 46-00193 List ofAcronyms and Abbreviations A.C.A. Arkansas Code Annotated AFIN ADEQ Facility Identification Number CFR Code ofFederal Regulations CO Carbon Monoxide HAP Hazardous Air Pollutant lb/hr Pound Per Hour No. Number NOx Nitrogen Oxide PM Particulate Matter PM IO Particulate Matter Smaller Than Ten Microns SOz Sulfur Dioxide Tpy Tons Per Year UTM Universal Transverse Mercator VOC Volatile Organic Compound 3 Tyson Foods, Inc. (River Valley Animal Foods) Permit #: 1684-AR-8 AFIN: 46-00193 Section I: FACILITY INFORMATION PERMITTEE: Tyson Foods, Inc. (River Valley Animal Foods) AFIN: 46-00193 PERMIT NUMBER: 1684-AR-8 FACILITY ADDRESS: 5465 Miller County Road 64 Texarkana, AR 71854 MAILING ADDRESS: 5465 Miller County Road 64 Texarkana, AR 71854 COUNTY: Miller County CONTACT NAME: Dan Crowe CONTACT POSITION: Plant Manager TELEPHONE NUMBER: 870-645-2693 REVIEWING ENGINEER: Melisha Griffin UTM North South (Y): Zone 15: 3710716.98 m UTM East West (X): Zone 15: 425205.53 m 4 Tyson Foods, Inc. (River Valley Animal Foods) Permit #: 1684-AR-8 AFIN: 46-00193 Section II: INTRODUCTION Summary ofPermit Activity Tyson Foods, Inc. (Tyson) operates a protein conversion plant in Texarkana, Arkansas, at 5465 Miller County Road 64. The facility produces high quality pet food grade poultry meal, high quality poultry fat, and high quality feather meal with blood meal additives. The purpose ofthis modification is to install the Diversey's comprehensive wet scrubber management system (ReNew). The new system will no longer utilize chlorine dioxide at SN-04, 05, and SN-ll through SN-14 but will instead use propylene glycol. The propylene glycol emissions are accounted for under the VOC totals for the sources. The changes resulted in a total emissions increase of 13.2 tpy ofVOC and a decrease of0.6 tpy ofchlorine dioxide. Process Description Poultry Meal Process Raw materials are transported to the plant in water-tight trailers and dumped into work bins. Dump room air is collected and sent through a packed bed scrubber (SN-13) treated by an approved technology (currently note #3). The clean product is conveyed to the steam heated cookers. In the cookers, proteins are coagulated, the excess water is evaporated and the fat cells are prepared for separation from the solid product. The steam is generated by three 1500 horsepower natural gas fired boilers. Natural gas combustion emissions from these boilers are designated SN-Ol, SN-02, and SN-03. After the product is cooked, it is conveyed out ofthe cooker and into a rotary screen where free­ run poultry fat is removed. The solids are conveyed to the presses where most ofthe residual fat is removed. All ofthe poultry fat is pumped through screens and is then centrifuged to remove fine solid particles. After centrifuging, the fat is pumped to storage tanks. The meal from the presses is now in the form ofa cake, which is cooled, ground, screened and classified before it is conveyed to bins for storage. After the poultry meal is processed, it is directed to a storage bin and then to the truck loadout (SN-09) where it is loaded onto a truck for distribution and/or to the bagging building (SN-15 & 16). Non-condensed vapors are sent to a high intensity packed bed scrubber (SN-04). Concentrated vapors from the presses, percolator, hopper, screens and centrifuges are sent to a venturi scrubber for particulate removal and then on to a packed bed scrubber (SN-04). Vapors from the grinders, central cleaning system, and aspirators are routed through a spray tower for particulate removal then on to the same packed bed scrubber (SN-04). This scrubber uses one ofthe approved odor control technologies (currently Note #3) to control the odors generated by these processes. The scrubbers are designed for maximum retention ofthe gases and maximum contact ofoxidizing solution with the air stream. Room air is scrubbed using the same type ofpacked bed scrubber (SN-05 & SN-ll). 5 Tyson Foods, Inc. (River Valley Animal Foods) Permit #: 1684-AR-8 AFIN: 46-00193 Feather Process Raw material is transported to the plant in water-tight trailers and dumped directly into a bin. The feathers are conveyed from the bin to the hydrolyzers where they are hydrolyzed (washed) under elevated temperature and pressure. They are then conveyed to a hot air dryer for moisture reduction. The moist meal product is passed through a natural gas fired 25 MMBtuJhr hot air dryer (SN-06). The dried product is separated from the exhaust by a cyclone collector. Finished meal is moved from the Rendering Plant into storage silos, then to the load-out building, ultimately being dropped directly into hopper-bottom trucks (SN-09) and/or via surge hoppers in a separate building into "Super Sacks" (SN-15) for transportation. Exhaust from the cyclone is routed through a spray tower condenser and into a packed bed scrubber (SN-07) treated with one ofthe approved treatment technologies (currently note #3). Odor emissions from the hydrolyzers are routed into a packed bed scrubber (SN-07) treated with an approved treatment technology (currently note #3). Feather processing room air is also sent to a packed bed scrubber (SN-12). Odor emissions from the centrifuges and hoppers are routed through the same scrubber system that serves the feather hydrolyzers (SN-07). Blood Processing and Drying Whole blood is processed and dried to recover protein as blood meal. Raw blood is pumped from a blood storage tank into a steam-injected, tubular vessel in which the blood solids coagulate. The coagulated blood solids and liquid are then separated in a centrifuge and added via a hopper to the wet hydrolyzed feathers to be dried in the hot air dryer (SN-06). Odor emissions from the centrifuges and hoppers are routed through the same scrubber system that serves the feather hydrolyzers (SN-07). After the blood meal is processed, it is directed to a storage bin. Meal is conveyed via auger conveyor from the grinding room storage bins directly through the new bagging load-out system (SN-16) in the bagging building. The auger conveyor moves the meal into small pre-loading surge hoppers, from which the bags are loaded by desired weight. The facility is capable ofloading hopper-bottom trucks and Super Sacks in any combination, interchangeably, with either poultry or feather meal, in the truck load-out building (SN-09) and in the bagging building (SN-15 & SN-16). Approved Odor Treatment Technologies Note #1: Radox Technology: The facility uses Radox Technology as another treatment method in all ofthe scrubbers. Peroxyacetic acid or its equivalent, Hydrogen Peroxide (or equivalent) and Sulfuric Acid (or equivalent) are injected into the pipe leading to the scrubber and maintained at a pH ofless than 6.5 with the optimum range between 5.0 and 5.5.
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