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Eastman Business Park Hazardous Waste Management Facility Epa Id Number Nyd 980592497

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Eastman Business Park Hazardous Waste Management Facility Epa Id Number Nyd 980592497 ATTACHMENT D MULTIPLE HEARTH INCINERATOR - HWMU-32 ENGINEERING DESCRIPTION OF THE MULTIPLE HEARTH INCINERATION SYSTEM RED ROCHESTER, LLC EASTMAN BUSINESS PARK HAZARDOUS WASTE MANAGEMENT FACILITY EPA ID NUMBER NYD 980592497 TABLE OF CONTENTS Multiple Hearth Incinerator Figure D2 – Building 95 Multiple Hearth Incinerator Figure D16 – Multiple Hearth Incinerator Waste Sludge Feed and Ash Management System Appendices: Appendix D-5 – SCC Burner Information Appendix D-6 – SCC Combustion Air Fan Curve Appendix D-7 – ID Fan (System) Performance Curve Appendix D-8 – Weigh Conveyor Vendor Diagrams HWMU-32 Drawings List Trial Burn / Comprehensive Performance Test Part 373 Permit Attachment D Submitted to NYSDEC — December 9, 2013 D1 MULTIIPLE HEARTH INCINERATOR (MHI) The MHI, serial no. 74445, was manufactured by Envirotech System, Inc. The MHI as shown in Figure D-2 is an eight hearth (0 to 7) unit. The zero hearth, located at the top of the unit serves as a flue gas pretreatment device. The sludge is fed to the #1 hearth by a screw conveyer system. Drying of the feed occurs on hearths #1 and #2. Burning or combustion of the feed takes place on hearth levels #3, #4, and #5. Ash cools down on levels 6 and 7 and is discharged at the bottom of the unit. The waste feed proceeds from one hearth level down to the next and, the feed is distributed across each hearth with a rotating rabble arm. The calculated residence time is approximately two hours (15-20 minutes in each hearth) for the waste feed inside the hearth, before it is "ashed" out in the bottom. Natural gas is used as needed as auxiliary fuel to support the combustion temperatures inside the hearth for the 2-hour duration. Depending on which hearth level the arm is located, the blades are pitched inward or outward to promote gradual waste feed movement to the center or outside wall of the MHI. Also, the arm serves to break up the Waste feed allowing uniform heat distribution through the waste feed layer. Non-contact cooling air is introduced at the bottom of the unit and flows through the center of the rotating hollow shaft and may either be discharged fully to atmosphere or partially returned to the #6 hearth to provide air below the burning zone. Combustion / flue gases exit from the top of the zero hearth and are sent to the SCC for further destruction of organics and hydrocarbons. Table D-5 provides the construction details of the MHI. The specifications of the burners are listed in Table D-6. SECONDARY COMBUSTION CHAMBER (SCC) Organics present in the flue gases exiting from the MHI are destroyed in the SCC. The SCC operates at temperatures and residence times sufficient to meet regulatory requirements for Destruction and Removal Efficiency (DRE) for organic compounds in the waste feed. The actual temperatures that will determine operating conditions were and will again be demonstrated during Comprehensive Performance Tests that are required every 5 years. As previously mentioned, no wastes are fed directly to the SCC. Part 373 Permit Attachment D Submitted to NYSDEC — December 9, 2013 D2 The SCC specifications are listed in Table D.7, Burner specifications are given in Table D-8. Drawings 095XX-312-017-Sheet 11 (SCC general arrangement) and E095XX-310-025 (process flow diagram) indicate the dimensions used in calculating residence time. Waste Feeds to MHI Sludge is pumped from one of-the four holding tanks. There are three (3) 50,000 gallon and one (1) 100,000 gallon holding tanks. Sludge is pumped from a holding tank to the dewatering equipment (centrifuge) for dewatering. The dewatered sludge is dropped from the centrifuge into the sludge storage bunker by gravity. A bunker conveyor moves the sludge to the horizontal portion of the elevating conveyor. Grit conveyed with a grit conveyor can be added to the sludge on the elevating conveyor. The elevating conveyor lifts the sludge and grit and drops it from a horizontal section into a screw auger, which feeds the sludge into the #1 hearth. RED has a waste feed measurement system. Drawings of this belt weigh scale system, are attached in Appendix D-8. As shown on the waste feed and ash handling system schematic (Figure D- 16), it is located at the end of the drag conveyor and before the drop chute to the screw conveyor. When the sludge weigh conveyor is out of service the incinerator is not operated. Combustion Air and Fuel to MHI Approximately 10,000 scfm of combustion air is provided to the MHI by a 100 horsepower (hp) fan. Additional combustion air is provided by a second blower with a rating of 2500 scfm at 7" static pressure and 5 hp. Commercially available natural gas is fed to the MHI at the rate of up to about 12,400 cfh at 3.5 psig. MHI burner specifications are given in Table D-6. A maximum heat load of about 48 MMBTU/HR is available at the MHI. In the event of an automatic waste feed cutoff, natural gas will continue to be used to support the combustion temperature inside the hearth and the secondary combustion chamber at the permit limit for a duration of 2.25 hours to ensure that the sludge remaining in the hearth is burned out. Drawing E095XX-770-003 shows combustion air and natural gas flows to the MHI. The drawing also provides details of MHI instrumentation. Part 373 Permit Attachment D Submitted to NYSDEC — December 9, 2013 D3 Auxiliary Fuel and Air to SCC The SCC burner combustion air is provided from a blower. The SCC burner and blower specifications are listed in Table D-8. Natural gas is fed to the SCC through a burner rated at approximately 22 MM Btu/hr. The available maximum heating load to the MHI and SCC combined is about 70 MMBTU/HR. Auxiliary Waste Feed to SCC No wastes are fed to the SCC. The feeds to the SCC consist of the exhaust gases, from the MHI, natural gas and- auxiliary combustion air provided by a blower as referenced in Table D-8. FEED LOCATIONS Table D-1 identifies the various feeds and where they are introduced to the system. Generally combustion is accomplished by the heating value of the waste feed. Auxiliary natural gas is fed to the MHI as needed. In the SCC, natural gas is used to elevate the temperature of the MHI flue gases in order to complete destruction of organics. AUTOMATIC WASTE FEED CUTOFF SYSTEMS (AWFCO) Parameters which will cause an automatic waste feed cutoff are listed in Table E-4 of Exhibit E in Module I Schedule I. Automatic cutoffs for waste feed are accomplished by turning off the power to the waste feed conveyor. A distributed control system (DCS), known as the MOD 300, located and operated from the control room by trained operators, provides the appropriate alarm that a waste feed cutoff has occurred and indicates the cause for the cutoff. SHUTDOWN PROCEDURES Shutdown definitions and parameters for the MHI and SCC are listed in Table D-10. The induced draft fan will be shut off, and emergency natural draft by-pass stack on the SCC will be opened if conditions trigger an emergency shutdown. This stack is sufficiently tall to vent and disperse MHI gases directly into the atmosphere. This will prevent fugitive emissions from escaping either into the building or at ground level. Part 373 Permit Attachment D Submitted to NYSDEC — December 9, 2013 D4 AIR POLLUTION CONTROL EQUIPMENT (APCE) Flue gases leaving the SCC enter the APCE where particulates, metals and acid gases are removed in staged equipment consisting of: a quench chamber, a packed bed condenser/scrubber, an entrainment separator, a variable throat venturi, and a WESP. Planned APCE setpoints -for these devices during normal operations are summarized in Table D-11. The various emission control processes of the APCE are described in the following sections. The hot flue gases from the SCC are first quenched to adiabatic saturation temperature in the quench. Quench water will be once through and comes from the secondary treatment effluent. The quench water will be continuously discharged from the quench bottoms sump and returned to the wastewater treatment plant to prevent build-up of suspended and dissolved solids. The Condenser, using once through secondary treatment effluent water, is a counter current flow packed scrubber equipped with a structured packing that resists build up and plugging. As gases pass through the packed section, they will be sub-cooled and water vapor condensed. In the condensation process, fine particles are formed which further act as nuclei to promote the growth of larger particles which are more easily collected downstream by the Venturi Scrubber. The cooled gases exit the Condenser through a mist eliminator and enter the Venturi Scrubber. The Venturi is an inertial impaction device where the gases containing particles are accelerated into the high velocity 'throat' area. At the throat, water injected from above is sheared into millions of droplets, which collide and encapsulate the gas particles. Particle collection efficiency is directly related or proportional to the pressure drop across the throat; it is inversely proportional to the size of the particle contained in the gas stream. As the gas flow varies through the scrubber, a damper in the throat can be manually or automatically modulated to maintain a constant pressure drop. The venturi differential is calculated by the MOD300 control system, once every second, by subtracting the inlet pressure (PT 1097) from the outlet pressure (PT 1091). The scrubber water is supplied by effluent (STE) recycled from the venturi and the entrainment separator.
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