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HomeMy WebLinkAboutAQ_F_0400032_20090715_CMPL_InspRpt (4) NORTH CAROLINA DIVISION OF Fayetteville Regional Office AIR QUALITY Smithfield-Clinton Plant Inspection Report NC Facility ID 8200027 County/FIPS: Sampson/163 ;Date: 07/15/2009 Facility Data Compliance Data Smithfield - Clinton Plant Inspection Date 07/13/2009 424 East Railroad Street Inspector's Name Tien Nguyen :Clinton,NC 28328 Operating Status Operating Lat' 34d 59.6180m Long: 78d 18.6930m Compliance Code Compliance-inspection SIC : 2011/Meat Packing Plants Action Code FCE NAILS: 311611 /Animal(except Poultry)Slaughtering On-Site Inspection Result Compliance j Contact Data Permit Data Facility Contact Authorized Contact Technical Contact permit 03034/R21 Norman Johnson Ken Wilson Norman Johnson Issued 10/13/2008 Environmental Manager General Manager Environmental Manager Expires 9/30/2012 910 299-3051 910 299-3000 910 299-3051 Classification Synthetic Minor Permit Status Active Inspector's Signature: Comments: _77�� Date.of Signature: ✓V M's o ff (I) DIRECTIONS TO SITE: Smithfield. —Clinton Plant is located at 424 Railroad Street in Clinton, NC, Sampson County. From FRO,take NC-24 East towards Clinton. Follow the 421 Bypass/Faircloth Freeway and exit towards NC-24 East. Turn left onto Southeast Blvd. The plant is approximately'/4 mile on the left. h(II) FACILITY DESCRIPTION: Smithfield- Clinton is a hog processing plant. The facility produces pork products for human consumption as well as rendering products for use in animal feed. All sources associated with the rendering plant are permitted. Approximately 85%of the raw material for the rendering process comes from the hog processing plant. The remaining 15%comes from dead stock from Smithfield Farms affiliates. Rendering products include feed fat, blood plasma, blood meal, and bone meal. These products are generally used in poultry and pork feed. A portion of the animal fat is now being used to produce biodiesel. The main facility (hog slaughter and meat preparation facility) processes approximately 10,200 hog per day and Clinton currently has approximately 1500 employees. The operates 24 hours per day,7 days per week. Smithfield facility also produces fresh meat products as well as smoked and cured products. Smithfield - Clinton currently operates under air permit no. 03034R20,issued 14 November 2007,with an expiration date of 31 August 2012. ,(II) INSPECTION SUMMARY: On 13 July 2009, I, Tien Nguyen of Fayetteville Regional Office, met with Mr. Norman Johnson, Environmental Manager, and Mr. Stan Mertz, Supervisor of Rendering Operations, to conduct a compliance inspection. Prior to entering the facility, I drove around the facility to observe odor and opacity. I did not notice any distinct rendering odor past the facility boundaries. All the boiler stacks had 0%opacity.During pre- inspection conference,Mr.Johnson checked the facility contact information for correctness.Upon meeting with Mr. Johnson I discussed the inspection procedure and permit requirements. Mr. Johnson provided monthly fuel usage and S02& NOx emissions records for review. Mr. Johnson stated that the facility has not burned No.2, No.6, or animal fat in years and has no plans to use them in the future. Mr. Johnson stated that the facility has never burned biogas.Mr.Johnson also provided a current Risk Management Program for review. Mr.Johnson led me on a detailed tour of the processing plant,focusing on the LPG-fired singer and smoke houses. The facility is currently burning/smoldering 400 lbs of hardwood daily in their smoke houses. Mr.Johnson also , f 3 r r f ave me a tour-of the':= :astewater t"'tmen-room:Thee :a tewat r tr n g w w s a eatme t is controlled b the wastew ter: sc , • '., y nw rubber .:Mr Stan Mertz-;Su ervisor of Renderan Q er Lions•ledmeon.a:tour at_the_renderin -facih rand p p i F'� ro-ade, Tall;renderm fec,r. for;' ur.<re =i , :4 v. d o.ds o v.ewR,.,The.records a eared m com lianceand•u to date I:made several p g- 1 pp p. P recommendations to:ensure=that_all momtorin 're uirernents::were:=r c r tt ,.,. .,_ .,. . _._ , .., .,.,: fd vie e o ed and m an:easily viable m i Y S < ' PE> LT.TED'EMISSYON SOURCES. At.the>;time':.of the-ans e¢tio rnth ld' n.S fie .. . .., ...�M r.,. _ .. ;_ . :.,, �. .r. .• ;.•. .y r, atrig and oP wpqer ermit No 03.034R20, '.' ,. ..•..... F.:,r,.... -a....:5,...:.. 3-.....,..: ..:,;--.._may.,-:...:..�r•.'s-ry .a..r _ -.S ,t.. i> - _ SY} „�': 2 _ r( � 1 f 1 r` f, \ i 1}; NG L:LP G/SBio as.-�Vlethane / aleablePork i : , Fat/:Saleable,'Poul . �Fat/,No.2 lNo6 Fuel. •L try N/A N/A - ,Oil F •'ed Boiler 25 1mmB �:_ r 4 i Boil r i N.G/LPG/Bio s::Methane ./Saleable=Pork.=< j -NSPS _try _ 1N/A f ). ,Oil.Fired er. •1`2 'rimB ,- v 6 tu/hr t j l. L Y - B3 Methane: Saleab e P r s i SPS lv - .Oil Fired Boiler 4., s - L` s` ethane /,Saleable P rk - /Sa eable`Poul. -Fat/No•2/:No.G Fuel :` r`: . A:< �: 1.�: -` A.` . ._• NSPS ; ., � s .il F j` •' O ired:Boiler._ 33 S:mmBtu/hr \ eab e 1- l . •Poul :, NSPS it Fir` B`,O ed oiler 33 5 irimBtu/hr , ' n > `Shell and T ef.,Conden. er, D.=1 • : f 3-. Eva oratve Condenser,.Cooker ; a S team Renderiri Cooker .24 00 .1 - S 0 bs/hr CD 4 CD 6 Venturi Scrubber g (., ) ,Cooker'Packed 1, C Z To r.s D we Scrubber;\2nd Stage4Packed i Tower:Scrubber Shell and The Condenser �vaporative Conden ker. .Hair H drol. .zer. •�' -CD:'4 D. CD 7.;` `Tower Scrubber 2nd:Sta a Packed - 1 Tower`Scrubber Shell and Tube Condenser CD=10 CD- Eva oratve.Condenser Cooker. p ES 3 , Steam.Renderm Cooker, 45 000`lbs/lr 3 'CD 4 CD- .. Venturi Scrubber Cooker:Packed 6` CD=7 Tower ber Scrub "2nd Stage Packed Toweri Scrubber Cooker Venturi:Scrubber Cooker ES-4: Low;Odor-Intensi �Renderin O. erations; .. CD 4 CD=6 ' ty g p Packed Tower Scrubber,2nd Stage CD-7� Packed Tower Scrubber B•, lood Venturi'Scrubber,;Blnod' ,. GD=S,"CD 5-5 Blood Rin .D er 6 000 lbs/hr Packed Tower.Scrubber 2nd Sta' e. 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N/ ,..,.,. a 5 ES-PTR . Wastewater F'retreatment.Room GD TR.. -..., >,iPacked-B;ed Scrub" _. t - ber APPLICABLE AIR l^'UAI,ITY REG'EATIONS _,t F a; ` h._�s is ,r A ADDITION,OF NEW FUEL TYPE The Permittee: hall:note DA iii.wrrtm .if the.facili starts:usm a J " _ 3' Q g ty. g n ew fuel bo as 'or ; 'ease ` oul"( g ,p k gr ,p try greasez or No 2 fuel oil) W. IN COMPLIANCE-:T ,- _. , h aczlz has not.cambusted.an netiv uel o l nd na f <; t3'.,, Y, f z,.a s no.;zmmedaate plans;to do:so f7' i `< :, tt ,B . -15A; CAC 2D.0503"PAR- -C _ kT N _,, ES FROM FUEL BURNING INDIRECT .EAT.EXCHANOERS { , :, :.:. ; ,::. The articulate..emissions,.from b filer :,ID , . L'_o,.. s,_. Nos .B,, 1. throw B.,4,_shall.not,exceed:,an emisst: n.rate:of.034 P .gh.., Q <. lbs mmB TU. Th .. e., articulate iris- '8"from.boiler ID No: S shall_not exceed an n. ' •:;: O p ssion° rate' f 0 32 lbs/mmBTU` r fl bs. . a__ ., IN-.COMPLIANCE .:...The AP =,e 4 .,,mzssrons,actor, or LPG:"zs:>0 006abs/m'mBTU` 'natural as is.0.007.No: .6.•: f f Y. g , . 4, - - ut e oil is 0. 2:06 . , Wlizle there,,are currentl."no..AP 42 ,actors,-or P,ork'an.d'.Poul Fat,PM',emrsszons: om,the. , < : f . Y,. . ,, 01 . f ,:. <, at rs�a sumed t ._o be less thanNo.:,6 uel oil, � but ;eater than No 2:,uel,. ,A111he.lzsted:emrssion actors;are well'below th f,3 f e perriiztted limits i ] .3 f ( .: `,. > - .. .' ::.i C :15A NCAC"2D ,0515 PARTICULATES FROM•MISCELLAhTEOIS INDUSTRIAL PROCESSES — �- h . , :; t Particulate.matter.;'from emissions-sources hall not:exceedahe::foll m P. o.ii ow g. E 4:10 (P) for 30 tons/hr or E=55*' 1/ - 0 for_ P30 toris%hr �/ :l ...T .�� - IN.COMPLIAN E n> C Records s owed t.at r h h o..utzne maintenance was. er armed on all arts o +the.,.reriderm _ f p f p f g t s s em Week r l exte nal zri:� t ec ions are per ormed r "-sc ubber,,.., ,,es`;ar -routWel cleaned'=_-and':zlter.;ba s-are 'Y,, Y p P f f g - .. chap ed F, . ,. „a .;rozzmatel ;eve ix months. An arts:a the:o erationtleat mz ht be sub.ectao artzcitldte matter• g pp Y: rY YP p g =J p,. emissions.ar'e:-controlled`b .,ba"h uses.:.condenser y g o s, an, or scrubbers D ..,15A:NCAC,�2D.":0516.°:SULFUR DIOXIDE=:EMISSIONS FROM COMBUSTYON SOURCES The sulfur ":: dioxide_emssionsfrom-the.combustionso c „,_ ur.es.shall dot exceed:an.emission rate of 2 3;lbs/mmBTU o` INCOMPLIANCE The AP-42 errussions actor or LP.G is,0.-.0001.'lbs/mmBTU natural as zs:.0.001 0.5%S. f :f , , g, 1Vo.:6 uel: ",f oil is Q.523 While;there are currentl no AP 42„ actors or Pork and Poul` `Fat SO emissions om Y.. f f , �'1' z fy'. 0 the fat is assumed to be much,less•than•0.,, 6,:.; 1Vo.;6 fuel.,oil. All the Izsted'emisszon'octors are well below the _ , . f permitted limits r. : E , 1' . ,- . 5� NCAC�, , .0521 CONTROL OF'`VISIBLE:.EMISSIONS`-"Facil -wide visible"`emissions shall•,not exceed'2'opacity IN COMPLIANCE Tkiere.was.no"excess visible:emissions noted on the o the`irisnection The faclity f ur'was,b, ,nin natural as on the d. .o ins ection and:has not burned,• uel oil since Janus 2006 All the boilers , g g aY f p f rY had 0%opacity / r , F. 15A NCAC 2D .0524 NEW SOURCE PERFORMAIC STANDARDS:;— Sulfur coritei�t of all"fuel oil'for boilers B-1-7 B-2, and B-3 shall be less than 0:5X sulfur la. 'wei' t .The. ermittee must conduct fuel sam lin _ P Y P g . \. on No. 6 fuel oil, keep fuel analysis on file (fuel certs for No. 2 fuel oil), and record the amount of fuel combusted during each month. IN COMPLIANCE—Fuel oil has not been combusted since January 2006 The facility has not combusted No. 2 fuel oil. The facility has combusted only natural gas since last year. G. 15A NCAC 2D .0524 NEW SOURCE PERFORMACE STANDARDS Sulfur content of all fuel oil for boilers B-4 and B-5 shall.be less than 0.5%sulfur by weight. Visible emissions shall be less than 20%opacity for boilers B-4 and B-5. The permittee must keep fuel certs / analysis on file and record the amount of fuel combusted during each month. The facility must take oil samples from the fuel tank immediately after the tank is filled and before any fuel is combusted. These samples must be analyzed for the sulfur content of the oil. Boilers B-4 and B-5 are limited to an annual capacity factor of 10%. Each time the facility combusts No.6 fuel. oil,the Permittee must perform a 6-minute visible emissions evaluation. IN COMPLIANCE-Smithfield-Clinton submitted a report in July for the amount of fuel combusted monthly. Mr. Johnson provided those records through May 2009. The facility has not received/combusted any No. 6 fuel oil since January 2006, therefore, the visible emissions evaluations and fuel analysis were reviewed during the last two compliance inspections. Mr. Bowen and Mr. Johnson provided certificates for VE certified personnel. The opacity from these boilers was 0%opacity on the day of the inspection. H. 15 NCAC 2D .0539 ODOR CONTROL OF FEED INGREDIENT MANUFACTURING PLANTS — Exhaust should be routed to odor control equipment. Raw material must be transported properly. Dead stock cannot be located at the facility for more than 24 hours. IN COMPLIANCE The facility utilizes oxidizing scrubbers (C102) to control odors from rendering processes. Smithfield — Clinton performs monthly calibrations, weekly external checks, data validation procedures, and performs schedule maintenance on all scrubbers, baghouses, and condensers. Raw material from the main facility is transferred to the rendering plant either through ducts or dump trucks. Raw material that is not ducted directly to the rendering facility is dumped into an enclosed container. The container is also controlled by the scrubber. The facility keeps records for every load of dead stock to insure that the raw material is not kept on site for more than 24 hours. The Department of Agriculture also required them to keep these records. Mr. Mertz did state that the facility may occasionally store material on-site for over 24 hours, but only if the material is kept in a refrigerated truck. Mr. Mertz stated that the facility is accepting very little dead stock now. I. TESTING REQUIREMENTS—The facility must conduct emissions testing within 90 days of initial startup of any boiler combusting saleable pork fat. Testing shall be conducted for the following pollutants: CO, PM, VE,NOX,S02,and VOC. IN COMPLIANCE—The facility has not started combusting saleable pork fat; therefore, the required testing has not been performed. The facility does not have any immediate plans to begin combusting pork fat. J. RECORDKEEPING FOR NON-FOSSIL FUELS—The Permittee must maintain fuel specifications for each load,both on-site and off-site products,of non-fossil fuels combusted at the facility. IN COMPLIANCE—The facility is not yet combusting any non fossil fuels. K. 15 NCAC 2D .0611 BAGFILTER REQUIREMENTS — The permittee shall perform an annual internal inspection on baghouse CD-9. The permittee shall also perform inspections and maintenance as required by the manufacturer. The facility shall record all maintenance activities in a logbook and kept on site. IN COMPLIANCE—Annual inspections are recorded in a maintenance logbook. L. 15 NCAC 2D .0611 CONDENSER REQUIREMENTS—The permittee shall perform periodic maintenance and inspections on condensers CD-1, CD-3, and CD-10 as required by the manufacturer. The facility shall record all maintenance activities in a logbook and kept on site. The facility must conduct at least weekly external inspections. The exit temperature of the condenser shall be less than 150T. IN COMPLIANCE—Mr. Mertz showed us the logbook for all condenser maintenance and inspections. The logbook was very thorough showing that weekly inspections are performed on the condensers. An operator records the condenser exit temperature every four hours during operation. The facility also has a continuous monitor, which records this exit temperature on a strip chart. The exit temperature was 1050F on the day of the inspection. M. 15 NCAC 2D .0611 SCRUBBER REQUIREMENTS — The permittee shall perform an annual internal inspection on scrubbers CD-4 through CD-8 and CD-11 for the spray nozzles,packing material, and chemical feed system. The Permittee must conduct twice daily external checks for leaks and odor, weekly internal inspections of nozzles, monthly cleaning/calibration of associated equipment, monthly inspection of chemical feed system, and quarterly inspection of packing material. The permittee shall also perform inspections and maintenance as required by the manufacturer. The facility shall record all maintenance activities in a logbook and kept on site. Scrubbers must also utilize oxidizing solution and be operated within the following parameters: Scrubber Type Liquid Flow Rate ORP ID No. ACF al/min PH m CD-PTR Waste water scrubber > 125 -- -- CD4 Cooker Venturi(10,000) >30 -- -- C135 Blood Venturi(4,000) > 12 -- -- CD6 Packed Tower(10,000) > 120 >9.0 400-800 CD7 Packed Tower(15,000) > 150 >9.0 400-800 CD 11 Packed Tower(4,000) >40 >9.0 400-800 CD8 2 Stage Cross Flow(100,000) >25>500 500 a '- 400-800 IN COMPLIANCE—Mr. Mertz showed us a logbook detailing all maintenance and inspection activities.. The logbook was detailed and up to date. Odor/leak checks are conducted_every four hours during operation. Weekly inspections are performed on the nozzles. Monthly cleanings and calibrations and chemical feed system inspections are done weekly by Chem Treat and monthly by Smithfield. Quarterly inspections of the packing material are also completed. Annual internal inspections are also conducted quarterly and were denoted in the I&M logbook. The oxidizing agent used in all scrubbers is chlorine dioxide(002). Smithfield—Clinton has a contractor from ChemTreat that provides the chlorine dioxide for the rendering facility and wastewater treatment facility. An operator records the scrubber operating parameters every four hours. These reading are taken manually and are maintained in a logbook. All ORP readings were between 600-750mv during the inspection. N. 15 NCAC 2D .1806 CONTROL AND PROHIBITION OF ODOROUS EMISSIONS — The odor at the facility's border should not be objectionable. IN COMPLIANCE A slight odor was present surrounding the rendering building. There was a very distinct odor in the wastewater treatment area also, specifically the sludge load out area. The facility had a recent odor complaint on April 1, 2009. An objectionable odor was not noted off-site on the day of the inspection. 0. 15 NCAC 2Q .0315 LIMITATION TO AVOID 15A NCAC 2Q .0501 (TV) — Facility wide PM-10, S02, NO,,, and VOC emissions shall be less than 100 tons per year. VOC and PM emissions shall be controlled by condensers,bagfilters,and scrubbers as described in the permitted source list. The amount of fuel combusted as well as S02 and NO,,emissions should be recorded monthly and totaled annually. Fuel certifications/analysis must also be maintained on site. S02 emissions shall be calculated using the sulfur content determined in the lab analysis for No.6 fuel oil. A report must be submitted 30 days after each calendar year quarter for total S02 and NO,emissions. IN COMPLIANCE—The facility provided up to date records detailing the fuel com busted as well as S02 and NOx emissions. Actual emissions are well below the permitted limit. Annual emissions through May 2009 show emissions of 13 tons of NO,and 0.09 tons of S02. P. 15 NCAC 2Q .0317 LIMITATION TO AVOID 15A NCAC 2D.0530(PSD)—Facility wide S02 emissions shall be less than 250 tons per year. Monitoring and recordkeeping requirements are met by complying with the requirement of 2Q.0315. IN COMPLIANCE—Smithfield—Clinton has all required records and is well below the PSD Avoidance limit. 1' - - r 4 0 T f. CFR PAR 6,8.RISK MANAGEMENT PROGRAMS .:The: ermittee shall com 1'.'will a11`r.' e,. p,K „p y equirements J: i /ncludiri submittal of a,Risk=Mana dgemerit Rl�,i to EPA. t _ g> rIN COMPLIANCE The: acrlr has a:current Rrs >Mana ement Pr'f z ty k g ogram for ammonia on site pF RMIT.ENEWT,;,EMISSION SOURCES. ;:Under the.:current: ermit `the , ollowin sources'-are'-1i ted`.'as p g ., s :_Insi i icant/F'ermit Exem"t�Acti�ties under IS., �NCAC`2 . 1 gn p 4_ Q 0 ve 5: LP:fired heatrn'''unrts:for>meat corm ID Nos.IMC,1 ,I1VI�;:2 IMC 3' II.MC.-4.and'IMC-S � ) g g_� ) COMPLIAN�CE HISTORY. `_ , f: a .77 00 Robert•H .:denans eetedahe'facli hich di not a ear to`b JL m i,. �� ... p • ,...�3',w' �l�e ili was d pp e _compl ance face- � o t f-u o com harice with the f 11 , in 0 ow ownershi than `e ermrt �7E violation recordkee`m and p g p g: P ,. P g , �,. - re ortm and control device-par, maintenance and recordkee lri p g p p in ;Februa <200°1` FRO;_issued an.NOV/NRE for liewiolations.>found.m the: revious s eetion: . p - r 1" 2001 Ju ;DA issued an.;enforcement�for5 591 to Lund Paciciri' Co. �— Q x Y g li.. / t Au'ust;2 002. FRO ssued a�n N:0�1/NRE for vrolatin "he odor-control"'sti"elation.r . g p :. Se tember 20:02 R P F O issued an NOU/NRE fox yiolatm ahe odor control"sti ulation g. p :Se tember 20.02 • .,::FRO:tissued:an NOU f r'f . . p /NRE ,o .",allure to.,submit a uarter� ,repair ,nor to,30 7ul 20.02 q,. Y p_ p Y Nouemb'er.2 003 FRO issued an NOV/NRE for failure tore ,ort excess emissions and alfunctions.' p rn L r Feliru 2 4 ark 00 Robert ay den ins ecte th"f r p d e hty,=which appeared tobe m com :Hance: e, a p y Jul 2605 ::.P..remium: tan r . dard„ e,formed NSPS Stack`_Test on Boilers B 2 B 3 :and.B 4 S_ p J " 2 anu 006 Premium Standard erformed NSPS Stack Test'on'Boilers L art' p 2' , March 006 :FRO"issued an NOV for failure to'submit NSP' :Source.Test Resultsb the.dea lm y d e, v Jul 2007 FR assued 4n NOV;for failure�recordtheresultsof visible emissions observations'=on thre e days r r",':when_the boilers were'o erational�a�id'condenser�exittern:erature:'obserationsr; ink` "` 1 p p dui g a two week eriod when the:unit:was.o'eratiorial' �s V; Se "teriber 200`8 FRO:assued;:an;NOV for failure tomairitam scrubbers.withm.o' erational `arairieters= P 1 p p. r2a' Novembe, 008 FR O_issued permit,applicabih ty additional,information for;continuous;monitbring of scrubber Y ki O idation Reduction Potential .ORP and wastewater effluent in aseous scrubbers&Venturi � ) g L s - , , . rngvIO : aenheoliseraogmdeu . 13CONCLUSNS NV B J Y e 009 ins ecton:Smithfield "Clinton Plant a eared to be iri coin Nance with all re uirements outlined in'th'eir air p PP P., q permit. txn ' cc 1 ;ZOO-Cehtral Ftl (yeli ) 777 FRO Faeihty Files'(blue). • t } r t 2 y.