| | AIR CONSTRUCTION PERMIT APPLICATION To Construct and |
| | 1,89 | | MB | Operate THE DEPARTMENT OF THE ARMY PUEBLO CHEMICAL |
| | 167 | | stron | DEPOT ASSEMBLED CHEMICALWEAPONS ALTERNATIVES PUEBLO |
| | CHEMICAL AGENT DESTRUCTION PILOT PLANT |
| | 3779 | | ID | U.S. Army's Chemical Materials Agency |
| | 2004 | | rok |
| | TABLE OF CONTENTS |
| | LIST OF ACRONYMNS AND ABBREVATIONS..x |
| | EXECUTIVE SUMMARY ..xiii |
| | SECTION A INTRODUCTION. A-1 |
| | A-1 Location. A-2 |
| | A-2 Stockpile A-2 |
| | A-3 Construction . A-3 |
| | A-4 Application Organization .. A-4 |
| | SECTION B PROCESS AND FACILITY DESCRIPTIONS ..B-1 |
| | B-1 Process OverviewB-1 |
| | B-2 Process Details .B-4 |
| | B-2a Energetics ProcessingB-6 |
| | B-2a(1) Munitions Unpacking and Reconfiguration SystemB-7 |
| | B-2a(2) Projectile/Mortar Disassembly System .B-8 |
| | B-2a(3) Energetics Rotary Hydrolyzer System ..B-9 |
| | B-2a(4) Heated Discharge Conveyor System B-10 |
| | B-2a(5) Energetics Neutralization System..B-11 |
| | B-2b Agent Processing..B-12 |
| | B-2b(1) Munitions Washout System (MWS) B-13 |
| | B-2b(2) Agent Collection and Neutralization System ..B-14 |
| | B-2b(3) Metal Parts Treatment System.B-17 |
| | B-2c Biotreatment System ..B-18 |
| | B-2d Water Recovery and Brine ReductionB-19 |
| | B-2d(1) Water Recovery System .B-19 |
| | B-2d(2) Brine Reduction System .B-21 |
| | B-2e Dunnage Processing B-23 |
| | B-2e(1) Dunnage Shredding and Handling SystemB-23 |
| | B-2e(2) Continuous Steam Treatment System .B-24 |
| | B-3 Design Basis for Process Emission EstimatesB-26 |
| | B-4 Process Off-Gas Treatment Systems..B-28 |
| | B-4a Metal Part Treatment System Off-Gas Treatment System..B-30 |
| | B-4b ERH/ENR Off-Gas Treatment System .B-31 |
| | B-4c Continuous Stream Treater Off-Gas Treatment System ..B-33 |
| | B-4d Munitions Washout System Off-Gas Treatment System .B-34 |
| | B-4e Biotreatment Area Off-Gas Treatment System.B-35 |
| | B-4f Brine Reduction System Off-Gas Treatment System B-35 |
| | B-4g Dunnage Shredding and Handling Off-Gas Treatment System B-36 |
| | B-4h DFA Process Filtration System .B-36 |
| | B-5 Facility Descriptions ..B-37 |
| | B-5a Energetics Processing Building.B-38 |
| | B-5b Agent Processing Building..B-39 |
| | B-5c Laboratory B-40 |
| | B-5d Control Support Building .B-40 |
| | B-5e Personnel and Maintenance Building.B-41 |
| | B-5f Process Auxiliary Building .B-41 |
| | B-5g Utility Building .B-42 |
| | B-5h Waste Storage Building.B-43 |
| | B-5i Main Electrical Building ..B-43 |
| | B-5j Filter Electrical Building..B-44 |
| | B-5k Biotreatment Electrical Building..B-44 |
| | B-5l Maintenance Building B-44 |
| | B-5m Entry Control Facilities .B-44 |
| | B-5n Gas Mask Storage Building.B-45 |
| | B-5o Clinic ..B-45 |
| | B-5p Warehouse Outside FenceB-46 |
| | B-5q Personnel Support Building (Existing) .B-46 |
| | B-6 Facility Air Emission Discharge Points B-46 |
| | B-6a DFA Ventilation Stack ..B-47 |
| | B-6b DFA Process Stack..B-47 |
| | B-6c BTA Process Stacks B-48 |
| | B-6d BRS Process Stack ..B-48 |
| | B-6e Laboratory Stack ..B-49 |
| | B-6f PMB Decontamination Stack .B-49 |
| | B-6g Process Auxiliary Building Roof Vents B-50 |
| | B-6h BTA 30-day Storage Tank Vents .B-50 |
| | B-6i Fuel Oil Storage and Day Tanks ..B-50 |
| | B-6j Bulk Chemical Storage TanksB-51 |
| | B-6k Steam and Hot Water Boiler Exhaust Vents ..B-51 |
| | B-6l Emergency Generator Exhaust Vents B-52 |
| | B-6m Fugitive Emissions from Vehicular Traffic B-53 |
| | B-7 Emissions Monitoring B-53 |
| | B-7a Agent Emission Limits..B-54 |
| | B-7b Stack Monitoring Approach B-55 |
| | SECTION C APEN GUIDANCE.. C-1 |
| | SECTION D EMISSION ESTIMATES D-1 |
| | D-1 Criteria Air Pollutant Emissions D-2 |
| | D-1a Chemical Agents and Munitions Treatment Processes .. D-2 |
| | D-1b Steam and Hot Water Boilers.. D-3 |
| | D-1c Emergency Generators D-4 |
| | D-1d Diesel Fuel Storage Tanks. D-5 |
| | D-1e Vehicular Traffic D-6 |
| | D-1f Total PCAPP Criteria Pollutant Emissions .. D-7 |
| | D-2 Non-Criteria Pollutant Emissions.. D-7 |
| | D-2a Chemical Agents and Munitions Treatment Processes .. D-7 |
| | D-2b Steam and Hot Water Boilers.. D-8 |
| | D-2c Emergency Generators D-8 |
| | D-2d Diesel Fuel Storage Tanks. D-8 |
| | D-2e Total PCAPP Non-Criteria Pollutant Emissions D-9 |
| | D-3 Existing PCD Air Pollutant Emissions (Currently Permitted) D-9 |
| | D-3a Criteria Pollutants.. D-9 |
| | D-3b Non-Criteria Pollutants .. D-9 |
| | D-4 Emissions Summary.. D-10 |
| | D-5 References .. D-10 |
| | SECTION E REGULATORY COMPLIANCE EVALUATION ..E-1 |
| | E-1 General Requirements For the PCAPP Facility ..E-1 |
| | E-1a Source Registration E-1 |
| | E-1b Odor Emission..E-2 |
| | E-1c Ambient Air Quality StandardsE-2 |
| | E-1d Construction Permits .E-2 |
| | E-1e Title V Operating Permit.E-3 |
| | E-1f Public Health and Safety .E-3 |
| | E-2 Applicable Rules and Regulations .E-3 |
| | E-2a CDPHE Regulatory Requirements.E-3 |
| | E-2a(1) Regulation 1: Particulate Matter, Smoke, Carbon Monoxide and Sulfur Oxides..E-3 |
| | E-2a(2) Regulation 2: Odor Emission, Part A, General Provisions .E-4 |
| | E-2a(3) Regulation 3: Air Contaminant Emissions NoticesE-4 |
| | E-2a(4) Regulation 6: Standards of Performance for New Stationary Sources ..E-4 |
| | E-2a(5) Regulation 7: Emissions of Volatile Organic Compounds.E-5 |
| | E-2b Compliance Evaluation with CDPHE RegulationsE-5 |
| | E-2b(1) CDPHE Operating Permit for the PCAPP Facility .E-5 |
| | E-2b(2) Diesel Emergency Generator Rated at 210 kW and Fuel Input Capacity of 2.3 MMbtu/hrE-6 |
| | |
| | E-2b(3) Diesel Emergency Generators Rated at 2,000 kW and Fuel Input Capacity of 18.6 |
| | MMbtu/hr.E-7 |
| | E-2b(4) Steam Boilers and Hot Water Boilers Rated at 1,000 and 1,100 BHP and Fuel Input |
| | Capacity of 41.84 and 46.03 MMbtu/hr (Natural Gas and Diesel Fuel).E-8 |
| | E-2b(5) Paved Roads Operation .E-9 |
| | E-2b(6) Diesel Fuel Storage Tanks (75,000 and 20,000 gallon) E-9 |
| | E-2c Federal Regulations.E-10 |
| | E-2c(1) 40CFR Part 60 Section Dc: Standards of Performance for Small Industrial-Commercial- |
| | Institutional Steam Generating Units.E-10 |
| | E-2c(2) 40 CFR Part 60 Subpart Kb: Standards of Performance for Volatile Organic Liquid Storage |
| | Vessels for which Construction, |
| | Reconstruction, or Modification Commenced after July 23, 1984 ..E-10 |
| | E-2c(3) Standards for Non-Road Diesel EnginesE-10 |
| | E-2d Compliance Evaluation with Federal Regulations ..E-11 |
| | E-2d(1) Steam Boilers Rated at 1,000 BHP and Fuel Input Capacity of 41.84 MMbtu/hr (Natural Gas |
| | and Diesel Fuel) E-11 |
| | E-2d(2) Diesel Storage Tanks (75,000 and 20,000 gallons)..E-12 |
| | E-2d(3) Standards for Non-Road Diesel EnginesE-12 |
| | E-3 Air Quality Impact Analysis for Criteria PollutantsE-13 |
| | E-3a Air Quality Modeling Methodology ..E-13 |
| | E-3a(1) Model Selection..E-14 |
| | E-3a(2) Modeling Options..E-14 |
| | E-3a(3) Meteorological Data .E-14 |
| | E-3a(4) Receptor Data ..E-15 |
| | E-3b Source Parameters E-16 |
| | E-3c Results of the Criteria Pollutant Air Quality Impact Analysis..E-17 |
| | E-4 Impact Analysis for Chemical Agent .E-17 |
| | E-4a Air Quality Modeling Methodology ..E-17 |
| | E-4b Source Parameters E-18 |
| | E-4c Modeling Results for Chemical Agent..E-18 |
| | E-5 Monitoring and ReportingE-18 |
| | E-6 RecordkeepingE-19 |
| | E-7 Operation and Maintenance Plan .E-19 |
| | SECTION F PROPOSED PERMIT CONDITIONS..F-1 |