Odor Management Plan. Clemens Food Group Coldwater Facility Coldwater, Michigan

Odor Management Plan Clemens Food Group Coldwater Facility Coldwater, Michigan Prepared for: Clemens Food Group Hatfield, Pennsylvania Submitted: Dece...
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Odor Management Plan Clemens Food Group Coldwater Facility Coldwater, Michigan Prepared for: Clemens Food Group Hatfield, Pennsylvania Submitted: December 30, 2014 Revised: February 5, 2015 Project No. G140834

ODOR MANAGEMENT PLAN CLEMENS FOOD GROUP – COLDWATER FACILITY COLDWATER, MICHIGAN

PREPARED FOR: CLEMENS FOOD GROUP CLEMENS, PENNSYLVANIA SUBMITTED: DECEMBER 30, 2014 REVISED: FEBRUARY 5, 2015 PROJECT NO. G140834

TABLE OF CONTENTS 1.0

INTRODUCTION.............................................................................................................................. 1

2.0

REGULATORY ANALYSIS .............................................................................................................. 2

3.0

PROCESS DESCRIPTION .............................................................................................................. 3 3.1 Harvesting ........................................................................................................................... 3 3.2 Blood Processing and Drying .............................................................................................. 3 3.3 Hair Hydrolizer .................................................................................................................... 4 3.4 Inedible Rendering .............................................................................................................. 4 3.5 Edible Rendering................................................................................................................. 5 3.6 Heat and Steam .................................................................................................................. 5 3.7 Refrigeration ........................................................................................................................ 5 3.8 Emergency Generators ....................................................................................................... 5 3.9 Industrial Pretreatment Plant .............................................................................................. 5

4.0

ODOR MANAGEMENT.................................................................................................................... 6 4.1 Facility Odor Control ........................................................................................................... 6 4.2 Multi-Stage System of Scrubbers ....................................................................................... 7 4.2.1 Industrial Pretreatment Plant Odor Control ............................................................... 9 4.2.1.1 Biofilter ................................................................................................ 9 4.2.1.2 Anaerobic Digestion ......................................................................... 10

5.0

ODOR MANAGEMENT SYSTEM O&M ........................................................................................ 10 5.1 Housekeeping ................................................................................................................... 10 5.2 Multi-Stage Scrubber Operation ....................................................................................... 10 5.3 Biofilter .............................................................................................................................. 11

6.0

MALFUNCTION REPORTING ....................................................................................................... 12

LIST OF FIGURES Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11

Harvesting (Wet Harvesting Area) Harvesting Harvesting (Chill Area) Blood Processing and Drying Inedible Rendering Edible Rendering Industrial Pretreatment Plant Site Location Building Layout – Process Equipment Building Layout –Industrial Pretreatment Plant Multi-Stage Scrubber System

LIST OF APPENDICES Appendix 1 Appendix 2 Appendix 3

Additional Information for a Rendering Process Michigan Air Pollution Rule 911 Michigan Air Pollution Rule 912

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TABLE OF CONTENTS LIST OF ABBREVIATIONS/ACRONYMS °F AQD cfm Clemens CO2 fpm FTCH gpm Hatfield hp MAP MDEQ MMBtu/hr O&M OMP ORP pH PM2.5 PMP POTW ppm psig Rule sq. ft. USDA VOC wc

degree Fahrenheit Air Quality Division (MDEQ) cubic feet per minute Clemens Food Group – Coldwater Facility carbon dioxide feet per minute Fishbeck, Thompson, Carr & Huber, Inc. gallon(s) per minute Hatfield, Pennsylvania, Clemens facility horsepower Malfunction Abatement Plan Michigan Department of Environmental Quality million British thermal units per hour Operation and Management Odor Management Plan Oxidation-Reduction Potential power of hydrogen fine particulate matter less than 2.5 microns Preventive Maintenance Plan Publicly Owned Treatment Works part(s) per million pound-force per square inch gauge Michigan Air Pollution Rule square feet U.S. Department of Agriculture volatile organic compound water column

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1.0

INTRODUCTION

Clemens Food Group – Coldwater Facility (Clemens) is a proposed hog harvesting facility to be located in Coldwater, Michigan. The site will be located on 455 acres in an area that is largely rural. A slaughterhouse and attached rendering facility will harvest up to 6.5 million animals per year, with operating hours from 6 a.m. until 11 p.m. Monday through Saturday. Meat by-product operations have traditionally been associated with odorous contaminants, though much of these odors are due to the by-product operations rather than to harvesting and meat dressing itself. In particular, inedible rendering facilities have been identified by the Michigan Department of Environmental Quality (MDEQ) as likely sources of odors. But this facility is an integrated facility and the rendering operations are subject to the same high levels of cleanliness as the meat packaging industry, greatly reducing the potential for odors. In addition, meat by-product operations having a potential for odors were identified by Clemens and the facility has been designed with state-of-the art ventilation and air pollution control equipment to address these activities. The purpose of this Odor Management Plan (OMP) is to describe site-specific provisions that will be established by Clemens to manage and minimize potential odors for their hog harvesting and processing facility. A process description is included, identifying potential sources of odor. In addition, specific work practices and air pollution control equipment that will be used to minimize odors from the facility will be outlined. This OMP also includes information required by the MDEQ Air Quality Division’s (AQD’s) Additional Technical Information for a Rendering Process (MDEQ Guidance), included as Appendix 1.

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2.0

REGULATORY ANALYSIS

Volatile organic compounds (VOCs) are the primary air pollutants emitted from rendering and their companion processes. These VOCs include small amounts of organic sulfides, disulfides, aldehydes and amines. Emissions of small amounts of VOCs like these would not be an air pollution concern except they can cause an odor nuisance to residential areas in close proximity to an animal by-product facility. The odor threshold for these compounds is low with some as low as 1 part per billion. None of the compounds that were listed as emissions from the animal by-product operations are listed as hazardous air pollutants. In Michigan, odors are regulated as a nuisance under Michigan Air Pollution Rule (Rule) 901. Rule 901 states that: Notwithstanding the provisions of any other department rule, a person shall not cause or permit the emission of an air contaminant or water vapor in quantities that cause, alone or in reaction with other air contaminants, either of the following: (a) Injurious effects to human health or safety, animal life, plant life of significant economic value, or property. (b) Unreasonable interference with the comfortable enjoyment of life and property. Animal by-product operations have been identified by the MDEQ as having a high potential to generate odors from their process and process equipment. As a result, the MDEQ will include in its application review an evaluation of the measures proposed to be taken by the source to minimize its potential to generate odors. If it is determined that sufficient steps will be taken by this new source to minimize its odor impact on the surrounding area, no further evaluation will be required. If, however, sufficient steps are not proposed by the source on its own initiative, then further discussion and evaluation by the permit engineer and district staff, along with the applicant, will be conducted. This evaluation, for both situations described above, will be documented both within the permit as conditions, as well as documentation within the permit file to describe the review that was conducted. If these evaluations result in permit conditions that require specific measures be taken by the source to minimize the odor impact on the surrounding area, then these conditions will have the citation of Rule 901 as an underlying applicable requirement. This evaluation is designed to ensure adequate odor control measures are taken to prevent a nuisance. The MDEQ Guidance also suggests that Rule 911, which requires a Malfunction Abatement Plan (MAP), will also apply to the proposed Clemens facility. A copy of Rule 911 is included in Appendix 2. After construction of the facility, a separate MAP will be submitted at the request of the MDEQ including final operating parameter values and maintenance for the multi-stage scrubber system and the biofilter. The MDEQ Guidance also referenced compliance with Rule 912. A copy of Rule 912 is included in Appendix 3. Rule 912 requires a source to report excess emissions. Circumstances under which Rule 912 requirements would be triggered have been identified in Section 6.0 and include the failure of the emissions control equipment or its bypass.

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3.0

PROCESS DESCRIPTION

3.1

HARVESTING

The Clemens hog harvesting and processing facility will be located outside Coldwater, Michigan, on a 455-acre site. Hogs are shipped to the site in loads of 240 to 260. The facility is designed to process 6,489,600 animals per year. They are unloaded from the truck to an indoor pen which is climate controlled where the animals rest prior to processing. The indoor pen contains between 4,000 and 6,000 hogs Animals walk from the pens to the stunning area. Animals are stunned with carbon dioxide (CO2) and rendered unconscious. Just over 2 million pounds per year CO2 will be used in this process. The stunned animals undergo exsanguinations (sticking) and blood is collected in storage tanks and routed for drying. Blood is allowed to drain from the animals to get the muscles relaxed for easier dehairing. After the blood is drained, pig carcasses are then dropped into scalding water which loosens the hair for subsequent removal. Pig carcasses then enter a dehairing machine which uses one or more cylinders with metal-tipped, rubber beaters that polish the outside of the carcass, removing hair. Hair that has been removed is routed to a hair hydrolizer. Carcasses are then singed with a natural gas torch to remove the rest of the hair. The carcasses then leave the “dirty” side of the plant and enter the “clean” side. The head is then severed from the backbone, washed and inspected. The carcass is then eviscerated, and the carcass is split the entire length. Red and black gut material is sent for processing. Non-edible offal is discarded and transported to inedible rendering. After splitting the carcass and removing the inedible material, the carcass is washed from the top to the bottom to remove loose bone, dust, blood and bacteria. This wash water is routed to the industrial pretreatment plant. The carcasses are then transported into a rapid chill process and the carcass is in a -35°F area for 110 minutes and then moved to a refrigerated area and kept for a 24-hour chilling period, as cutting and deboning is easier to perform at lower temperatures. The carcass is first split into the four primal pieces: belly, loin, ham, and shoulder. Edible materials, like fat trimmings from cutting up the carcass, are segregated and sent to the edible rendering area. The four pieces are cut into smaller pieces and resulting meat is transported on automated trays and conveyors for packaging. Meat products are packaged and stored at low temperatures. Wastewater from the cutting area is also routed to the industrial pretreatment plant. The Harvesting process is illustrated in Figures 1 through 3.

3.2

BLOOD PROCESSING AND DRYING

Blood is drained from pig carcasses and stored in tanks. Blood is routed through a series of centrifuges to separate the red blood cells from the white blood cells. The white blood cells are stored in an over-the-road tanker and shipped to another location for further processing. The red blood cells are processed in a steam coagulator. The coagulated blood is sent through several centrifuges, separating the liquid and the solid protein. The liquid portion is pretreated and then sent to the wastewater treatment 2/5/2015

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plant for processing. The solid material enters the blood dryer where it is heated in an inclined, tubular vessel. As the dryer rotates, the blood solids fall to the lower end of the vessel because of gravity. While the blood moves through the dryer, the lifting plates in the dryer increase contact between the blood solids and hot combustion gases, drying the blood solids from 55 to 65 percent moisture to about 10 percent moisture. Several sources of odors with small amounts of VOC emissions have been associated with Blood Drying and Processing and are vented through the multi-stage scrubber system system. The blood meal produced from the blood dryer is stored in silos and sold for use in pet food or fertilizers. The dryer is rated at approximately 3 million British thermal units per hour (MMBtu/hr) and is fired with natural gas. The plant is expected to produce about 3,500 tons per year protein meal with 10 % moisture content. This process is depicted in Figure 4.

3.3

HAIR HYDROLIZER

Hair that is removed from the animal carcasses is routed to a continuous hydrolizer and is processed for 30 to 45 minutes at temperatures from 280 to 300°F with pressures ranging from 40 to 50 psig. After cooking, the moist meal is combined with the separated blood and routed to the blood dryer to remove additional moisture. The dried meal is transferred to storage. The hair hydrolizer produces about 3,500 tons per year protein meal, which is stored with the blood meal. This process is included in Figure 2.

3.4

INEDIBLE RENDERING

Materials recovered from processing the hogs may be unsuitable for human consumption for aesthetic or sanitary reasons. These materials are routed through the inedible rendering area. Because this rendering area is associated with a U.S. Department of Agriculture (USDA)-regulated facility, it is an integrated rendering process and subject to much stricter oversight by the USDA than rendering plants that are not associated with a slaughterhouse. Materials collected from the harvest operation are screw conveyed, ground, and then heated to about 260°F to release the moisture and break up the fat cells. After the cooking cycle, contents are discharged to a percolator pan. Vapor emissions pass through a heat exchanger and the waste heat is recovered to make hot water for the entire process facility. The remaining vapor stream is sent to a condenser where the water vapor is condensed and the noncondensibles are discharged as VOC emissions. The percolator drain pan contains a screen that separates the liquid fat from protein solids. From the percolator drain pan, the protein solids, which still contain about 25 percent fat, are conveyed to the screw press. The screw press completes the separation of fat from solids, and yields protein solids that have a residual fat content of about 10 percent. These solids, called cracklings, are then ground and screened to produce protein meal. The fat from both the screw press and the percolator drain pan is pumped to the crude animal fat tank, centrifuged or filtered to remove any remaining protein solids, and stored in the animal fat storage tank. In summary, products from inedible rendering include liquid fat, pork meal and vapors from cooking and the screw conveyor. Several sources of odors with small amounts of VOC emissions have been associated with the inedible 2/5/2015

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rendering process and are vented through the multi-stage scrubber system. The Inedible Rendering process is presented in Figure 5.

3.5

EDIBLE RENDERING

Fat and other trimmings from cutting the meat are ground and then belt conveyed to a melt tank. The melt tank heats the materials to about 110°F and the melted fatty tissue is pumped to a disintegrator which ruptures the fat cells. Proteinaceous materials are separated from the melted fat and water using a centrifuge. This material is then routed and ground, and sent to the inedible rendering process along with the balance of inedible material from the rest of the facility. Melted fat and water are then heated with steam to about 210°F and routed through a second centrifuge where the edible fat is separated from water. This water may also contain protein fines. This wastewater is discharged to the wastewater treatment plant and the “polished fat” is pumped to storage. In the edible rendering area, direct heat contact with edible fat is minimal and no emission points are included, as illustrated in Figure 6.

3.6

HEAT AND STEAM

Process heat and steam are provided by four boilers rated at 1,000 hp each (40 MMBtu/hr). These boilers can fire animal fat generated at the facility, vegetable oil, natural gas, and No. 2 fuel oil.

3.7

REFRIGERATION

The animal carcasses are stored in a refrigerated area and packaged meat is refrigerated. An ammonia refrigeration system is used to cool these areas and 11 ammonia storage tanks with a total volume just under 14,000 gallons will be located at the site.

3.8

EMERGENCY GENERATORS

Three emergency generators will be located at the site and will be used to provide emergency lighting in the event of a power outage. Each is rated at approximately 270 hp.

3.9

INDUSTRIAL PRETREATMENT PLANT

Water is used to wash the facility and as a processing aid. Detergents and bleach solutions are used in washing down the plant. Wash water also contains waste materials like blood, bone, or fat. Wash water is routed to a pretreatment system which includes a screening device and a fat skimmer, the screenings and fat skimmings are sent to inedible rendering to be combined with the remaining inedible material. After the wastewater is pretreated, it is pumped to a equalization basin at the treatment plant, the water is then treated in a diffusion air flotation system utilizing typical flocculants to remove any inorganic material. The wastewater is then sent to the biologic treatment process to treat for any organic material and ultimately discharge to the City of Coldwater Publicly Owned Treatment Works (POTW). The sludge material is transferred to a holding tank, sent to a belt filter press to reduce the moisture to approximately 78% and then sent to the wastewater sludge dryer. The sludge material is dried and stored in an onsite bunker to be utilized by local farmers as fertilizer. The exhaust from the sludge dryer is treated in a dual cyclone 2/5/2015

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system to remove any particulate and ultimate discharge is to the onsite biofilter. This process is illustrated in Figure 7.

4.0

ODOR MANAGEMENT

4.1

FACILITY ODOR CONTROL

The Clemens facility has been designed to minimize or prevent odor emissions. First, the facility will be located on a 455-acre plot of land in an area that is mostly rural. A site plan is included as Figure 8. Locating the facility on a large parcel of land will create a natural buffer between the facility and its neighbors, which is one of the most effective ways of minimizing odors. In addition, because of the slaughterhouse, the facility will be heavily regulated by the USDA, Food Safety and Inspection Services and have inspectors housed onsite. The entire facility will be subject to the high standards of cleanliness and pest control as areas handling meat. In addition, as an integrated facility, animal by-products will be fresher and less likely to create odors than a stand-alone facility that relies on a variety of raw materials that must be transported to the site. The Clemens Food Group has been operating an existing facility in Hatfield, Pennsylvania (Hatfield), and has few odor complaints and no odor violations. In addition, the proposed facility has been designed using lessons learned at Hatfield during its more than 20 years of operation. This proposed facility is designed to allow segregation of the areas creating odors from other areas of the plant for ventilation through the control system. A building layout is included as Figure 9 and illustrates the location of several emission units. An additional layout, Figure 10, depicts the industrial pretreatment plant. The unit operations with a potential for odors have been identified and are listed as follows: ●

Blood dryer



Blood centrifuge



Blood coagulator



Raw blood storage



Hair hydrolizer (shaft)



Hair hydrolizer



Cooker



Dupps Press #1



Dupps Press #2



Centrifuge



Drainor/Overpressor



Conveyors

These emission sources are associated with processing blood, the hair hydrolizer, and inedible rendering operations. Emissions from the edible rendering process are considered insignificant because no cooking vapors are emitted and direct contact with the edible fat is minimal. 2/5/2015

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4.2

MULTI-STAGE SYSTEM OF SCRUBBERS

Clemens will use a multi-stage system of scrubbers to reduce odors from the site. A diagram of the system is included in Figure 11. First, the unit operations listed above that have the highest potential for odors will be routed through hoods to a 25,000 cubic feet per minute (cfm) venturi scrubber. The venturi scrubber will function to remove particulate and cool gases before discharge to an equally-sized, packed-bed, chemical scrubber. Vented process gases from equipment used in the rendering operations are received at the venturi inlet and accelerated in velocity as they pass through a restrictive throat section. As the gas flows through the venturi throat section at a velocity of 12,000 feet per minute (fpm), the gas is saturated with liquid recycled from the venturi sump at a rate of 4 gallons per minute (gpm) per 1,000 cfm. Saturated particulate and condensed vapor exit the throat section and enter an expanded area before passing through two rows of impingement trays. As the gas velocity slows, liquid is removed by the impingement trays to the sump collection area. A constant flow of makeup water is supplied to the sump and overflowed. The constant overflow of water keeps buildup of solid and absorbed contaminates to a minimum and compensates for water lost to evaporation. The gas then proceeds through a mist eliminator wherein small water droplets are removed before exiting the venturi. This system is very similar to the system at the Hatfield facility, though it is larger and has an additional chemical scrubber stage so it will be more effective. A blower located after the venturi creates air flow needed to convey collected gases to the venturi inlet and overcoming resistance created by network of collection ductwork, restrictive throat and system affects. 25,000 cfm Venturi Scrubber (Model RT-25-VS) Designed air flow: 25,000 cfm Pressure drop: Not less than 4-inch water column (wc) Inlet diameter: 38-inch dia. = 7.876 square feet (sq. ft.) Outlet size: 36-inch x 72-inch = 18 ft sq. ft. Operating temperature: Not more than 110°F Recycle rate: Not less than 95 gpm Water makeup: Not less than 2 gpm Efficiency rating: 85% PM2.5 The 25,000 cfm packed-bed, 8-foot-diameter tower scrubber will receive exhaust from the 25,000 cfm venturi scrubber where odorous contaminates are chemical treated. The pre-treated process gases enter the tower inlet directly below a 9-foot-deep bed of polypropylene packing. Within the tower, gases pass through the bed of packing at a velocity of 500 fpm while exposing gaseous contaminates to an oxidant solution, flowing counter-current (downward) through the packing material. The recycled oxidant solution made up of sodium hypochlorite at a controlled pH is delivered to the packed bed at a rate of 10 gpm per 1,000 cfm. As the gas flows through the packed bed, odorous contaminates are absorbed and oxidized. Treated gases then flow through a Chevron blade mist eliminator located directly above the spray header/nozzle assembly. Water droplets entrained in the gas impinge on the eliminator surface where they separate from the gas stream and fall back on to the packed bed. 2/5/2015

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A blower located after the packed-bed tower creates air flow and static pressure needed to convey gases vented from process equipment, through the venturi and tower overcoming resistance created by system affects. The scrubber will have pH and Oxidation-Reduction Potential (ORP) analyzer/controllers to maintain the recycled scrubbing solution made up of 12 percent sodium hypochlorite and 50 percent sodium hydroxide to absorb and oxidize odorous contaminates. Analyzers will constantly monitor the amount of residual chemical in solution needed and energizes feed pumps to deliver chemical as needed so they are neither under or over supplied. The optimum level of chemical maintained in recycled scrubbing solution will be determined at startup and usually falls in the range of 50 parts per million (ppm) to 100 ppm of total chlorine at 8 to 10 pH. 25,000 cfm Packed Bed Scrubber: (Model RT-25-PBS) Designed air flow: 25,000 cfm Pressure drop: Not more than 6-inch wc Tower diameter: 84-inch dia. = 50.26 sq. ft. Inlet size: 36-inch x 73-inch = 18.0 sq. ft. Outlet diameter: 38-inch dia. = 7.876 sq. ft. Packing style and size: Polypropylene 3.5-inch Tri Pack Packing depth: 9.0 ft. Treated gas is then discharged to a 100,000 cfm packed-bed scrubber where it mixes with plant air and chemical scrubber for a second time before discharged to the atmosphere. Exhaust from the 25,000 cfm packed-bed scrubber will mix with 75,000 cfm of less odorous plant air before entering a 100,000 cfm packed-bed, 14-foot-diameter tower scrubber. The mixed gases enter the tower inlet directly below an 11-foot-deep bed of polypropylene packing. Within the tower, gases pass through the bed of packing at a velocity of 650 fpm while exposing odorous contaminates to an oxidant solution, flowing counter-current (downward) through the packing material. A recycled scrubbing solution of sodium hypochlorite at a controlled pH is delivered to the packed bed at a rate of 1,000 gpm. As the gas flows through the packed bed, odorous contaminates are absorbed in the recycled solution and oxidized. Treated gases then flow through a Chevron blade mist eliminator located directly above the spray header/nozzle assembly. Water droplets entrained in the gas impinge on the eliminator surface where they separate from the gas stream and fall back onto the packed bed. A blower located after the packed-bed tower creates air flow and static pressure needed to vent plant air and overcome resistance created by system affects. Exhaust from the 100,000 cfm system fan discharges to the atmosphere via a 4-foot by 5-foot stack with reduced 64-inch-diameter outlet at a velocity of 4,476 fpm and elevation of 65 feet above grade. The scrubber will have pH and ORP analyzer/controllers to maintain the recycled scrubbing solution made up of 12% sodium hypochlorite and 50% sodium hydroxide to absorb and oxidize odorous contaminates. Analyzers will constantly monitor the amount of residual chemical in solution needed and energize feed pumps to deliver chemical as needed so they are neither under or over supplied. The

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optimum level of chemical maintained in recycled scrubbing solution will be determined at startup and usually falls in the range of 25 ppm to 50 ppm of total chlorine at 8 to 10 pH. 100,000 cfm Packed Bed Scrubber: (Model RT-100-PBS) Designed air flow: 100,000 cfm Pressure drop: Not more than 6-inch wc Tower diameter: 168-inch dia. = 154.0 sq. ft. Inlet size: 60-inch x 144-inch = 60.0 sq ft. Outlet diameter: 74-inch dia. = 29.87 sq. ft. Packing style and size: Polypropylene 3.5-inch Tri Pack Packing depth: 11.0 ft.

4.2.1

INDUSTRIAL PRETREATMENT PLANT ODOR CONTROL

Odors have been associated with sludge dryers like the one associated with the industrial pretreatment plant at the Clemens Food Group and depicted in Figure 7.

4.2.1.1

BIOFILTER

Biofiltration is a relatively new pollution control technology. It is an attractive technique for the elimination of malodorous gas emissions and of low concentrations of VOCs. Exhaust from the sludge drier is routed through a biofilter primarily to control odors. When applied to air filtration and purification, biofilters use microorganisms to remove air pollution. The biological degradation process occurs by oxidation, and can be written as follows: Organic Pollutant + O2  CO2 + H2O + Heat + Biomass To promote the biofiltration process, contaminated air is moistened by a humidifier or water sprays and is pumped into the biofilter through a chamber below the filter medium. While the air slowly flows upward through the filter media, the contaminants in the air stream are absorbed and metabolized. The air flows through a packed bed and the pollutant transfers into a thin biofilm on the surface of the packing material. Microorganisms, including bacteria and fungi are immobilized in the biofilm and degrade the pollutant. The box that makes up this biofilter contains a filter material, which is the breeding ground for the microorganisms. The purified air passes out of the top of the biofilter and into the atmosphere. The microorganisms live in a thin layer of moisture, the "biofilm," which surrounds the particles that make up the filter media. The moist filter medium provides physical and chemical conditions appropriate for the transfer of contaminants from the air to the liquid phase and the biodegradation of the contaminants in the biofilm layer. The mechanism of the biofiltration process includes a combination of adsorption, absorption, and microbial degradation. Microorganisms contained in the biofilm layer continually metabolize the contaminants, as they are absorbed, converting them ultimately to water, carbon dioxide, and salts.

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4.2.1.2

ANAEROBIC DIGESTION

Rendering wastewater and condensate usually contain sufficient nutrients to necessitate further wastewater treatment. Clemens may install an anaerobic digestion system to further treat this wastewater. Anaerobic digestion not only reduces odor levels, but can provide valuable methane for use in the boiler system. Clemens is proposing to burn the methane-rich biogas produced from the anaerobic sludge digestion in its boilers to produce steam.

5.0

ODOR MANAGEMENT SYSTEM O&M

The MDEQ Guidance suggests that the proposed facility will require a Malfunction Abatement Plan (MAP) for process equipment and the associated emissions control devices. The MAP will explain how Clemens is minimizing the opportunity for process upset conditions and excessive air emissions. Since housekeeping can minimize the opportunity for odors, a good housekeeping plan will be established and will be referenced in the MAP. All of the equipment identified as subject to the OMP requirements will need to be addressed in the MAP. It is important to note that the MAP should also include a Preventive Maintenance Plan (PMP) specifying maintenance inspections and other activities intended to maintain optimal operation of this equipment and minimize the opportunity for equipment malfunctions. Through conformance with the MAP and PMP, there should be minimal potential for excessive odors. Emissions control at Clemens is focused on the elimination of odor. These controls are divided into two categories: (1) those controlling high intensity odor emissions from meat by-product processing and the industrial pretreatment plant, and (2) those controlling plant ventilating air emissions. Controls in place at Clemens are typical of controls found at facilities of this type and the design of the system at Clemens is based on “lessons learned” at its Hatfield facility. But odor perception is highly subjective and because the purpose of the control devices is to control odors, its operation will be controlling odors and some changes to its operation may be needed to optimize performance.

5.1

HOUSEKEEPING

Effective and consistent housekeeping measures will minimize the potential for odorous emissions. The facility is subject to USDA, Food Safety and Inspection Services standards for housekeeping and pest control and has USDA staff onsite to ensure these standards are maintained.

5.2

MULTI-STAGE SCRUBBER OPERATION

Monitoring of parameters associated with the proper operation of the venturi scrubber and the two packed-bed scrubbers will ensure the equipment operates as designed. Alarms will be established during facility startup for pH, ORP, liquid levels, and other operating parameters. Facility rounds will be completed by operators at least once per day that the facility is operating, and the following data will be observed: scrubber liquid flow rates, reagent concentration, and pH. Optimum operating parameters will be identified during facility startup. In addition, operators will also check for equipment problems like 2/5/2015

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leaks, fires, excessive vibration, excessive bearing temperatures, motors overheating, and equipment that is not operating. Reporting by exception will be completed, with a maintenance person inspecting all equipment problems. A preventive maintenance program will also be established and will include checking the accuracy of probes, calibration of measuring equipment, along with inspection and cleaning of pumps, tanks, and packing.

5.3

BIOFILTER

Biofilters are a passive system of air pollution control and their operation is relatively simple. Typical biofilter media material includes compost-based materials, earth, heather, plastic, or wood-product based material. Clemens currently operates a similar biofilter system at its Hatfield location and uses a woody material at that facility. The purpose of the biofilter media is to provide a large surface area for the absorption and adsorption of contaminants. The media also serves as a nutrient source for the microbial population. In fact, some types of media lack proper nutrients and will require the manual addition of nutrients (e.g., nitrogen and phosphorous compounds) in order to sustain microbial life. Most biofilters will operate for 5 to 7 years before it is necessary to renew the filter media. The air is humidified before it enters the bed with a watering (spray) system or humidifier. One of the main challenges to optimum biofilter operation is maintaining proper moisture throughout the system. The operation and maintenance of the biofiltration system would require weekly site visits during startup. However, after acclimation and all system problems are resolved, the frequency of site visits could be reduced to biweekly or monthly. As long as the material remains at the correct moisture level it will operate as intended.

2/5/2015

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11

INTERNET

6.0

MALFUNCTION REPORTING

Under Rule 912, Clemens must have a system to report startup, shutdowns, or malfunctions that result in excess emissions. Since the air pollution control equipment will be installed primarily for odor control, there is not likely a scenario in which failure to operate the control equipment will result in excess emissions. To ensure compliance with Rule 901, Clemens will report a bypass or failure of its multi-stage scrubber or biofilter systems. If that bypass or failure lasts more than two hours, Clemens will report the malfunction to the MDEQ District Office in Kalamazoo (269-567-3500). This report can be phoned in, emailed, or faxed and should be made as soon as possible, but must be made within two days of the incident or discovery. Information on the incident must include the date, time, specific process equipment operating along with control equipment operating, and nature of the problem along with corrective measures being taken. Within ten days of the incident or its discovery, a written report must be submitted to: MDEQ-AQD Kalamazoo District 7953 Adobe Road Kalamazoo, MI 49009-5026 Fax: 269-567-3555 The report must include: ●

Date and time of incident



Probable causes or reasons for the incident



Information on the process equipment operating at the time of incident and an estimate of excess emissions, if possible



Summary of actions taken to correct and prevent a recurrence



Certification by the responsible official

2/5/2015

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12

INTERNET

Michigan Department of Environmental Quality - Air Quality Division ADDITIONAL TECHNICAL INFORMATION FOR A RENDERING PROCESS The following information will be used for the technical review of a permit to install application for a rendering process. This information is in addition to the general requirements outlined in the AQD document “Information for an Administratively Complete Permit to Install Application”, Part 2 - Additional Supporting Information, Items A through F. All of the information may not be needed for each application. Also, this document may not be all inclusive. Additional information beyond that identified may be necessary to complete the technical review of any individual application. In the event a determination is made that new additional information is needed for a technical review, this document will be updated. All referenced guidance documents are available at http://www.deq.state.mi.us/aps or you may contact the Permit Section at 517-373-7023.

A. Process Description 1. Provide a process flow diagram and a detailed written description of the process, including the amounts and types of raw materials rendered, the amounts and types of rendering products and waste materials produced and material/product storage conditions. Process components such as cookers, percolator pans, screw presses, tallow processing equipment, blood processing equipment, wastewater treatment equipment, boilers, etc. should be described including manufacturer name, model, and processing capacity information. Information on boilers and heated process components should include the method of heating, the types of any fuels fired, the maximum amount of fuel to be used in an hour and a year, and the fuel firing capacity (in MMBtu/hr). 2. Describe the waste streams associated with the process, the proposed odor control equipment, and any onsite wastewater treatment system. The description should include the following: a) Process waste products should be described and quantified along with a description of proposed methods of on-site storage, treatment, and disposal so as to prevent excessive odor emissions. b) Scrubber effluent should be quantified and described in terms of gallons per hour generated and method of storage, disposal, and/or treatment. c) Wastewater disposal and/or treatment should be described including information on amounts and types of wastewater generated; the type of on-site treatment system proposed; the ultimate fate of the raw or treated wastewater; and a description of the measures taken to prevent generation of excessive odor emissions from any wastewater storage and/or treatment system. 3. Describe and quantify all solvent-containing cleaning or disinfecting solutions or additives used. Estimates of maximum daily and annual usage of any such materials should be provided along with material safety data sheets (MSDS) for the materials used.

B. Regulatory Discussion The following State and Federal air pollution control regulations may be applicable. Please review these regulations carefully to determine if they apply to your process and summarize the results in the application. The Air Pollution Control Rules may be viewed and downloaded from the AQD website at: www.michigan.gov/deqair. y

State of Michigan, Department of Environmental Quality, Act 451 of 1994, Natural Resources and Environmental Protection Act, Part 55 Air Pollution Control and the following promulgated rules: 1. Rule 901(b) prohibits the emission of an air contaminant in quantities that cause unreasonable interference with the comfortable enjoyment of life and property. The AQD evaluates odor impacts to prevent emissions in quantities which cause odor nuisance situations. As a result, an odor analysis may be required as part of a permit application review whenever a source exhibits a significant potential to emit odorous emissions. Existing rendering sources with past verified odor complaints are considered to exhibit a potential. New rendering sources may also be considered to have a significant 1

(Rev 10/2009)

potential to emit odors based on the nature of the process. Contact the AQD, prior to submittal of an application, to discuss any particular situation which may cause odors and to determine if an odor analysis should be performed. If required, the AQD will provide guidance on performing an odor analysis. 2. Rule 911 allows the DEQ to request preparation and submittal of a malfunction abatement plan (MAP) to prevent, detect, and correct malfunctions or equipment failures resulting in emissions exceeding any applicable emission limitations. Since rendering facilities have a high potential for creating odor problems, a written MAP should be submitted to insure that process equipment and any proposed odor control equipment are properly maintained to prevent equipment and operational malfunctions that could result in odor nuisance problems. The MAP should at a minimum, specify all of the following: a) A complete preventative maintenance program, including identification of the supervisory personnel responsible for overseeing the inspection, maintenance, and repair of air-cleaning devices, a description of the items or identification of the major replacement parts that shall be maintained in inventory for quick replacement. b) Identification of the source and air-cleaning device operating variables that shall be monitored to detect a malfunction or failure, the normal operating range of these variables, and a description of the method of monitoring or surveillance procedures. c) A description of the corrective procedures or operational changes that shall be taken in the event of a malfunction or failure to achieve compliance with the applicable emission limits.”

C. Control Technology Analysis 1. Provide a demonstration that the selected odor control options will be sufficient so as to prevent violations of Rule 901. The demonstration should include information on the expected effectiveness of the odor control options proposed for the equipment being permitted, based on available odor emission testing, equipment vendor information, and/or case studies. The demonstration can also include dispersion modeling of odor emissions to predict maximum expected odor levels in the plant vicinity. 2. A detailed description of odor control equipment and odor control measures, including information on pertinent operational parameters. Provide the following (if applicable): a) Scrubber Odor Control Systems - Provide all of the information requested on the information sheets for scrubbers (available separately) and the following: • Types of oxidant and/or other additives; recommended concentrations of oxidant and/or other additives; and proposed oxidant/additive level monitoring and control systems; • Liquid recirculation design rates and temperatures, and proposed monitoring systems for these operational parameters; • Design exhaust air temperature; and proposed temperature monitoring system; • Expected odor control efficiency and odor emission rate (if available). b) Boiler Incinerator Odor Control Systems - Provide all of the information requested on the information sheets for boilers (available separately) and the following: • Description of pre-treatment and mixing systems for rendering exhaust air vented to boiler combustion systems for odor control; • Minimum firebox temperature and retention time for odor emissions vented to the boiler for control; and proposed temperature monitoring and control system; • Expected odor control efficiency and odor emission rate (if available). c) Condensers or Heat Exchangers used in Odor Control Systems - Provide all of the information requested on the information sheets for condensers (available separately) and the following: • Design liquid recirculation rates and temperatures and proposed monitoring systems for these operational parameters • Design exhaust air temperature; and proposed temperature monitoring system • Expected odor control efficiency and odor emission rate (if available) 2

(Rev 10/2009)

Appendix 2 Michigan Air Pollution Rule 911 Rule 911 states: (1) Upon request of the department, a person responsible for the operation of a source of an air contaminant shall prepare a malfunction abatement plan to prevent, detect, and correct malfunctions or equipment failures resulting in emissions exceeding any applicable emission limitation. (2) A malfunction abatement plan required by subrule (1) of this rule shall be in writing and shall, at a minimum, specify all of the following: (a) A complete preventative maintenance program, including identification of the supervisory personnel responsible for overseeing the inspection, maintenance, and repair of aircleaning devices, a description of the items or conditions that shall be inspected, the frequency of the inspections or repairs, and an identification of the major replacement parts that shall be maintained in inventory for quick replacement. (b) An identification of the source and air-cleaning device operating variables that shall be monitored to detect a malfunction or failure, the normal operating range of these variables, and a description of the method of monitoring or surveillance procedures. (c) A description of the corrective procedures or operational changes that shall be taken in the event of a malfunction or failure to achieve compliance with the applicable emission limits. (3) A malfunction abatement plan required by subrule (1) of this rule shall be submit-ted to the department and shall be subject to review and approval by the department. If, in the opinion of the commission, the plan does not adequately carry out the objectives as set forth in subrules (1) and (2) of this rule, then the department may disapprove the plan, state its reasons for disapproval, and order the preparation of an amended plan within the time period specified in the order. If, within the time period specified in the order, an amended plan is submitted which, in the opinion of the department, fails to meet the objective, then the department, on its own initiative, may amend the plan to cause it to meet the objective. (4) Within 180 days after the department approves a malfunction abatement plan, a person responsible for the preparation of a malfunction abatement plan shall implement the malfunction abatement plan required by subrule (1) of this rule.

C:\USERS\SERRANOG\APPDATA\LOCAL\MICROSOFT\WINDOWS\TEMPORARY INTERNET FILES\CONTENT.OUTLOOK\AUV1NIT7\APPX_2_OMP_CLEMENS_FOOD.DOCX

Appendix 3 Michigan Air Pollution Rule 912 Rule 912 states: (1) The owner or operator of a source, process, or process equipment shall, to the extent reasonably possible, operate a source, process, or process equipment in a manner consistent with good air pollution control practices for minimizing emissions during periods of abnormal conditions, start-up, shutdown ,and malfunctions. A source, process, or process equipment that complies with all applicable emission standards and limitations during periods of abnormal conditions, start-up, shutdown, and malfunction shall be presumed to have been operated in a manner consistent with good air pollution control practices for minimizing emissions. (2) The owner or operator of a source, process, or process equipment shall provide notice of an abnormal condition, start-up, shutdown, or a malfunction that results in emissions of a hazardous air pollutant which continue for more than 1 hour in excess of any applicable standard or limitation established by the clean air act or the emissions of a toxic air contaminant which continue for more than 1 hour in excess of an emission standard established by a rule promulgated under the air pollution act or an emission limitation specified in a permit issued or order entered under the air pollution act. (3) The owner or operator of a source, process, or process equipment shall provide notice and a written report of an abnormal condition, start-up, shutdown, or a malfunction that results in emissions of any air contaminant continuing for more than 2 hours in excess of a standard or limitation established by any applicable requirement. (4) The notices required by this rule shall be provided to the department as soon as reasonably possible, but not later than 2 business days after the start-up or shutdown or after discovery of the abnormal conditions or malfunction. Notice shall be by any reasonable means, including electronic, telephonic, or oral communication. (5) The written reports required under this rule shall be submitted within 10 days after the startup or shutdown occurred, within 10 days after the abnormal conditions or malfunction has been corrected, or within 30 days of discovery of the abnormal conditions or malfunction, whichever is first. The written reports shall include all of the following information: (a) The time and date, the probable causes or reasons for, and the duration of the abnormal conditions, start-up, shutdown, or malfunction. (b) An identification of the source, process, or process equipment which experienced abnormal conditions, was started up or shut down, or which malfunctioned and all other affected process or process equipment that have emissions in excess of an applicable requirement, including a description of the type and, where known or where it is reasonably possible to estimate, the quantity or magnitude of emissions in excess of applicable requirements. (c) Information describing the measures taken and air pollution control practices followed to minimize emissions. (d) For abnormal conditions and malfunctions, the report shall also include a summary of the actions taken to correct and to prevent a reoccurrence of the abnormal conditions or malfunction and the time taken to correct the malfunction. (6) Actions taken to correct and to prevent a reoccurrence of an abnormal condition or a malfunction shall become a part of any preventative maintenance and malfunction abatement plan required by R 336.1911. (7) The truth, accuracy, and completeness of the written reports required under this rule for a stationary source subject to the requirements of R 336.1210 shall be certified by a responsible official in a manner consistent with the clean air act.

C:\USERS\SERRANOG\APPDATA\LOCAL\MICROSOFT\WINDOWS\TEMPORARY INTERNET FILES\CONTENT.OUTLOOK\AUV1NIT7\APPX_3_OMP_CLEMENS_FOOD.DOCX

WET HARVESTING  AREA CLIMATE‐CONTROLLED HOLDING PEN

STUNNING AREA

BLOOD DRYING AND  PROCESSING STICKING AREA

HOGS ARRIVE  IN  LOTS OF 240 ‐ 260 CO2

CARCASSES  CARCASSES MOVE TOWARD  DEHAIRING MACHINE

WASTEWATER  AND  SLUDGE DRYER LEGEND ANIMALS GAS CARCASSES BLOOD WASTEWATER

Figure 1. Harvesting (Wet Harvesting Area)

HARVESTING (cont’d) CARCASSES FROM  WET HARVESTING  AREA

“DIRTY SIDE “ OF PLANT OF PLANT

SINGERS (8 MMBTU/HR  (8 MMBTU/HR EACH)

DEHAIRING  MACHINE

HAIR HAIR  HYDROLIZER

STEAM

BLOOD  DRYER

“CLEAN SIDE “ OF PLANT OF PLANT

EDIBLE MATERIAL TO  CLEANING AND  PACKAGING

CARCASS  SPLIT

CARCASS  WASHED

WASTEWATER  TO  INDUSTRIAL  PRETREATMENT PLANT

MULTI‐STAGE  MULTI STAGE SCRUBBER  SYSTEM

PORK MEAL LEGEND

OFFAL TO  OFFAL TO INEDIBLE RENDERING

CARCASSES SOLIDS WASTEWATER AIR EXHAUST STREAM AIR EXHAUST STREAM

OFFAL AREA OFFAL AREA

STEAM

Figure 2. Harvesting

EDIBLE  RENDERING

HARVESTING  (cont’d) (cont d)

MEAT PACKAGING AND AND  REFRIGERATED  STORAGE

INEDIBLE  RENDERING RAPID CHILL ( 35°F) (‐35°F

REFRIGERATED  AREA

CUTTING AND BONING

WASHED CARCASSES FROM  OFFAL AREA O

LEGEND CARCASSES

WASTEWATER  TO INDUSTRIAL  PRETREATMENT  PLANT 

SOLIDS WASTEWATER

Figure 3. Harvesting (Chill Area)

BLOOD PROCESSING AND DRYING

BLOOD STORAGE

COAGULATOR

CENTRIFUGE

WASTEWATER TO INDUSTRIAL TO INDUSTRIAL  PRETREATMENT PLANT

MULTI‐STAGE  MULTI STAGE SCRUBBER  SYSTEM

BLOOD DRYER BLOOD DRYER (8 MMBTU/HR)

PLASMA   OR BLOOD MEAL 

LEGEND BLOOD SLURRY SOLIDS AIR EXHAUST STREAM WASTEWATER

Figure 4. Blood Processing and Drying

MULTI‐STAGE  SCRUBBBER  SYSTEM

SCREW  CONVEYOR

GRINDER

CONTINUOUS  COOKER 260°FF 260

FAT & OFFAL

CONDENSER

PERCOLATOR  PAN

HEAT  EXCHANGER

MULTI‐STAGE  SCRUBBBER

GRINDER

SCREW PRESS

CRUDE ANIMAL  FAT STORAGE  TANK

CENTRIFUGE

LEGEND AIR EXHAUST STREAM SOLIDS

SCREEN

FILTER

SLURRY LIQUIDS

Figure 5. Inedible Rendering

PROTEIN  MEAL

ANIMAL FAT  STORAGE TANK

GRINDER

CUTTING DEBONING  (FAT AND MEAT  TRIMMINGS)

MELT TANK (110°F)

CHOICE WHITE  CHOICE WHITE GREASE

DISINTEGRATOR

GRINDER

COOKER (210°F)

INEDIBLE  RENDERING

INDUSTRIAL  PRETREATMENT  PLANT

LEGEND WASTEWATER

* EDIBLE RENDERING HAS

SOLIDS SLURRY

NO AIR EMISSION POINTS

Figure 6. Edible Rendering

SCREENING  DEVICE

FAT SKIMMER

FLOCCULATION

DISSOLVED AIR  FLOTATION FLOTATION  SYSTEM

BIOLOGICAL  BIOLOGICAL TREATMENT

WASTEWATER  WASTEWATER FROM CLEANING  ACTIVITIES 

FILTER  PRESS

INEDIBLE  RENDERING

(MAY CONTAIN BLOOD,  BONE, FAT, ETC.)

POTW SLUDGE DRYER  (3 MMBTU/HR) (3 MMBTU/HR)

LEGEND AIR EXHAUST STREAM

CYCLONE

SOLIDS SLURRY WASTEWATER WASTE ACTIVATED SLUDGE

BIOFILTER

Figure 7. Industrial Pretreatment Plant

STORAGE  BUNKER

VICINITY MAP MICHIGAN

engineers scientists architects constructors

CITY OF COLDWATER BRANCH COUNTY

_ ^

fishbeck, thompson, carr & huber, inc.

Odor Management Plan

Coldwater Twp., Branch County, Michigan

Clemens Food Group - Coldwater Facility

PLOT INFO: Z:\2014\140834\CAD\GIS\MAPDOC\FIG01_LOCATION MAP.mxd Date: 12/31/2014 9:03:44 AM User: acs

Hard copy is intended to be 8.5"x11" when plotted. Scale(s) indicated and graphic quality may not be accurate for any other size.

PROJECT NO.

LOCATION MAP NORTH 0

500

FEET 1,000

Source: Esri, DigitalGlobe, GeoEye, i-cubed, Earthstar Geographics, CNES/Airbus DS, USDA, USGS, AEX, Getmapping, Aerogrid, IGN, IGP, swisstopo, and the GIS User Community, Esri, HERE, DeLorme, MapmyIndia, © OpenStreetMap contributors, Esri, HERE, DeLorme, TomTom, MapmyIndia, © OpenStreetMap contributors, and the GIS user community

G140834 FIGURE NO.

8

©Copyright 2014 All Rights Reserved

fishbeck, thompson, carr & huber, inc. Hard copy is intended to be 11"x17" when plotted. Scale(s) indicated and graphic quality may not be accurate for any other size.

01

02

03

04

05

06

07

OFFICE 162 SF

OFFICE 162 SF

OFFICE 162 SF

OFFICE 162 SF

WATER SOFTENERS

WOMEN'S 229 SF

BOILER ROOM 4,750 SF

OFFICE 116 SF

CONF. RM. 635 SF

MUCOSA

T8

T7

T6

WELD SHOP 2,526 SF

ER8

BOILER OFFICE 92 SF

MRO 7,160 SF

ER7

MAINT. 5,012 SF

VAT WASH 1,426 SF

AIR COMP. RM. 2,016 SF

16 07 06 04 03

05

23 22 21 20 19

02

T3 01

1

PALLETIZING

3

SNAP CHILL

69 TEAM MEMBERS NO GREEN HATS INCLUDED IN THE COUNT (2 USDA INSPECTORS INCLUDED IN COUNT)

SUSPECT

UTILITY / MECHANICAL HALLWAY

T9 13 12 11 10 09 08

2

WET HARVEST

15 14

32

ALL PENS THE SAME SIZE 1170 SF. 180 HEAD

31 30 29 28 27 26 25 24

TOWER

CO2 STUN AREA

18k head (55,590 sf) rail spacing 36" 12 rails per bay 8 bays = 96 total rails hog spacing 10" oc (our current spacing is 8.25" on a 67'-8" rail) rail length 156'-8" (1,880") 1,880" / 10" = 188 hogs per rail 188hogs x 12 rails = 2256 hogs per bay 8 bays x 2256hogs = 18,048 total hogs

MT PALLET FEED

OFFICE FOR 3

USDA WOMEN'S RM.

USDA MEN'S RM.

USDA OFFICE #1

USDA OFFICE #2

MEN'S RM. ELEVATOR MECH.

CUT FLOOR / BONING SUPERVISORS

ELEVATOR

QA TECHS.

HARVEST SIDE

PROCESS SIDE ER2A

QA SUPERVISOR OFFICE

CAFETERIA SUPPLIES / BOX DOCK

UP

QA SUPERVISOR

WOMEN'S RM.

UP

T1

COMP. RM. 2,535 SF

MARINATE ROOM 5,768 SF

BONING

ER3

18

TRASH 2,079 SF

WOMEN'S 160 SF

ER9

17

INEDIBLE 2,484 SF

TRIM BLEND 5,330 SF

VAT STORAGE

SUSPECT 147 SF

SANITATION 2,180 SF

KNIFE SHARP 419 SF

ER1A

HARVEST MAINT. 2,236 SF

SUSPECT 147 SF

CHEM. 1,188 SF

MEN'S 160 SF

USER: ACS

BATTERY RM. 2,164 SF

ER1B

HARVEST MAINT. SUPERVISOR 120 SF

TIME: 1:24:55 PM

ER?

UTILITY 453 SF

OUTLINE OF BASEMENT 25,685 SF

CASING / OFFAL COOLER 24,745 SF

REFRIG. 1,540 SF

WOMEN'S 229 SF

BLOOD PLASMA PET FOOD 2,702 SF

ELECT. 2,504 SF

COMP. ROOM 6,528 SF

MEN'S 229 SF

MEN'S 229 SF

PET FOOD

DATE: 1/5/2015

OFFICE 161 SF

T?

FORK TRUCK MAINT. 1,470 SF

WOMEN'S 229 SF

DOCK 2,300 SF

LAYOUT: LAYOUT1

OFFICE 161 SF

BOILER #1

CIP PUMP ROOM 397 SF

PLASMA

OFFICE 161 SF

Odor Management Plan

BOILER #2

OFFICE 116 SF

OFFICE 161 SF

Coldwater Twp., Branch County, Michigan

T5

BOILER #3

MEN'S 229 SF

RAMP TO BASEMENT

FUTURE BOILER #4

ER6

CLEAN SIDE CONFERENCE ROOM

DIRTY SIDE CONFERENCE ROOM

T2

OUTLINE OF 2nd FLOOR 45,726 SF

LAUNDRY ROOM

HARD CHILL COMP. ROOM EQUIPMENT 3,487 SF

PLOT INFO: Z:\2014\140834\CAD\SUPPORT\NEWTON ROAD SITE_8_OMP.DWG

PPE AREA

PPE AREA CAFETERIA KITCHEN

CLEAN SIDE LOCKER AREA

CLEAN SIDE DINING ROOM

BOOT ROOM

DIRTY SIDE DINING ROOM

DIRTY SIDE EMPLOYEE ENTRANCE

DIRTY SIDE SERVING AREA

CLEAN SIDE SERVING AREA

CLEAN SIDE EMPLOYEE ENTRANCE

HR AREA

INFIRMARY

ELEV.

HR CONFERENCE ROOM

BUILDING LAYOUT PROCESS EQUIPMENT

G140834

9 2014 All Rights Reserved

2015 All Rights Reserved 31031

1651 CONTACT CHAMBER

1652

EFFLUENT TANK

1655

EFFLUENT TANK

CLARIFIER TANK

1653 1653

1607

8"

6"

1605 1605

8"

6"

6"

4"

12"

8"

8"

8"

10"

10"

8"

1610

1610

10"

10"

8"

10"

10"

1650

1615

1615 1620 1620 OUTLINE OF BASEMENT BELOW

1625

EQUALIZATION TANK

ER4B 1625 DENITRIFICATION TANK

DENITRIFICATION TANK

NITRIFICATION TANK

NITRIFICATION TANK

NITRIFICATION TANK

#1

BUILDING LAYOUT - IPP Odor Management Plan

Coldwater Twp., Branch County, Michigan

10"

8"

10"

USER: ACS

WASTE WATER 12,598 SF

8"

TIME: 4:34:19 PM

6"

RETURN SLUDGE PIT

1601 1601

DOWN

DATE: 1/27/2015

ER4A

T4

LAYOUT: LAYOUT1 (2)

UP

CLARIFIER TANK

1655

PLOT INFO: Z:\2014\140834\CAD\SUPPORT\NEWTON ROAD SITE_8_OMP.DWG

#2

1635 1635

LIME

#3

4"

6"

6" 4"

18" STEP DOWN

1640

1640

HATGRO BUNKER 2487 SF. fishbeck, thompson, carr & huber, inc. Hard copy is intended to be 11"x17" when plotted. Scale(s) indicated and graphic quality may not be accurate for any other size.

BIO FILTER

REUSE HOLDING TANK

G140834

10

EXHAUST TO ATMOSPHERE AT 00 F T 7,000 c m -

BLOOD DRYER EXHAUST BLOOD CENTRIFUGE BLOOD COAGULATED



RAT BLOOD TANK

-

5 0 0 CFM 600 CFM -

HAIR HYDROLYZER SHAFT SEALS • s o o c m EACH N / C GAS HAIR HYDROLYZER HEAT EXCHANGER

1,000 CFM -

N / C GAS CONTINUOUS — COOKER HEAT EXCHANGER

1,500 CFM -

0

,

A

100,000 CFM SYSTEM BLOWER

85,000 CFM SYSTEM BLOWER EXHAUST TO 100,000 CFM PBS

1,600 CFM -

# 1 PRESSOR

1,500 CFM -

GREASE CENTRIFUGE

-

760 CFM -

DRAINER/OVERPRESSER SCREW -

-

750 CFM-

AIR BALANCE

75,000 CFM PLANT AIR VENTILATION

1,800 CFM -

# 8 PRESSORS

SCREW CONVEYORS

ABOVE GRADE

1,600 CFM -

- 1,000 C F M - 6,000 C F M -

I \j M \i

25,000 CFM VENTURI SCRUBBER

L~A- — A- —A * —A »— *• - A M / \ / \ / \ / \ / \ / W \ / V \ V \ \ \ \l \

M \

25,000 CFM PACKED BED SCRUBBER

100,000 CFM PACKED BED SCRUBBER

C 3 G3IZH3I

ROBERTSON TECHNOLOGIES LLC SCHEMATIC FLOW DIAGRAN OF CONTROL EQUIP.

TITLE:

FOR PROPOSED NEW PROTEIN RECOVERY PLANT CLEMENS FOOD GROUP - HATFIELD, PA PROJECT: SCALE: DRAWNBY: DATE: CS-2012 NTS JJIOBERTSON 11/20/14 DRAWING*:

CS-2012-4

SHEET: 1 OF 1 REl': 1

Figure 11 Multi-stage Scrubber System

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