Bunge: Boiler MACT & Particulate Control Study

Location: Five Plants in Illinois, Indiana and Ohio

Client: Bunge NA Inc.

Completion Date: 2004

Bunge hired Burns & McDonnell to develop and perform a Phase I Boiler Maximum Achievable Control Technology (MACT) study for five of plant facilities in Illinois, Indiana and Ohio. The goal of the study was to identify the air pollution control modifications necessary for these facilities to meet the requirements of the National Emission Standards for Hazardous Air Pollutants (NESHAP) for Industrial, Commercial and Institutional Boilers and Process Heaters, commonly referred to as the Industrial Boiler MACT.

The Phase I Boiler MACT effort included both baseline surveys and feasibility studies. The baseline survey work was intended to establish baseline emissions data for comparison to the emission limitations in the MACT standard. This work included stack testing to analyze particulate matter (PM), mercury and hydrogen chloride (HCl); site-specific test plans; coal and ash analysis sampling; assessment of pertinent boiler physical/operational characteristics; and a summary report. Coordination with Bunge for plant and testing requirements and scheduling logistics was a vital aspect of this effort.

The feasibility studies were designed to identify and evaluate air pollution alternatives that would bring each of the five facilities into compliance with the requirements of the Industrial Boiler MACT and any other identified regulatory programs. Burns & McDonnell worked with Bunge to develop both a regulatory basis and plant design basis. Utilizing this information, in conjunction with the results of the baseline surveys work, Burns & McDonnell developed compliance alternatives and associated capital costs and operating cost estimates (+/- 30 percent). The capital and operating costs were then entered into a pro forma economic analysis to determine the most economic alternative(s). Implementation schedules and constructability assessments for the alternatives were also provided.

  • Baseline surveys (stack testing and fuel analysis sampling)
  • Development of design basis
  • Regulatory review
  • Alternatives evaluation
  • Economic analysis
  • Feasibility studies