United States
Environmental Protection
Agency
Risk Reduction Engineering
Laboratory
Cincinnati OH 45268
EPA/540/5-89/007a
April 1989
Superfund
Technology Evaluation
Report:
SITE Program
Demonstration Test
Shirco Pilot-Scale Infrared
Incineration System at the
Rose Township Demode
Road Superfund Site
Volume I
IPERFUND INNOVATIVE
CHNOLOGY EVALUATION
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EPA/540/5-89/007a
April 1989
Technology Evaluation Report:
SITE Program Demonstration Test
Shirco Pilot-Scale Infrared Incineration System at the
Rose Township Demode Road Superfund Site
Volume I
Risk Reduction Engineering Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, OH 45268
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NOTICE
The information in this document has been funded, wholly or in
part, by the U.S. Environmental Protection Agency under
Contract No. 68-03-3255 to Foster Wheeler Enviresponse,
Incorporated and the Superfund Innovative Technology
Evaluation (SITE) Program. It has been subjected to the
Agency's peer and administrative review, and it has been
approved for publication as an EPA document. Mention of trade
names or commercial products does not constitute an
endorsement or recommendation for use.
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FOREWORD
The Superfund
was authorized in
a joint effort
and the Office
purpose of the
waste treatment
Innovative Technology Evaluation (SITE) program
the 1986 Superfund amendments. The program is
between EPA's Office of Research and Development
of Solid Waste and Emergency Response. The
program is to assist the development of hazardous
technologies necessary to implement new cleanup
standards which require greater reliance on permanent remedies.
This is accomplished through technology demonstrations which are
designed to provide engineering and cost data on selected
technologi es.
This project consists of an analysis of Shirco's Pilot-Scale
Infrared Incineration System and represents the third field
demonstration in the SITE program. The technology demonstration
took place at an abandoned waste site which comprises the Demode
Road Superfund Site in Rose Township, Michigan. The
demonstration effort was directed at obtaining information on the
performance and cost of the system for use in assessments at
other sites. Documentation will consist of two reports This
Technology Evaluation Report describes the field activities and
laboratory results. An Applications Analysis Report will follow
and provide an interpretation of the data and conclusions on the
results and potential applicability of the technology.
Additional copies of this report may be obtained at no charge
from EPA s Center for Environmental Research Information, 26 West
Martin Luther King Drive, Cincinnati, Ohio, 45268, using the EPA
document number found on the report's front cover. Once this
supply is exhausted, copies can be purchased from the National
Technical Information Service, Ravensworth Bldg., Sprinqfield
VA 22161, (702) 487-4600. Reference copies will be available at
EPA libraries in their Hazardous Waste Collection. You can also
call the SITE Clearinghouse hotline at 1-800-424-9346 or (202)
382-3000 in Washington, DC to inquire about the availability of
other reports.
Margarejt M
DirectoV, Technology Staff,
Office of Program Management
and Technology
W .LjjKhsrey, Acting
arrOffice of
Environmental Engineering
and Technology Demonstration
111
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ABSTRACT
The Shirco Pilot-Scale Infrared Incineration System was
evaluated during a series of seventeen test runs under varied
operating conditions at the Demode Road Superfund Site located
in Rose Township, Michigan. The tests sought to demonstrate
the effectiveness of the unit and the technology in thermal
destruction of soil contaminants, as recommended by the
Remedial Investigation and Feasibility Study conducted between
1984 and 1986. The report includes a process description ot
the unit and field operations documentation including a
discussion of the operational history during the test program,
a summary of operating conditions, and the operating log
data. The report also includes sampling and analytical
procedures and data along with the approved quality assurance
project plan. The report provides a performance evaluation ot
the unit based on the test program data and observations and
an overall unit cost analysis and evaluation. Based on the
above information, the report provides the initial data and
evaluation criteria to enable the EPA to determine the
applicability of the Shirco technology to Superfund site
investigations and cleanups throughout the country. The
report covers a period from May 11, 1987 to September 30,
1988, with the test demonstration of the unit occurring from
November 2, 1987 to November 13, 1987.
i v
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VOLUME I
CONTENTS
Foreword . .
Abstract . .
Figures . .
Tables ...
Abbreviations
Conversi ons
Acknowledgments
and Symbols
1. Introduction '' .
1.1 Background .......
1.2 Program Objectives . •! . • '.
2. Executive Summary ......
3. Process Description ....!.'].'!
3.1 General Process Description .'
3.2 Detailed Process Description
4. Field Operations Documentation . .
4.1 Pretest Samp!ing
4.2 Test Summary
4.3 Operating Log Data . . ' ' •
5. Sampling and Analysis Program . .'
5.1 Sampling Procedures . .
5.2 Analytical Procedures . !
5.3 Sampling and Analytical Report
6. Performance Data Evaluation
6
6
6,
6,
6,
6.
6.7
6
6
6.
6.
6.
6.
8
9
10
11
12
13
Introduction
Characteristics of the Feed .' .'
Characteristics of the Furnace Ash*
Residual PCBs in Furnace Ash
Mobility of Heavy Metals ....
Destruction and Removal Efficiency'
(ORE) of PCBs
Other Organic Stack Gas and PCC
Offgas Emissions
Acid Gas Removal .....'.'.'.'*
Parti cul ate Emissions .'.'.'. ,' .' [
Analysis of Scrubber Makeup Water,'
Scrubber Water, and Scrubber Solids
Overall Disposition of Metals .
Optimum Operating Conditions .
QA Summary
Page
iii
i v
vi i
vi i i
x
xiv
xv
1
1
2
4
20
20
21
28
28
33
45
48
58
73
80
81
81
82
84
87
88
90
93
93
96
96
98
103
104
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VOLUME II
CONTENTS
Appendices
A. Operating Log Data
B. Sampling and Analytical Report
C. Quality Assurance Project Plan/Test Plan
D. Pretest Waste Characterization Analytical Results
E. Test Plan for the Monitoring of Vapor Phase Lead
Emissions From the Shirco Portable Pilot Unit
During the Rose Township Demonstration Test
F. Monitoring Studies for Vapor Phase Lead Emissions
From The Shirco Portable Unit During the Rose
Township Demonstration Tests
G. Evaluation of EP and TCLP Extraction Procedures
For Pb-Contamiriated Soils and Combustion
Residues
VI
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FIGURES
Number
1
2
3 .
4
5 ;
6
System process flow
Overall test site..-. .-.-, ,
Demode Road Superfund Site .:<
Pretest sampling grid . . . . .
Sampling locations - system, process flow
Sampling locations - overall tes>t site ,
Page
6
7
29
30
59
60.
VI 1
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Number
1
2
3
4
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
TABLES
Page
SITE Demonstration Test Results Summary . . . 11
Safety Interlock Systems ..-:.. 27
Pretest Sample Analyses 31
Pretest Sample Analyses - Composite of
All Sectors 32
Pretest Sample Analyses - Composite of
Ten Grid Sectors with Maximum PCB and
Lead Contamination 34
Proposed Test Matrix 35
Operations Summary 39
Power Usage - Actual Operations ........ 40
Summary of Sampling and Analytical Program,
Phase I 49
Summary of Sampling and Analytical Program,
Phase II 55
Feed Characteristics • • • 83
Characteristics of the Furnace Ash - Organics
and Metals Analyses 85
Characteristics of the Furnace Ash - Ultimate
Analyses . 85
Comparison of Leachable Lead in the
Feed and Furnace Ash • • 89
Destruction and Removal Efficiency of PCBs . 92
PCC Offgas and Stack Gas Organic Emissions . 94
Acid Gas Removal Efficiency -95
Particulate Emissions ,......« 97
Scrubber Makeup Water Analysis "
Scrubber Water Analysis 100
VI 1 1
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TABLES (continued)
21
22
23
Lead Flows Through the System
Lead Concentrations in Feed, Ash, and
Particulates ....... .....
Optimum Operating Conditions - Energy
Consumption ..........
102
103
105
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ABBREVIATIONS AND SYMBOLS
AAS Atomic absorption spectroscopy
acfm Actual cubic feet per minute
APC Air pollution control
Btu British thermal units ,
CC Cubic centimeter
CEM Continuous emission monitor
CFR Code of Federal Regulations
Cl Chlorine
CO Carbon monoxide
C0£ Carbon dioxide
DE Decontamination efficiency
DGM Dry gas meter
ORE Destruction and removal efficiency
dscf Dry standard cubic feet
dscfm Dry standard cubic feet per minute
dscm Dry standard cubic meters
dscmm Dry standard cubic meters per minute
ECD Electron capture detection
EMB Emissions Measurement Branch
EPA U.S. Environmental Protection Agency
EP Tox EP Toxicity Test Procedure
FID Flame ionization detection
ft Feet
FWEI Foster Wheeler: Enviresponse, Inc.
g Grams
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gal
GC
GMW
gpm
HC1
HHV
ICAP
ID
in
J
kg
Kw
L
Ib
m
MDNR
mg
min
ml
m
ug
MM5
MS
NBS
ND
NDIR
ABBREVIATIONS AND SYMBOLS (continued)
Gallons
Gas chromatograph
General Motor Works
Gallons per minute
Hydrogen chloride
High heating value
Inductively coupled argon plasma
Inside di ameter
Inches
Joules
Ki1ograms
Kilowatts
Liters
Pound
Meters. ;
Michigan Department of Natural Resources
Mi 11igrams
Minutes , ,
Mi 11i Ti ters
micron
M i c r o g r a m s •-•••.
Modified Method 5 ,
Mass spectrophotometer
National Bureau of Standards
Notdetected
Non dispersive infrared
xi
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ng
Mm3
NOX
OAQPS
OD
ORD
OSWER
02
Pb
PCBs
PCC
PCDD
PCDF
PIC
POHC
PP
ppb
ppm
ppt
psig
PUF
%
QA/QC
QAPP
RCRA
RF
RI/FS
ABBREVIATIONS AND SYMBOLS (continued)
Nanograms
Normal cubic meters
Nitrogen oxide
Office of Air Quality, Planning, and Standards
Outside diameter
Office of Research and Development
Office of Solid Waste and Emergency Response
Oxygen
Lead
Polychlorinated biphenyls
Primary combustion chamber
Polychlorinated dibenzo-p-dioxin
Polychlorinated dibenzofuran
Product of incomplete combustion
Principal organic hazardous constituent
Priority pollutant
Parts per bi11i on
Parts per million
Parts per trillion
Pounds per square inch gauge
Polyurethane foam
Percent
Quality Assurance/Quality Control
Quality Assurance Project Plan
Resource Conservation and Recovery Act
Response Factor
Remedial Investigation/Feasibility Study
xi i
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ROD
RREL
S
S&A
SARA
SASS
SCC,
SCFM
sec
SITE
sq ft
SV
TCDD
TCDF
TCLP
TDS
THC
TOC
TSCA
TSS
UV
v
V
VOA
VOST
WC
wt
ABBREVIATIONS AND SYMBOLS (continued)
Record of Decision
Risk Reduction Engineering Laboratory
Sulfur
Sampling and Analysis
Superfund Amendments and Reauthorization Act of
1986
Source assessment sampling system
Secondary combustion chamber
Standard cubic feet per minute
Seconds
Superfund Innovative Technology Evaluation Program
Square feet
Semivolatile
Tetrachlorodibenzo-p-dioxin
Tetrachlorodibenzofuran
Toxicity Characteristic Leaching Procedure
Total dissolved solids
Total hydrocarbons
Total organic carbon
Toxic Substances Control Act of 1976
Total suspended solids
Ultraviolet
Volume
Volatile
Volatile organic analysis
Volatile organic sampling train
Water column
Weight
xi i i
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CONVERSIONS
To convert from
Btu/lb
Cu ft
Cu yd
ft
°F
gal
HP
Ib
Btu/hr
to.
J/g
m3
m3
m
°C
m3
kW
kg
J/hr
Multiply bv
2.326 E+00
2.832 E-02
7.646 E-01
3,048 E-01
(t,:-32)/1.8
3.785 E-03
7.46 E-01
4.535 E-01
1.055 E + 03
xiv
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ACKNOWLEDGEMENTS
This report was prepared under the direction and coordination of Mr
Howard Wall, EPA SITE Program Manager in the Risk Reduction Engineering
Laboratory (RREL), Cincinnati, Ohio. Contributors and reviewers for this
/SESnJ WeC6 Ml> ?teven L"zkow of the Michigan Department of Natural Resources
(MDNR), the Michigan SITE Project Manager j Ms. Linda Galer of the Office of
Solid Waste and Emergency Response (OSWER); Mr. Kevin Adler of EPA Region V-
Mr. Frank Freestone of RREL. Organizations which contributed to the report
were MDRN, Shirco Infrared Systems, Inc.; ECOVA Corporation; and Radian
Corporation (sampling and analysis).
This report was prepared for EPA's Superfund Innovative Technology
Evaluation (SITE) Program by Mr. Seymour Rosenthal, Task Manager for Foster
Wheeler Enviresponse, Inc. for the U.S. Environmental Protection Agency under
Contract No. 68-03-3255.
xv
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SECTION 1
INTRODUCTION
1.1 BACKGROUND
In response to the Superfund Amendments and Reauthorization
Act of 1986 (SARA), the U.S. Environmental Protection Agency's
(EPA) Offices of Research and Development (ORD) and Solid
Waste and Emergency Response (OSWER) have established a formal
program to accelerate the development, demonstration, and use
of new or innovative technologies for hazardous waste site
cleanups. This program is called the Superfund Innovative
Technology Evaluation (SITE) Program.
The major objective of this demonstration
develop reliable cost and performance info
innovative alternative technologies, so th
considered in Superfund decision making.
monitoring, and evaluation guidelines and
developed by ORD and are used to collect d
from the demonstrations. SITE demonstrati
conducted at Superfund Federal or State si
facilities, private sites, and EPA or deve
evaluation facilities can be used.
program is to
rmation on
at they can be
Common measurement,
protocols have been
ata and information
ons usually will be
tes. Federal
loper test and
One site that has been chosen to demonstrate an innovative
technology is the Demode Road Superfund Site located in Rose
Township, Oakland County, Michigan, approximately 40 miles
northwest of Detroit.
The 12-acre waste site first was used for disposal and storage
of industrial wastes in 1966. Bulk wastes brought to the site
were discharged to surface and shallow lagoons and pits.
Drums of waste either were buried, dumped into disposal pits,
or stockpiled. The site was used as a disposal facility
through 1968, and possibly was used on an intermittent basis
until 1971.
In June 1979, the Michigan Department of Natural Resources
(MDNR) inspected the site and discovered many drums leaking.
Sampling of the drums showed the contents to be paint sludges
solvents, polychlorinated biphenyls (PCBs), oils and greases,
phenols, and heavy metals. MDNR proceeded to remove over
5,000 drums of waste material. In 1983, an additional 1,500
tons of contaminated soil were removed.
MDNR conducted a Remedial Investigation and Feasibility Study
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be cleaned
groundwater
(RI/FS) of the site from 1984 through 1986. The data from the
RI/FS indicated that the soils at the site contained
concentrations of PCBs .as high as 980 ppm, lead conceintrati ons
as high as 1,480 ppm, and quantities of other organics and
heavy metals. The RI/FS recommended that the site
up by extraction and treatment of the contaminated
and thermal destruction of contaminants in the soil. The
recommendation led the SITE Program to select the Demode Road
Superfund Site for the demonstration of the Shirco Pilot-Scale
Infrared Incineration System. Thermal destruction ultimately
was chosen in the Record of Decision (ROD) for this site,
which was signed on September 30, 1987.
During the period from November 2-13, 1987, Shirco Infrared
Systems, Inc., Dallas, Texas, demonstrated the capability of
its pilot-scale unit to treat 1,799 kg (3,967 Ib), at test
conditions, of the contaminated soil at the Demode Road site.
The Shirco Pilot-Scale Infrared Incineration System is
enclosed in a single 45-ft trailer and is designed to treat
wastes at a pilot-scale rate of one ton per day. A specific
process description of the unit is presented in Section 4.1 of
this report.
During the test period, a detailed sampling and analytical
program as defined by an EPA Category II Quality Assurance
Project Plan (QAPP), included in Appendix C, Volume II, was
conducted.
1.2 PROGRAM OBJECTIVES
The major objectives of this demonstration were to determine
the following:
o ORE levels for PCBs and the presence of PICs in the stack
gas. The regulatory standards are 99.99% ORE under the
Resource Conservation and Recovery Act (RCRA) and 99.9999%
ORE under the Toxic Substances and Control Act (TSCA).
o Level of hydrogen chloride (HC1) and particulates in the
stack gas. The RCRA standard for HC1 in the stack gas is
1.8 kg/hr (4 Ib/hr) or 99 wt% HC1 removal efficiency. The
RCRA standard for particulate emissions in the stack gas
is 180 mg/dscm (0.08 gr/dscf).
Level of residual PCBs in the
varied operating conditions.
furnace ash at normal and
Mobility of
furnace ash
heavy metals, particularly lead, in the
as compared to the feed.
Mobility of heavy metals in the furnace ash as compared to
the RCRA Extraction Procedure Toxicity (EP Tox)
Characteristic (as measured by the EP Tox test) and the
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proposed toxicity characteristic (as measured by the
Toxicity Characteristic Leaching Procedure (TCLP)).
Level of residual heavy metals and organic compounds, and
other physical and chemical characteristics in the
scrubber water discharged from the unit.
The operating conditions that reduce energy consumption
without decreasing soil decontamination effectiveness.
Effect of varying operating conditions on residual levels
of heavy metals and organics in the furnace ash versus the
level s in the feed. . ,•
Adherence-of the quality assurance (QA) procedures to the
requirements of the RREL approved QA Project Plan
(Category II), as defined by the Document No. PA
QAPP-0007-GFS, "Preparation Aid for HWERL's Category II
Quality Assurance Project Plans", June, 1987. •
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SECTION 2
EXECUTIVE SUMMARY
INTRODUCTION
In response to the Superfund Amendments and Reauthorization
Act of 1986 (SARA), the Environmental Protection Agency's
Office of Research and Development (ORD) and Solid Waste and
Emergency Response (OSWER) have established a formal program
to accelerate the development, demonstration, and use of new
or innovative technologies as alternatives to current
containment systems for hazardous wastes. This new program is
called Superfund Innovative Technology Evaluation or SITE.
The principal goal of the SITE program is to demonstrate new
technologies in the field and develop reliable economics and
performance information.
The SITE program demonstration of the Shirco Pilot-Scale
Infrared Incineration System for thermal treatment developed
by Shirco Infrared Systems, Inc. of Dallas, Texas, was
conducted at the Demode Road Superfund Site in Rose Township,
Michigan. The Demode Road site is a 12-acre waste site
previously used to bury, dump, and store industrial wastes
such as paint sludges, solvents, and other wastes containing
PCBs, oils and greases, phenols, and heavy metals. PCBs and
lead are the principal contaminants in the soil used for the
test of the Infrared System.
The test was conducted from November 2-13, 1987 and treated
1,799 kg (3,967 Ib) of contaminated soil under various test
conditions. The major objectives of this demonstration were
to determine the following:
o ORE levels for PCBs and the presence of PICs in the stack
gas. The regulatory standards are 99.99%. ORE. under the
Resource Conservation and Recovery Act (RCRA) and 99.9999%
DRE under the Toxic Substances and Control Act (TSCA).
o Level of hydrogen chloride (HC1) and particulates in the
stack gas. The RCRA standard for HC1 in the stack gas is
1.8 kg/hr (4 Ib/hr) or 99 wt% HC1 removal efficiency. The
RCRA standard for particulate emissions in the stack gas
is 180 mg/dscm (0.08 gr/dscf).
o Level of residual PCBs in the furnace ash at normal and ..
varied operating conditions.
Mobility of
furnace ash
heavy metals, particularly lead, in the
as compared to the feed.
Mobility of heavy metals in the furnace ash as compared to
the RCRA Extraction Procedure Toxicity (EP Tox)
-------
Characteristic (as measured by the EP Tox test) and the
proposed toxicity characteristic (as measured by the
Toxicity Characteristic Leaching Procedure (TCLP)).
Level of residual heavy metals and organic compounds, and
other physical and chemical characteristics in the
scrubber water discharged from the unit.
The operating conditions that reduce energy consumption
without decreasing soil decontamination effectiveness.
Effect of varying operating conditions on residual
of heavy metals and organics in the furnace ash
levels in the feed.
1 eve!s
versus the
o Adherence of the quality assurance (QA) procedures to the
requirements of the RREL approved QA Project Plan
(Category II), as defined by the Document No. PA
QAPP-0007-GFS, "Preparation Aid for HWERL's Category II
Quality Assurance Project Plans", June, 1987.
FEED PREPARATION
The demonstration test used soil from an area of the site that
was highly contaminated with PCBs and lead, as determined in
the original remedial investigations performed at the site.
Pretest sampling and analysis further identified those sectors
within the area most highly contaminated with PCBs and lead
for excavation. Other organic and heavy metals were also
present in these sectors. Soil from these sectors to be used
as feed for the test was excavated and mixed into a pile using
a front-end loader, and then screened to remove aggregate and
debris greater than one inch in diameter. The screened soil
was drummed and transferred to a designated zone adjacent to
the test unit. Two drums of soil were blended with 3 wt% fuel
oil to be used for several of the test runs to investigate the
effect of increased feed heating value on overall unit
performance and energy consumption at varying operating
conditions. s
PROCESS DESCRIPTION
The Shirco
of a waste
combustion
combustion
system, an
system, all
Pilot-Scale Infrared Incineration System consists
feed system, an (electric) infrared primary
chamber, a supplemental propane-fired secondary
chamber, a venturi scrubber emissions control
exhaust system, and a data collection and control
enclosed in a 45-ft trailer. The system process
flow and the overall 250 ft x 100 ft test site "
presented schematically in Figures 1 and
2,
layout are
respectively.
During the test, the feed material was transferred from the
drums to pails, weighed, and then fed manually to a hopper
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FENCING
EXCLUSION ZONE
DRUM STORAGE AREA
• WASTE FEED
• ASH
• SLOWDOWN WATER
• EMPTY DRUMS
SHIRCO PILOT-SCALE INFRARED INCINERATOR SYSTEM
WASTE FEED
TRANSFER -
DRUMS TO
PAILS
PCC TO SCC VAPOR DUCT
SCC VAPOR OUTLET DUCT
BURNER FORCED
AIR BLOWER
WASTE FEED
WEIGH SCALE
CONTROL CABINET
BELT SPEED CONTROL
BURNER CONTROL
LIGHT PANEL
MOTOR CONTROL CENTER
TRANSFORMER
ELECTRICAL SERVICE
HEPC
SECONDARY COMBUSTION CHAMBER
>
PRIMARY COMBUSTION CHAMBER
CONTAMINATION! / / / / / / / /««/ ' / / ™™E / / / '
REDUCTION !
ZONE '
SUPPLY
/WATER/ / SCRUBBER //////
DRUM SLOWDOWN /\J GRADE
DRUM
MAKEUP WATER
FROM WATER
SUPPLY TRAILER
Figure 1. System process flow.
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FENCING
X—X—X—
EXCLUSION ZONE
WASTE FEED
TRANSFER -
DRUMS TO
PAILS
DRUM STORAGE AREA
• WASTE FEED
• ASH
• SLOWDOWN WATER
• EMPTY DRUMS
WEIGH SCALE
SHIRCO PILOT-SCALE INFRARED
INCINERATOR SYSTEM
I CONTAMINATION I
1 REDUCTION I
ELECTRICAL
SUPPLY-
DIESEL
GENERATORS
RADIAN ANALYTICAL
TRAILER
SHIRCO SUPPORT TRAILER
EXISTING VEGETATION
SITE PROGRAM OFFICE TRAILER
-x—x—x—x—x—x—x—x—x—x—x—x—x—x
FENCING
figure 2. Overall test site.
PARKING AREA
TO FENCED
HAZARDOUS
WASTE SITE
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-------
mounted over a metering conveyor belt. The waste was fed at a
controlled rate through a sealed feed chute onto the ^ •
incinerator conveyor (a tightly woven wire belt which moved
the waste material through the primary combustion chamber).
The conveyor belt speed can be adjusted to achieve feed
residence times in the PCC from 6 to 60 min. Typically
residence times range from 10 to 25 min. The depth of the
waste on the conveyor belt ranged from one to one and a halt
inches.
The primary combustion chamber (PCC) is a rectangular box
insulated by layers of ceramic fiber. Combustion air-i s •
supplied to the primary combustion chamber through a series of
air ports at points along the length of the chamber. The gas
flow in the incinerator is countercurrent -to the conveyed feed
material. Electric infrared heating elements installed above
the conveyor belt heat the waste to the designated temperature
(nominally 1,600°F), which results in desorption or .
incineration of organic contaminants from the feed. Rotary
rakes gently turn the material to ensure adequate mixing- and
complete desorption. When the thermally treated soi , now
referred to as furnace ash, reaches the discharge end of the
PCC, it drops off the belt through a chute and into an. _
enclosed hopper and discharge storage drum. The drums of.
furnace ash are then stored for final disposal.
Exhaust gas containing the desorbed -contaminants .-exits -the -
primary combustion chamber into a secondary combustion chamber
(SCC) or afterburner, where a propane-fired burner combusts
residual organic compounds into C02, CO, HC1, and H20.;
The SCC is typically operated at 2:2000F and a gas residence
time exceeding 2 sec. Secondary air is supplied to ensure
adequate excess oxygen levels for complete combustion.
Exhaust gas from the secondary combustion chamber then is
quenched by a water-fed venturi scrubber emissions control
system to remove particulate matter and acid gases. An .
induced draft fan transfers the gas to the exhaust stack for
discharge to the atmosphere.
The same trailer housing the thermal system also contains the
control panel for the main unit, and data collection
indicators and recorders. Safety interlocks also are .
integrated into the tailor-mounted unit to automatically
correct abnormal operating conditions, maintain system . . . <
performance, and if necessary, shut down feed and heat input
to the unit.
TEST PROCEDURE
: C
In order to meet the objectives of the demonstration test (see
Introduction), a total of 17 test runs were conducted Three?
runs were performed under design operating conditions to
8
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anH
and 14
UnU °Per^tio"
runs were conducted
system performance (Phase
under varying operational
? ?nOF r
a 2,200 F SCC
mm. Each of
UUfo PCBlat'An
it tor PCBs. An
9 condlt°s
were c°nducted at 1,600°F PCC temperature,
temperature, and a PCC residence time of 20
the three runs was sufficiently long (six to
k as
at the same
samples that
tional run
t0 bta1n
was
conducted
stack
ns
n
successfully collected during two of the previous
had
makpnn
makeup
solids
The Phase II runs were conducted for approximately one hour
under varied operating conditions that included the PCC
temperature (900, 1,200, 1,400, and 1,600°F), SCC
temperature (1,800 and 2 200°F), PCC feed 'residence time
iiJV5'.20' ?nd 25 minutes),- and PCC combustion air flow (on,
atmosphere)1 oxidizi"9 or non-oxidizing (pyrolytic) PCC
e I rUnS' samPles were tal
-------
monoxide, oxides of nitrogen, and total hydrocarbons. All of
the remaining sampled streams were analyzed for PCBs, dvoxins
and furans metals, and other physical and chemical properties
and components specific to the characterization of each
samPUdPma?rix. In addition, the EP Tox and TCLP leaching
tests were performed on these samples and the extracts were
evaluated for metals.
conducted in
of the
All of the sampling and analytical work was nnalitv
accordance with QA/QC Category II and include data q ality
credibility statements for the precision and accuracy
data reported.
RESULTS AND DISCUSSION
A detailed summary of the SITE demonstration test results is
Presented in Table 1. Based on the test objectives outlined
in the Introduction, the following results were obtained.
o Characteristics of the Feed
Based on data from the previous remedial investigation of
the site, a specific area within the site was identified
with the highest concentrations of both PCBs and lead, the
major soil contaminants of concern. The remedial
investigation also described the soil as a dry, brown,
sandy, and silty clay topsoil which upon excavation proved
to be an accurate observation. Subsequent Pretest
sampling and analysis of the specific area of the site
identified particular sectors with the hl9hest
contamination of PCBs and lead * composite sample of all
the sectors within the area indicated a 7.8 pH, 9.0 wt./o
molstSrl? 81 it % ash, less than 1000 Btu/lb high heating
va ue, and a 0.95 g/cc density. The composite sample
contained 570 ppm of total PCBs and 580 ppm lead
(elemental lead after digestion and conversion to
inorganic form). A composite sample of the 10 sectors _
chosen for excavation contained 626 ppm PCBs 560 ppm of
lead 55 ppb of tetrachlorodibenzo-p-dioxin (TCDD), and
4?2 ppb of tetrachlorodibenzofuran (TCDF) Once the feed
excavation was begun, it became evident that the front-end
loader could not confine its large-scale activi1 IBS to the
10 specific sectors and an area comprising 14 specific
sectors was excavated for the unit's feed source.
Table 1 summarizes the PCB and lead contaminant
concentrations measured in the soil from the composite of
the grab samples of feed taken during each of the test
runs In addition to lead, where concentrations ranged
frSm 290 to 3000 ppm and averaged 778 ppm, several other
metals were present at average concentrations exceeding 50
10
-------
TABLE 1. SITE DEMONSTRATION TEST RESULTS SUMMARY
Operating Conditions , Uaste Feed
PCC Characteristics
Temp.
0-
F
900(a.b)
900
1600(a,b)
(a)
CO
(9)
(h)
Residence EP Tox TCLP
time PCB Pb (Pb) (Pb)
min. ppm ppm ppm ppm
20 327 590 0.29 0.81
20 20.2 660 0.67 0.88
25 367 290 0.32 7.00
20 297 640 0.05 0.56
15 27.6 870 0.20 0.44
25 456 590 0.12 0.53
20 669 610 0.20 0.71
15 602 470 0.18 0.53
15 309 370 0.21 0.96
20 , 56.0 740 0.07 0.89
20 10.2 3000 0.15 0.67
20 35.2 1400 0.20 0.35
20 20.4 550 0.23 1.30
20 (f) 1100 0.14 0.49
10 391 620 0.25 0.73
15 451 620 ND 0.66
15(c) 271 390 0.53 1.80
15 , 311 500 0.07 0.55
3.00(g) 1.40(g)
Waste feed blended with 3 wt.% fuel oil.
, Non-oxidizing atmosphere.
PCC bed depth at 1 inch. All other tests at 1
PCB levels below analytical detection limits.
indicated in analyses.
ND - nondetectable value.
PCB
ppm
2.079
3.396
0.168
0.115(d)
0.077
0.108(d)
0.066(d)
0.025(d)
0.066(d)
0.087(d)
0.037
' 0.112
0.003
(f)
0.045(d)
0.117(d)
0.004
0.061(d)
1/2 inches.
Total shown is
Furnace Ash
Characteristics
(Pb)
ppm
1000
1400
860
1100
1000
1200
1200
2000
1000
1600
1100
1300
1100
420
1700
840
1500
800
sum of
EP Tox
(Pb)
ppm
0,38
0.89
0.88
4.10
0.38
0.14
0.06
4.90(g)
(h)
0.46
ND
0.05
ND
0.13
0.28
ND
0.43
0.27
1.10
TCLP
(Pb)
ppm
2.90
6.20
3.80.
1.60
3.60
, 0.05
4.10
2.80(g)
(h) ,
0.82
0.15
ND
ND
0.05
1.80
1.00
0.17
0.23
2.40
detectable limits
Run was conducted to makeup for incomplete semivolatile organics, PCDD/PCDF, soluble
chromium and stack gas particulate samplings on
Data from additional EP Tox and TCLP tests.
ND due to broken sample container.
other runs.
11
-------
ppm including barium (591 ppm), zinc (301 ppm), and
chromium (85 ppm). Total PCBs concentration ranged from
10.2 to 669 ppm and averaged 272 ppm.
Several samples of the feed contained small quantities of
TCDFs ranging from 0.04 to 0.1 ppb. Volatile and _
semivolatile organic compounds including methyl ethyl
ketone, trichloroethene, and bis(2-ethylhexyl)phthalate
were measured in feed samples at concentrations less than
50 ppm. Methyl ethyl ketone and trichloroethene were also
detected in solvent blanks and are attributed to
analytical laboratory contamination.
Characteristics of the of Furnace Ash
Table 1 summarizes the PCB and lead contaminant
concentrations measured in the furnace ash from the
composited grab samples taken at the conclusion of each
test run. In addition to lead, where concentrations
ranged from 420 to 2000 ppm and averaged 1173 ppm, several
other metals were present at average concentrations
exceeding 50 ppm including barium (1061 ppm), zinc (410
ppm), and chromium (81 ppm). Total PCBs concentration
ranged from 0.004 to 3.396 ppm. Two samples of furnace
ash contained 0.07 and 0.3 ppb of TCDF during two runs
conducted at a 900°F PCC operating temperature; the
normal PCC operating temperature is 1600°F. These runs
were also conducted without the input of PCC combustion
air to simulate non-oxidizing or pyrolytic combustion
conditions. The low PCC temperature and pyrolytic
environment could have led to the incomplete desorption or
incineration of TCDF present in the feed or to the •
production of TCDF from the incomplete combustion of PCBs
in the feed. Volatile compounds including - methylene
chloride, methyl ethyl ketone, tetrachloroethene, and
trichloroethene were also measured in the furnace ash
samples in concentrations ranging from 3.9 to 64 ppm with
one sample containing 980 ppm of methylene chloride.
Methyl ethyl ketone and trichloroethene were also detected
in solvent blanks and methylene chloride is commonly
employed in laboratory procedures; therefore .these
compounds may be products of incomplete combustion and/or
the result of laboratory contamination.
Residual PCBs in Furnace Ash
During the demonstration test, a total of 17 runs were
conducted at varying operating conditions. In addition to
the ORE levels, which are an indication of the performance
of the Shirco Pilot-Scale Infrared Incineration System and
its ability to meet RCRA and/or TSCA regulatory standards,
the reduction of PCB concentration from the feed to the
12
-------
furnace ash is also a measure of the unit's ability to
effectively destroy PCBs and produce a furnace ash with a
PCB concentration below the T.SCA guidance level of 2 ppm
of
The
Based on the data presented in Table 1, two samples
furnace as.h exceeded the TSCA guidance levels and
contained 3.396 and 2.079 ppm of total residual PCBs
satngles were produced during two runs conducted at a
900 F PCC operating temperature (20 minutes residence
time), which is significantly lower than the normal PCC
operating temperature of 1600°F. These runs were also
conducted without the input of PCC combustion air to
simulate non-oxidizing or pyrolytic combustion
conditions. At this low PCC temperature and pyrolytic
condition, these higher total residual PCB levels in the
furnace ash may be the result of the incomplete combustion
?$BV!Lthe feed- This is further substantiated by the
residual TCDF present in the furnace ash samples from
these same two runs, as discussed previously. The
remaining runs conducted at 1200, 1400, and 1600°F
resulted in total residual PCB concentrations in the
furnace ash ranging from 0.003 to 0.117 ppm. A third run,
which was conducted at a 900°F PCC operating temperature
but with an increased PCC residence time of 25 minutes
resulted in a total furnace ash PCB
ppm with no detectable TCDF. It is
increased residence time in the PCC
low 900°F PCC operating temperature
additional processing time for the
destruction of the PCBs in the feed
concentration of 0.
possible that the
may have offset the
and provided the
sati sf act.ory
168
o Mobility of Heavy Metals - Feed and Furnace
Ash
In order to determine whether heavy metals, particularly
lead, would leach from the furnace ash produced in the
Shirco Pilot-Scale Infrared Incineration System, EP Tox
and JCLP tests were conducted to determine the mobility of
heavy metals from the furnace ash as compared to the feed.
The initial EP Tox analyses for lead in the leachate
ranged from 0.05 to 0.67 ppm for the feed and 0.05 to 4 1
ppm for the furnace ash. The initial TCLP analyses ranged
from 0.35 to 1.80 ppm (with one sample at 7.0 ppm) for the
teed and 0.05 to 4.1 ppm (with one sample at 6.2 ppm) for
the furnace ash. .
on
A comparison of the EP Tox and TCLP analyses conducted
the furnace ash and the feed do not show any trend or
evidence that indicate reduced mobility of lead from the
furnace ash versus the feed as a result of the thermal
treatment. The comparison did reveal that the
concentrations of lead in the TCLP leachates from both the
13
-------
feed and the furnace ash were
corresponding EP Tox tests on
consistently higher than
the same samples.
the
When several samples were retested to verify the results,
the concentrations of lead in the EP Tox leachates (4.9
ppm feed, 3.0 ppm furnace ash) were higher than during the
initial tests and, in direct reversal to the original
data, exceeding corresponding TCLP leachate concentrations
(2.8 ppm feed, 1.4 ppm furnace ash). The results of the
retest again did not indicate reduced mobility of lead
from the furnace ash versus the feed as a result of the
thermal treatment.
Mobility of Heavy Metals - EP Tox and Proposed TCLP
Toxicity Characteristic Standards
EP Tox and TCLP tests were conducted on the feed, furnace
ash, scrubber water, and scrubber solids. All of the
results were below the EP Tox and proposed TCLP toxicity
characteristic standards of 5 ppm arsenic, 100 ppm barium,
1 ppm cadmium, 5 ppm chromium, 5 ppm lead, 0.2 ppm
mercury, 1 ppm selenium, and 5 ppm silver except for one
feed sample at 7.0 ppm lead (TCLP) and one furnace ash
sample at 6.2 ppm lead (TCLP). A comparison of the EP Tox
and TCLP analyses on all the sampled streams to the
abovementioned standards do not show any trend or evidence
that indicate reduced mobility of heavy metals as a result
of the thermal treatment.
Destruction and Removal Efficiency (ORE) of PCBs
the first
The ORE of PCBs for
greater than 99.99%. In contrast,
for incineration under the RCRA is
TSCA is 99.9999% ORE. The low PCB
feed resulted in PCB levels in the
less than the analytical detection
runs.
on the
three runs (Phase I) is
the regulatory standard
99.99% ORE and under
concentrati ons
stack gas that
1imits for two
in the
were
of the
Therefore for these runs, ORE is calculated based
sum of the detection limits of the PCB congeners in
order to compare the ORE for the runs on the same basis.,
Stack gas measurements conducted during the third run did
detect trichlorobiphenyl and tetrachlorobiphenyl congeners
and a ORE is shown based on this measurement. Ihe less
rigorous sampling in Phase II of the test was not designed
to allow calculation of ORE.
Other Organic Stack Gas and PCC Offgas Emissions
Several volatile and semivolati1e organic compounds were
detected in the stack gas at concentrations less than 100
ppb and established standards for direct inhalation. Low
levels of several phthalate compounds were also detected
in blank samples and may be traced to contamination f;rom
14
-------
plastic components in the process, sampling equipment, or
laboratory apparatus. Several volatile organic compounds
including benzene and toluene were detected in the stack,
gas and the scrubber makeup water and may be attributable
to contamination from the makeup water although PIC
formation is a possibility. Other volatile and
sennvolatile organic compounds, which probably represent
PICs, were detected. They include halomethanes,
chlorinated species including chlorobenzene and methylene
chloride, other volatile organics including xylenes,
styrene and ethyl benzene, oxygenated hydrocarbons
including acetone and acrolein, carbon disulfide, and
p-cnlor-m-cresol . Dioxins and furans were not detected in
the stack gas samples.
The majority of the organic compounds present in the PCC
off gas samples at levels less than 500 ppb were also
present in the stack gas. The additional destruction of
organics that take place in the SCC and emissions
scrubbing system reduced the concentration of these
organic compounds in the corresponding stack gas samples.
o Acid Gas Removal
During the Phase I Runs 1-3, HC1 emissions ranged from
0.181 to 0.998 g/hr, which were significantly below the
RCRA performance standard of 1800 g/hr that would require
a 99 wt.% HC1 removal efficiency. HC1 removal
efficiencies ranged from 97.23 to 99.35 wt.%. Acid gas
removal was not measured in Phase II.
o Particulate Emissions
Particulate emissions were measured throughout the test
and ranged from 7 to 68 mg/dscm, well below the RCRA
standard of 180 mg/dscm.
Analysis of Scrubber Makeup
S c r u b b e r S o 1 i d s
Water, Scrubber Water, and
i n a
Scrubber makeup water was transported to the site
tank truck that may have contained some residual
contamination prior to fill up. Samples of scrubber
makeup water were taken at the end of each run. No PCBs,
dioxins, furans, or semivolatile organic compounds were
detected. Several volatile organics including benzene,
toluene, and trichloroethene were measured at
concentrations less than 15 ppm. The concentrations of
heavy metals were all less than 0.2 ppm.
Samples of the water recirculation through the venturi
scrubber system, referred to as scrubber water, were also
15
-------
taken at the end of each run. PCB concentrations were
less than 200 ppt and no dioxins, furans, or semivolatile
organic compounds were detected Small quantities of
benzene (2 ppm) and toluene (5.7 to 11 ppm) were measured
in several of the samples and are attributable to the
similar contaminants in the scrubber makeup water. The
concentrations of heavy metals in the scrubber water were
all less than 1 ppm except for barium, which ranged from
0.2 to 2.2 ppm, and lead, which ranged from 0.12 to 1.8
ppm.
Insufficient quantities of scrubber solids in the scrubber
water were available for analysis.
o Overall Disposition of Metals
Total metals analyses of the feed, furnace ash, PCC offgas
and stack gas particulars, scrubber makeup water,
scrubber water, and scrubber solids showed that the
majority of the detectable metals, including lead, that
entered the unit with the feed remained in the furnace
ash. An overall mass balance of lead through the unit was
calculated based on the analysis of lead in the samples,
the measured feed rate as weighed during the runs
operating periods, the calculated furnace ash flow rate
based on the ultimate analysis of ash in the feed sample,
and the measured particle mass and gas volume obtained
from the gas' EPA Method 5 sampling trains. Phase I
results indicate an average lead mass flow rate of 28.3
g/hr in the feed, 37.0 g/hr in the furnace ash, 0.206 g/hr
in the PCC offgas particulates, and 0.109 g/hr in the
stack gas particulates. The quantity of lead leaving the
unit with scrubber water effluent is approximately 0.204
g/hr based on the maximum measured concentration of 1.8
Dpm lead in the scrubber water and an overall approximate
water flow rate of 30 gph. The PCC offgas participates
sampled during the Phase I runs contained an average of
5364 ppm of lead as compared to stack gas particulates,
which contained an average of 15,830 ppm of lead. By
contrast, the average concentration of lead in the teed
was 1550 ppm. Although the concentration of lead in the
particulate matter increases as the process flow
progresses through the unit, the actual mass flow
decreases as the gas stream is cooled and treated
the emissions control system.
For the Phase I runs sampling and analysis procedures were
conducted to evaluate vaporous lead concentrations in the
PCC offgas and soluble chromium concentrations in the HLL
offgas and stack gas particulates. The special sampling
for vapor phase lead and soluble chromium were unable to
detect any of either metal at levels less than 2.7 ppb and
264 ppb, respectively; therefore the evaluations were
i nconclusive.
of lead
through
16
-------
Other heavy metals, particularly barium and zinc, with
average concentrations exceeding 100 ppm in the feed
(barium 591 ppm, zinc 301 ppm) were also present in high
concentrations, relative to other heavy metals, in the
furnace ash (barium 1061 ppm, zinc 410 ppm) and scrubber
water (barium 0.8 ppm, zinc 0.3 ppm).
o Optimum Operating Conditions
Phase II was designed to examine the effect on energy
consumption and changes in the residual levels of heavy
metals and organics in the furnace ash versus the levels
in the feed by varying operating conditions.
Based on the data obtained an analysis was conducted to
compare energy consumption in the unit at operating
conditions that did not affect the performance of the
?2nn6r J r?o™oion ln the PCC Derating temperature from
1600 F to 1200UF reduced the average PCC power usage
48% from 0.2294 to 0.1200 kwhr/lb feed. A reduction in
the SCC operating temperature from 2200°F to 1800°F
oooTC?d ^roanera-?e ProPatie ^1 consumption by 51% from
3997 to 1952 Btu/lb feed. The use of 3 wt.% fuel oil to
supplement the fuel value of the feed further decreased
Jf iSSSor US39?oo^6 to 67% at PCC operating temperatures
of 1600°F and 1200°F, respectively, with accompanying
increases in overall feed rate of 32% and 26%. The costs
for fuel oil and its attendant facilities still must be
examined for specific applications to determine the cost
effectiveness of a fuel oil additive to the waste feed
As discussed in previous sections the resul
provide any trend or change in the residual
heavy metals and organics in the furnace as
levels in the feed as the operating conditi
and PCC operating temperatures were maintai
1600 F. At an abnormally low PCC operating
of 900UF, without the input of combustion a
simulate non-oxidizing or pyrolytic combust
total PCB and TCDF concentrations in the fu
increased. The increases may indicate that
conditions led to incomplete desorption or
PCB and TCDF and to the production of TCDF
incomplete combustion of PCBs in the feed.
QA Summary
ts did not
levels of the
h versus the
ons were varied
ned at 1200 to
temperature
i r to
ion conditions,
rnace ash
these PCC
incineration of
from the
The Phase I and II runs had a well-defined quality
assurance/quality control program to ensure the collection
of accurate data. This program was developed as part of
the test program preparation activities and was formalized
in the RREL approved QA Project Plan (Category II). All
of the sampling and analytical work was conducted in
17
-------
accordance with this QA Project Plan and the results
include data quality credibility statements and
information that confirm the satisfactory precision and
accuracy of the data reported..
CONCLUSIONS
Based on the above
conclusions can be
performance of the
System.
data and discussion, the following
made concerning the operation and
Shirco Pilot-Scale Infrared Incineration
1.
2.
The PCC equipped with infrared heating rods reduced PCBs
f?om an average of 272 ppm and a maximum of 669 ppm in the
feed to less than 0.2 ppm PCBs in the furnace ash when PCC
temperature was 1200°F or higher. Performance was well
below the TSCA guidance level of 2 ppm of PCBs in
treatment residuals. ".....''
The majority of the lead and other heavy metals present in
the feed remained in the furnace ash, regardless of
operating conditions. However, the scrubber water
contained levels of lead and barium (up to 1.8 to 2.2 ppm,
respectively), and metals also concentrated to some^extent
in the furnace ash. Both residual streams may require
further treatment when metals are present in the feed.
(See below).
Based on two leaching tests, the EP Tox
mobility of lead and other heavy metals
feed and the furnace ash, and there was
treatment affected metals leaching.
and TCLP, the
was similar in the
no evidence that
the extract of
on
In most cases concentrations of metals in
the furnace ash did not exceed their respective EP Tox and
TCLP toxicity characteristic standards. The need tor
further treatment of the furnace ash to reduce °r
immobilize the metals is site specific, and will depend
the cleanup standards for the site.
The unit achieved DREs of PCBs greater than 99 99%, based
on one actual calculation and in two cases on detection
limits. PCB concentrations in the feed and analytical
detection limits did not allow the demonstration of
99 9999% ORE required under TSCA. However, this unit
achieved greater than 99.9999% ORE in other tests, and
this time at least one full-scale infrared system has
demonstrated greater than 99.9999% ORE for PCBs and is
permitted undir TSCA to process PCB waste. The upcoming
Applications Analysis Report will incorporate this
additional data.
at
18
-------
8,
The unit achieved regulatory standards for acid gas
removal and particulate emissions. These data apply-to
.the operation and performance of the air pollution control
system installed on this unit.-. Additional data on the
performance of air pollution control systems on full-scale
Shirco Infrared units will be discussed in the
Applications Analysis Report.
Several semivolatile and volatile organic compounds
measured in. the stack gas in the parts per bi 11 i on may be
PICs. These levels are much lower than established
standards for direct inhalation of these compounds.
The unit was able to reduce the PCBs in the feed using
less power when fuel oil was added to the waste and when
PCC temperature was reduced. The addition of fuel oil
also increased the feed rate. Cost savings in specific
applications will depend on local fuel and electrical
costs, and a minimum PCC temperature must be maintained to
avoid .inadequate desorption of the organics in the feed
and the production of PICs.
19
-------
SECTION 3
PROCESS DESCRIPTION
3.1 GENERAL PROCESS DESCRIPTION
Contaminated soils at the Demode Road Superfund Site were
incinerated in the Shirco Pilot-Scale Infrared Incineration
System designed and manufactured by Shirco Infrared Systems,
Inc. of Dallas, Texas. The system consists of a waste feed
system, infrared primary combustion chamber (PCC), ,crr\
supplemental propane-fired secondary combustion chamber (SLL),
venturi scrubber emissions control system, exhaust system, and
data collection and control system all enclosed in a 45-ft
trailer. The system process flow is presented in Figure 1 and
the overall 250xlOO-ft test site layout is presented
schematically in Figure 2.
The waste feed material is fed manually to a hopper mounted
over a metering conveyor belt. This metering conveyor belt is
synchronized with the primary combustion chamber conveyor to
control the material feedrate through a sealed feed chute to
the primary combustion chamber.
The incinerator conveyor, a tightly woven wire belt, moves the
waste material through the insulated heating modules of the
primary combustion chamber. The waste material is heated by
electric infrared heating elements and contaminant desorption
from the solid waste feed and subsequent volatilization of the
organic contaminants occurs. Rotary rakes gently turn the
material to ensure adequate mixing and contact with the heated
chamber environment. When the combusted feed residual ,. now
furnace ash, reaches the discharge end of the furnace, it
drops off the belt through a chute and into an enclosed hopper
and discharge storage drum. Combustion air is supplied to the
primary combustion chamber through a series of overfire air
ports at points along the length of the chamber. The gas flow
in the incinerator is countercurrent to the conveyed waste
feed materi al.
Exhaust gas containing the desorbed contaminants exits the
primary combustion chamber and passes to a secondary
combustion chamber (afterburner) where a propane-fired burner
provides the final thermal destruction of any residual
organics. Secondary air is supplied to ensure adequate excess
Oo levels for complete combustion. Exhaust gas from the
secondary combustion chamber then is quenched by a water-fed
venturi scrubber emissions control system to remove
particulate matter and acid gases. The gas then is
transferred to the exhaust stack by an induced draft fan and
discharged to the atmosphere.
20
-------
The main unit controls and data collection
indicators/recorders comprising the data collection and
control system are housed in the system trailer. Safety
interlocks also are integrated into the trailer-mounted unit
to automatically correct abnormal unit operating conditions
maintain system performance, and, if necessary shut down waste
feed and heat input to the unit.
3.2 DETAILED PROCESS DESCRIPTION
The Shirco Pilot-Scale Infrared Incineration System consists
of the following major mechanical subsystems and components:
o Waste Feed System ,
o Primary Combustion Chamber (electrically heated)
o Secondary Combustion Chamber
o Emissions Control System
o Exhaust System
o Data Collection and Control System
Additional equipment was provided to support the unit during
operation; this includes two diesel generator sets to meet
electrical requirements and a water supply tank trailer for
makeup water needs.
3.2.1 Waste Feed System
Up to 150 Ib/hr of waste material (prescreened or preprocessed
soils, solids, semi-solids, and sludges) is fed manually from
s-gai pails into a hopper mounted over a metering conveyor
belt. The conveyor is shrouded and equipped with rubber
skirts to minimize infiltration of air or escape of furnace
gases. An adjustable guillotine-type gate is provided at the
conveyor discharge. The gate distributes the material across
the width of the metering belt and assists in furnace
S5- I9ki F.in?i feed area sealin9 is provided by an additional
adjustable knife gate in the feed chute into the primary
combustion chamber. The metering conveyor belt is
synchronized with the primary combustion chamber conveyor for
control of the material feedrate.
3.2.2 Primary Combustion Chamber
The primary combustion chamber design and operation is unique
to the Shirco technology. It is in this primary chamber that
the waste material is brought to a specified operating
temperature by electric infrared heating and conveyed through
temperature-controlled zones at a predetermined rate. The
primary combustion chamber provides the heat required for the
initial contaminant desorption of organic contaminants from
the solid waste feed. The majority of the metai.contaminants
remain in the furnace ash that exits the primary combustion
chamber.
21
-------
ion chamber is a rectangular, box ( length
ft, height 6.58 ft) constructed of 0.25-vn
It is insulated with ceramic fiber blanket
on stainless steel studs and retained with
The insulation is manufactured by
consists of an 85% silica/15% alumina
that can sustain a continuous surface
°F. The insulation is 7 in thick .on the
and end plates, and 5 in on the chamber
The primary combust
9.75 ft, width 2.5
A36 carbon steel.
insulation mounted
ceramic fasteners.
Carborundum Co. and
asbestos-free blend
temperature of 2400
chamber top, sides,
bottom. ,
The material to be processed is conveyed through the furnace
on a woven wire belt, at a bed depth ranging from 0.5_to 2 in,
that is supported on high-temperature alloy shafts. The
shafts are, in turn, supported by external flange-mounted
bearings. A friction drive system is used to pull the belt
through the furnace. The belt is woven (to a thickness of
0.25 in) from 16-gauge, Type-314 stainless steel, ^^belt •
speed is controlled via a constant speed motor/variab e speed
reducer, and can be adjusted to achieve waste material
residence times of 6 to 60 min.
energy is provided by 18 transversely-mounted silicon
rod heating elements mounted on 3.07-in centers 8.75
the furnace belt. These 1.0-in OD (outside diameter)
elements are manufactured by Carborundum Co., and are
33 1 watts/in2 of radiating surface with a maximum
temperature of 2000°F. The primary chamber is
into two temperature control zones, with six heating
serving each zone. The temperature in each zone can
sely regulated between 500°F and 1850UF. The
operating temperature of the primary chamber zones is
Infrared
carbide
in above
heating
rated at
surface
divided
elements
be preci
maximum
1900°F.
Four rotary rakes transversely-mounted on 1-ft centers gently.
turn the material on the belt, increasing exposure. The
rotary ?akes consist of L-s.haped fingers (O.J9-}n OD^Jnconel •
601) welded to Type-316 stainless steel shafts that rotate at
a rate of 1.8 revolutions/in of belt travel. The shafts are
synchronized with the belt speed through a chain and sprocket
drive system.
Combustion air is supplied to the primary chamber through 16
1.0-in-diameter overfire air ports located 1.75-in above the
belt surface in a single row of 8 ports on each side of^the
chamber. Combustion air flowrate and distribution to each
group of four ports (two groups per chamber side) are ' __-
Controlled by manual gate valves. The combustion air b ower
is manufactured by New York Blower Co. and is rated at 185
scfm at a static pressure of 0.25-in water column (WC); The
combustion air supply can be controlled to provide either
oxidizing or reducing atmospheres.
22
-------
meUI contamJnllf JJ9tt5^desorbed or9anic contaminants and
pyitc £°ntamlnants ^^ did not remain in the furnace ash
^,,0 /rJmarfCombustlQn chamber and flows through the
flue gas ductwork to the secondary combustion chamber./
3.2.3 Secondary Combustion Chamber
hnut1on Camber consists of a rectangular
carbon steel box (length 11.0 ft, width 3.33 ft, height 3 33
?n u at1nnWlth i1^" "Carborundum ceramic fiber blanket
nfni? ? + ,all int!;rior walls. The insulation type is
identical to that used in the primary chamber The internal
cross-sectional area of the chamber is 1.56 ft2 and -the --
internal volume is 28.9 ft5. The unit is designed for
nXCtSS air.°Peration with a maximum continuous
ng temperature of 2300°F and a minimum residence time
of 1.3 sec at a maximum actual gas flow of 830 acfm At these
?hT?Un? ^ndit^°!]S the secondary combustion chamber prov des
cont npH ,1 ;e[["al Destruction of the organic contaminants
contained in the flue gas from, the primary combustion chamber.
Supplemental fuel firing is supplied by a 375,000 Btu/hr "
propane burner manufactured by MAXON. The burner is equipped
with a .continuous pilot flame monitor, automatic fuel shut off"
and purge system interlocked with the secondary combustion
chamber temperature sensor and manual fuel contro? valve •
adjustable l?r revert ^ b"™" •** Control led by .manual ly
+ion air (excess .air) is. supplied to the
thp rhh u?u tW° '-in-^ameter ports located at the tap of
the chamber: they are directed at the interface of the burner
flame pattern and the exhaust gas inlet flow. Secondary
^nnni! ;." ai? 1S suPP11ed by the same fan that is used to
supply the primary chamber combustion air. A splitter
manifold with dampers at the fan outlet allows air
distribution to both chambers. A manual gate valve adjusts
the air flowrate to the secondary chamber!
3.2.4 .Emissions Control System . :
The emissions control
nw
tower
Z
system consists of a venturi , scrubber
tower' Water is used as the'scrubbing'
ime-s1urry system 1s Provided if acid gas 9
0J 1S re(1uyed- The venturi section and separator
, are each equipped with two water-spray nozzles The
vetn. at%r fl°wrate is 2 gpm and' 10 gpm to {he
venturi and separator tower, respectively. If an external
^?Lh?rViCe °t 25-3° P5ig and "5 9Pm (minimum) is no[
available, a makeup water system is provided. The venturi
rnnt^°? 1S equiPPed w1*h a manually adjustable plumb bob to
control gas phase pressure drop between 8 and 14 in WC and to
effect maximum collection efficiency. . ana to
23
-------
The scrubber is equipped with an integral 45-gal sump tank,
external 50-gal holding tank, and recirculation pump tor
Affluent handling and disposal. Makeup water is supplied from
a water supply tank trailer, as required to account for >
evaporative losses. Total scrubber water blowdown is
approximately 30-45 gal/day.
In addition to removing particulate, the scrubber cools the
gases (incoming temperatures: 1000°F - 2300°F, depending
on system configuration) to saturation temperature (usually
about 180°F). Subcooling to a lower temperature can be
performed if required, but this procedure consumes
substantially more water than cooling to saturation
temperature.
3.2.5 Exhaust System
An induced draft fan located downstream of the scrubber
exhausts the scrubbed gas to the stack. The fan is
manufactured by New York Blower Co. and is rated at 400 acfm
at a static pressure of 14-in WC.
Exhaust gases are vented to the atmosphere through a 4.0-in ID
stack, which extends through the roof of the trailer to an
elevation of 23.6-in above grade (10 ft above trailer roof).
The stack is equipped with two 3.0-in ID sampling ports.
Access to the sampling ports is from the trailer roof.
3.2.6 Data Collection and Control System
The data collection and control system is designed to ensure
that the various process operating conditions are maintained
wUhin the appropriate range for effective thermal treatment
of the waste Operating conditions are logged and compiled
for future evaluation of the system's performance.
The Shirco Portable Demonstration Unit is fully instrumented
to monitor the following process parameters:
o Temperature
Primary Chamber:
Waste feed zone
Zone Al
Zone A2
Mid-zone
Zone Bl
Zone B2
Exhaust gas
Ash discharge chute
24
-------
Secondary Chamber:
Mid-chamber
Exhaust gas
Stack:
Recorder:
Pressure
Exhaust gas
Six-point continuous stripchart
Combustion air fan outlet
Primary chamber draft
Primary chamber exhaust draft
Secondary chamber draft
Secondary chamber combustion air
Scrubber differential pressure
Scrubbing liquor delivery pressure
o Liquor Flow
Venturi 'scrubber liquor
Separator tower liquor
o Exhaust Gas Analysis - Secondary Chamber Outlet
Continuous 0? monitor w/strip chart recorder
Continuous CO monitor w/strip chart recorder
Continuous C02 monitor w/strip chart recorder
o Master Control Panel
A master control panel contains the following devices for
process data monitoring, recording, and control:
Nine-point digital temperature display with rotary
selector
Six-point temperature strip chart recorder
Primary chamber heat zone temperature controllers
Primary chamber belt speed controller
Annunciator
Hand-Off-Auto switches for mechanical components.
Three-point stripchart recorder for continuous
emissionmonitors.
25
-------
of
o Safety Interlocks \
The Shirco system is equipped with safety interlocks. to
automatically correct abnormal incinerator operating
conditions and maintain system performance. A description
the various interlock systems, corrective actions, and
corrective action limits is presented in Table 2. The system
also is equipped with an automatic waste feed cutoff system
that will stop the waste feed conveyor belt motion in the
event of low secondary chamber temperature. The cutoff limit
for the waste feed shutdown control is adjustable.
26
-------
TABLE 2. SAFETY INTERLOCK SYSTEMS
Interlock
Corrective action
Corrective
action
limit
Low primary chamber
temperature
High primary chamber
temperature
Low secondary chamber
temperature
High secondary chamber
temperature
Emissions control
during unit shutdown
Excessive stack gas
temperature
Low secondary chamber
exhaust 02
High secondary chamber
exhaust CO
Infrared electric heating
element power center on/
Waste feed belt stop
Infrared electric heating
element power center off
Propane burner on/
Waste feed belt stop
Propane burner off
Secondary chamber
temperature maintained
until primary chamber
temperature drops below
action limits
Alarm (manual adjustment
of scrubbing liquor flow)
Alarm/Waste feed belt stop
Alarm/Waste feed belt stop
1600°F*
1850°F
1800°F
2300°F
400°F
200°F
4%
100 ppm
* This was modified temporarily to allow the 900°F and 1200°F
runs in Phase II testing.
27
-------
SECTION 4
FIELD OPERATIONS DOCUMENTATION
4.1 PRETEST SAMPLING
The Demode Road Superfund Site is a 12-acre field,
approximately 950x550 ft. By 1983, MDNR had removed drums of
waste that were either buried or left on the ground and over
1,500 tons of contaminated soil. From 1984 to 1987 MDNR
conducted a remedial investigation and feasibi1ity study
(RI/FS) to determine the nature and extent of the remaining
contamination at the site and evaluate alternative cleanup
technologies and methodologies. Based on the data presented
in the RI/FS, a 10,000-sq ft area located in the southwestern
section of the site was identified as having the highest soil
PCB contamination. The remedial investigation described the
soil as a dry, brown, sandy, and silty clay topsoi;l . This
area was the focus of the pretest sampling phase, which was
performed during the week of July 13, 1987 to identify the
most highly contaminated waste feed source for the planned
SITE test program. Figure 3 illustrates the entire Rose
Township site and the specific excavation area as identified
by the RI/FS.
The area was surveyed from existing survey markers, and a
12,100-sq ft grid with 100-sq ft sections was superimposed
over the identified 10,000-sq ft site; the overlap ensured
complete coverage of the area. Figure 4 illustrates the grid
definition and specific sector ID numbers.
Based on the sampling grid the area was divided into
thirty-six 100 sq ft sectors, S-l through S-36. Four samples
were taken in each sector (:a total of 144 samples) and
composited. These 36 soil samples were analyzed for PCB and
lead content as presented in Table 3. A single composite
sample of the 36 soil samples was analyzed for density, pH,
moisture, ash, Btu value, and ultimate analysis, as presented
in Table 4. A summary report of the pretest characterization
analyses is presented in Appendix D, Volume II. These
analyses confirmed significant PCB and lead contamination in
sectors that were to be excavated to provide the waste feed
source for the Shirco unit operation during the SITE
demonstration. The analyses also characterized the waste feed
source so that Shirco could define optimum unit operating
conditions.
Ten of the 36 sectors were identified as areas that contained
the maximum PCB- and/or lead-contaminated soils. Ten sectors
28
-------
ro
10
-V -« y ' " / 7..--/V-- 'A^"1*"^;/-'---'^-- -.-::?i:-,-\/« >•Y\'llf',r^l'V5'H nf\t-f+r\u iit+& I c. e+r\C.f\' \ls"VN-y\
r~^ * •-'','/'• -''^ s^- '---^^ *^^'^S^-; '45*s^i/']'/^V;'''l\l ;>- ' A«' : '//^~~'' V- 'i:>VY-~ "::!t%!; :^
^%o»A j'™"v /'/O'' x~^^^^r^"""'"-'^^'^ ! ^•-•^'fL.-:^"*Tr^''ii/- • '"-;i1;/° /."/{>•'£• //-,">,,{C"'-'^oSl iV'.V.v^' ->i^ f AA'1^1 •""'; . • / • y////- -'1«B ^'C
DEMODE
ROAD
'/ o
EXCAVATION AREA
' NO V
DEMONSTRATION
AREA
Figure 3. Demode Road Superfund Site.
-------
CO
o
A1
B >
C .
D S
E .
F S:
G
H
I
J
K
L
2 3 4 5 6 7 8 9 10 11 12
7 S8 S9
~^>
Sll
3 S14 S15 $16 S17 S
S20
SE2
S26 S27 S28 SE9 S
8
6
NOTES N
1) CIRCLED SECTORS CONTAIN MAXIMUM PCS AND LEAD
CONTAMINATION.
2) BOXED AREAS REPRESENT ACTUAL EXCAVATED SECTORS.
Figure 4. Pretest sampling grid.
-------
TABLE 3. PRETEST SAMPLE ANALYSES
Grid sector
sample ID No.
SI
S2
S3
S4 (a) (b)
S5 (a) (b)
S6 (b)
S7
S8
S9
S10 (a) (b)
Sll (b)
S12 (a) (b)
S13
S 1 4
SI 5
S16 .
S17
S 1 8
• S19 (a) (b)
S20 (b)
S21 (a) (b)
S22 (a) (b)
S23 (a) (b.)
S24 (a) (b;)
S25 :-; (b)
S26 .
S27 . - .
. S28 .
S29
S30 ,
S31 (a) (b)
S3 2
S33
S34 • '
S35
S36 , -;.
(a) Ten sectors designated
Calculated composite PC
sectors is 902 ppm PCB
Total PCB
content (com)
70
49
169
1,270
29
28
132
71
232
1,230 .
180
29
200
164
610
301
360 ;
115
66
47
1,550
1,300
1,410
1,120
550
128
270 •
262-
46
290
1,020
295
. 28 •• •>-. .
148
103
560
as maximum PCB- and 1
B and lead concentrat
and 446 ppm lead.
(b) Actual sectors that were field-excavated for
Shi rco unit.
Total Lead
content (ppm)
100
240
310
370
740
560
. 400 :
130
:'"'.' 240 -
.'' 330 '
530
i,foo • ; ' -
• 450 .
4'0 0 ' r
22:0
210
34.0". "U;
: •'".' 140
680 rv- '
440-
240
160
200
1 80
300
240
.: 390
'9 3 • - •
260
180
, ..-• . ,4&0
380
- • • 81
110
340
ead-contami nated .
ions for these ten
waste feed supply to
31
-------
TABLE 4. PRETEST SAMPLE ANALYSES--
COMPOSITE OF ALL SECTORS
Analytical parameter
pH
Moisture, wt.%
Ash, wt.%
HHV, Btu/lb
Density, g/cc
Ultimate Analysis, wt.%
C
H
N
0
Cl
S
P
PCB, ppm
Pb, ppm
7.8
9.0
81
<1000
0.95
2.27
0.84
ND/0.06*
4.06
0.15
0.032
0.042
570
580
* ND denotes not detected. Value shown is the detection
1imit.
32
-------
were chosen to ensure that sufficient soil quantities would be
unUaVd3 r?nt0theei/Hhe W3S^ feed requirements of the Sh r o
thlL ?n 9 + he 12*WS of operation. A composite sample of
these 10 sectors also was prepared and analyzed for PCBs,
Prnn,P^HCDrSrli;ated dibenz°-P-dioxins, and dibenzofurans
(PCDDs and PCDFs) as presented in Table 5. A summary report
of these analyses 1S included in Appendix D, Volume II The
"
Based on the pretest sampling and analyses discussed above,
comprehensive profile of the 10,000-sq ft area and its
inchvidual sectors was obtained. Tables 3, 4, and 5 present
the analytical results of this pretest sampling program
10 S^t0rs were chosen for excavation to a
" th*.waste feed suPPly for the SITE test
PvHpnth e*9avatlon activities began, it became
evident that an exacting excavation of these 10 specific
sectors was precluded because of the difficult terrain and the
crude excavation ability of the front-end loader The
nnurp l°h arhaSKthe!l Were def1ned m°re broadly as shown in
Figure 4 by the boxed areas. Table 3 defines the originally
specified 10 sectors and the more broadly defined areas that
were actually excavated for the waste feed supply to the
Shirco unit. Section 4.2.2 discusses the waste feed
nfC?hn iaVC£iVit1eS ^hat Preceded the drumming and transport
of the waste feed supply to the Shirco unit.
4.2 TEST SUMMARY
4.2.1 Pretest Operations
On 10/26/87 Sh
screening and
During the fol
covered with g
that seri ously
gravel fill an
resulted in a
support traile
and set up for
Unit arrived o
unloaded, and
the Rose Towns
irco personnel arrived on site to observe feed
site preparation for the portable unit test
lowing week, the test site was leveled and
ravel fill. Following a significant rainfall
deteriorated portions of the site, additional
d drainage to a sump hole were provided that
level and well-drained test site. The Shirco
r and two diesel power generators were delivered
the test. The Shirco Portable Demonstration
n site on 10/30/87. Demonstration supplies were
the trailer was prepared for a public viewing at
hip Hall on 10/31/87.
successful public showing at the Township Hall, the
; Unit was taken back to the job site for setup. On
electrical power was hooked up, and scrubber water
supply hose control panel instruments, the ash discharge
barrel scrubber drain hose, the interior trailer lights, and
the exhaust stack all were installed by Shirco personnel The
33
-------
TABLE 5. PRETEST SAMPLE ANALYSES--
COMPOSITE OF TEN GRID SECTORS WITH
MAXIMUM PCB AND LEAD CONTAMINATION
Composited arid sectors
S4
S5
S10
S12
S19
S21
S22
S23
S24
S31
Total PCDD, ppb
Total PCDF, ppb
Total PCB, ppm
Total Pb, ppm
Actual composite
analvsi s
55
4.2
626
560
Calculated composite
anal y <: i s (Table 3)
902
446
34
-------
overall test site layout is presented schematically in Figure
Ine furnace was heated to processing temperatures and then
cooled to verify that all systems were operational.
A Health and Safety Plan was issued that defined the specific
program organization and individual personnel responsible for
specific health and safety and operating activities. The
health and safety procedures also discussed site-specific and
process-specific hazards, levels of protection, health and
training requirements, and medical monitoring. An exclusion
zone surrounding the waste feed handling and input area of the
Snirco unit required Level C personnel protection from waste
feed particles. Access to other sectors within the
demonstration area, as agreed upon by FWEI, MDNR, and Shirco
health and safety personnel, required Level D personnel
protection with coveralls, gloves, boots and coverings, safety
glasses, and a hard hat. Discussions with the local fire
department ensured that the local authorities who would be
responsible for a site emergency response were aware of the
test program.
4.2.2 Material Feed
Based on the pretest sampling and analysis, as discussed in
Section 4.1, feed material from selected contaminated areas
was excavated using a front-end loader and transported to an
adjacent flat staging area within the hazardous waste site
The excavated area was located within a steeply sloped
irregular in grade, and overgrown terrain. This precluded a
sophisticated large-scale grubbing and excavation operation
consistent with the small-scale pretest sampling "and analysis
that provided the definition of the overall sector as
presented in Tables 3, 4, and 5. The staging area was covered
with plastic sheeting to eliminate any cross-contamination
from the excavated soil to the staging area soil. The
excavated soil was mixed using the front-end loader shovel to
produce a blended mix and then dumped onto a free-standing
screen to remove any debris larger than one inch in diameter
before being shoveled into 55-gal drums. Two of the drums
were filled with screened soil that had been blended with 3
wt/0 oil. The drums then were moved into the exclusion zone
inside the test area for storage. The material was
transferred from the drums to 5-gal pails in 40-lb increments
for feeding to the unit. The scale was tared with the pail to
zero, so that when the pails were weighed, the weight recorded
would be the net weight of the feed. A lid was quickly placed
on the pail to minimize any evaporation of organics in the
feed .
4.2.3 Operational History
The initiation of the formal demonstration test runs began on
November 2, 1987. The program originally was designed to
35
-------
TABLE 6
PROPOSED TEST MATRIX
Day
1
2
3
4
5
5
6
7
8
8
8
9
9
10
10
11
11
11
12
12
12
Run
0 A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Time
0900-1800
0900-1800
0900-1800
0900-1800
0900-1300
1400-1800
0900-1300
1400-1530
1600-1800
0900-1300
1400-1800
0900-1300
1400-1800
0900-1300
1330-1530
1600-1800
0900-1300
1330-1530
1600-1800
Operating t«
PCC(°F)
1600
1600
1600
1600
1600
1600
1600
1600
1600
1200
1200
1200
1200
1200
1200
1200
900
900
900
>mperature
SCC(°F)
2200
2200
2200
2200
1800
2200
1800
2200
1800
2200
1800
2200
1800
2200
1800
1800
2200
1800
1800
Approximate F
Waste feed r
(Ibs) t
40-60
40-60
40-60
40-60
35-50
40-60
50-75
60-90
50-75
35-50
35-50
40-60
40-60
50-75
50-75
50-75
35-50
40-60
40-60
urnace
•esidence
:ime(min;
20
20
20
20
25
20
15
10
15
25
25
20
20
15
15
15
25
20
20
> Atmosphere N
1
Oxidizing
Oxidizing
Oxidizing
Oxidizing
Oxidizing!
Oxidizing
Oxidizing
Oxidizing
Non-OxidSzing
Nox- Oxidizing
Oxidizing
Non-Oxidizing
Oxidizing
Non-Oxidizing
Oxidizing
Non-Oxidizing
Non-Oxidizing
Non-Oxidizing
Non-Oxidizing
lisc.
B
• C
C
B
C
C
A - Formal sampling not proposed. System shakedown and checkout to be performed.
B - Secondary combustion chamber to be heated electrically.
C - Feed to be blended with 3-5% fuel oil.
36
-------
follow the proposed test matrix, as summarized in Table 6 and
.the daily chronology in Section 4.2.3.1.
Section 4.2.3.2.defines the actual operations and test matrix
that was fo owed during the test program. Differences from
inSection3! 2 !^3posed Pr°9ram ™* test matrix are discussed
4.2.3.1 Daily Chronology of Proposed Program
Day 1 of the test program was designed for system shakedown
and checkout. The selection of operating parameters during
this day was based, upon previous experience decontaminating
PCB-contaminated soils.
These parameters were also selected for the three replicate
runs to be conducted on Days 2, 3, and 4.
Day 5 of the program was to consist of two 4-hour runs with an
oxidizing atmosphere in the primary chamber. The residence
time in the furnace would be varied to help determine the
minimum time required for detoxification. In addition the
secondary combustion chamber temperature would be varied to
obtain data regarding optimization of utility requirements
Note that during one of these proposed runs, the secondary
chamber was to be heated by electrical heating elements.
Results of previous testing conducted with the Shirco system
have met EPA-required DREs for PCBs with secondary chamber
temperatures of 1800°F.
Days 6 and 7 were set aside for preventative maintenance on
the pilot unit and preparation for the foil owing week's
testing. 3
Day 8 of the program was to consist of three runs. One run
would employ a non-oxidizing atmosphere in the primary furnace
to determine the effect on lead fixation. Temperatures in the
secondary chamber and furnace residence time were to be varied
again for further optimization of system operating parameters
and material throughput. In addition, two of the runs were to
be conducted utilizing feed material blended with 3-5% fuel
oil. This would provide data regarding maximization of
material throughput as well as minimization of utility
consumption.
Day 9 of the program was designed to consist of two runs
utilizing lower temperature in the primary furnace to
determine the minimum operating temperature and the effect on
metals present in the feed. The atmosphere in the furnace
again would be varied to provide data on metals fixation; the
secondary chamber temperature was to be lowered during one run
to optimize utility consumption.
37
-------
Day 10 of the program was to consist of two runs similar to
those conducted on Day 9. However, the secondary chamber
would be heated electrically to further investigate the_
potential minimization of utility consumption, and the furnace
residence time would be reduced to maximize throughput.
Day 11 of the program was to consist of three runs similar to
those of Days 9 and 10; however, furnace residence time would
be reduced further. In addition, one of the runs would be
conducted utilizing feed blended with fuel oil to determine
the effect on material throughput.
Day 12 of the program was to consist of three runs, all of
which would be conducted with a non-oxidizing atmosphere and
lower temperatures in the primary furnace. The primary
objective of these tests was to provide data on potential
metals fixation with the Shirco process.
In order to fully evaluate the effect of proposed variations
in process operating parameters, composite samples of feed,
ash, and scrubber blowdown water were to be taken during each
of the runs.
Upon completion of testing, Shirco personnel were to initiate
decontamination procedures on the pilot unit and prepare for
demobilization 15 days after arrival.
4.2.3.2 Actual Operations
the
The actual test program schedule of runs deviated from
proposed test matrix outlined in Section 4.2.3.1. The
following discussion summarizes the actual operational history
of the overall program. Tables 7 and 8 present a summary of
the operating conditions and energy input to the unit during
the demonstration test runs. The references to run numbers
refers to the original proposed test matrix, as discussed and
defined in Section 4.2.3.1 and Table 6. The actual test^
oroqram operated at test conditions for 51 hrs 11 mm and
processed 1,799 kg (3,967 Ibs) of contaminated waste feed.
November 2. 1987. The primary combustion chamber heatup was
started at 08:20 hours. When the primary combustion chamber
reached 1000°F, the secondary combustion chamber was fired
and brought up to 2200°F using maximum propane flow to
minimize heatup time. This heatup procedure was followed
during all startups. While the sampling and analytical
subcontractor was completing the setup of their equipment, the
system was maintained at operating temperature. Feed material
was introduced to the unit at 15:20 hours at 20 mm residence
time and a bed depth of 1 1/2-in in the primary combustion ,
chamber. Unit operation continued until 17:13 hours to
establish feedrate and stack velocity for the demonstration ,
tests.
38
-------
TABLE 7
OPERATIONS SUMMARY
Date
11-02-87
11-03-87
11-04-87
11-05-87
11-06-87
11-07-87
11-08-87
11-09-87
11-10-87
ll-12-87
ll -13-87
1 —
Time period Test run
15:20-17:13
-------
TABLE 8. POWER USAGE - ACTUAL OPERATIONS
Date
11-03-87
11-04-87
11-05-87
11-06-87
11-09-87
11-10-87
11-11-87
11-12-87
Time period
Time intervals
11:40-18:25
09:45-20:13
08:16-18:37
10:32-15:31
09:34-10:35
11:26-12:27
13:45-14:47
09:30-10:30
11:20-12:20
13:13-14:14
15:07-16:07
09:04-10:05
11:30-12:31
13:20-14:20
15:10-16:10
10:27-11:27
.12:35-13:35
Hrs.
6.75
10.47
10.35
4.98
1.02
1.02
1.03
1.00
1.00
1.02
1.00
1.02
1.02
1.00
•-• 1.00
• i.oo
1.00
Zone A
81.5
119.3
124.3
60.5
8.6
8.7
9.2
12.5
9.0
1.6
0.9 '
12.7
5.4
3.0
7.9
5.5
5.8
Primary combustion chamber
kwhr kw
Zone B Cumulative
52.1
71.6
75.8
43.9
6.7
6.9
7.5
8.7
7.4
3.0
1.3
8.5
3.3
2.0
2.6
3.6
4.6
133.6
190.9
200.1
103.9
15.3
15.6
16.7
21.2
16.4
4.6
2.2
21.2
8.7
5.0
. 10.5
9.1
10.4
19.79
18.24
19.33
20.85
15.05
15.34
16.16
21.20
16.40
4.52
2.20
20.85
8.56
5.00
10.50
9.10
10.40
kwhr/Lb feed
0.2975
0.2495
0.2497
0.2919
0.1913
0.1608
0.2456
0.1914
0.1367
0.0451
0.0275
0.1827
0.1360
0.0678
0.1189
-0.1400
' 0.1486
Secondary combustion chamber
Propane usage
Lb/Hr Btu/Hr Btu/Lb feed
13.75
13.45
16.38
12.56
10.73
9.14
17.99
9.36
8.97
8.04
10.75
16.69
16.69
11.95
11.95
17.13
8.77
295895
289463
352501
270165
231570
197277
385950
201543
192975
173678
231570
360220
360220
. 257300
257300
368788
188678
4458.24
3914.35
4560.48
3846.64
2992.24
2102.14
6060.09
1819.47
1608.13
1759.91
2894.63
'3209.59
5817.69
3484.09
2914.25
5673.66
2695.40
11-13-87- 10:12-11:12
1,00 11.8
9.0
20.8
20.80 -
0.2356
9.96
214408
2428.45
-------
ncVnn ur 3l 1987' The Portable -unit heatup was started at
05:00 hours to prepare the unit for a test start at 08-00
hours Feed was introduced to the unit at 07:30 hours to
stabilize the unit for testing. Feeding was halted at 08:30
hours and the system was maintained on operating status to
allow the sampling and analytical subcontractor the time to
complete setup of their equipment. Feed material was again
initiated to the unit under an oxidizing atmosphere at 10-20
hours at 20-min residence time and a bed depth of 1 1/2-in in
the primary combustion chamber. The primary combustion
chamber temperature was set at 1600°F, and the secondary
combustion chamber was controlled at 2200°F. Run 1 was
started at 11:40 hours with all continuous monitoring and
sampling equipment checked out and operating properly
Testing was stopped at 18:25 hours to secure the unit'for the
night. Because of the shortened operating period during Run 1
the sample trains for semivolatile organics, PCDD/PCDF, and
soluble chromium were not run. These remaining sampling runs
dur^n" R W6re reschedu1ed for November 6 and were conducted
November 4, 1987,
OA -r Tne portable unit heatup was started at
20 hours. Feed was introduced to the unit at 07:33 Run
under an oxidizing atmosphere, was not started until 09-45
to allow time for the safety meeting and the final setup
The operating parameters were set at
a primary
secondary
05
2
hours
of sampling equipment.
20-min residence time, a bed depth of 1 1/2-in,
combustion chamber temperature of 1600°F, and a
combustion chamber temperature of 2200°F. The secondary
combustion chamber automatic temperature control system began
to malfunction at 12:45 hours; the operator switched to manual
control without affecting the test. As a result of the
problem with the secondary combustion chamber control system
the burner tripped off at 15:40 hours. The burner was
restarted without affecting the test. Run 2 was completed at
20:13 hours, and unit cooldown began as soon as all of the
waste material had been discharged into the ash chute. During
Kun 2 the Method 5 sampling train for participate matter
malfunctioned and data was not obtained. This sampling run
was rescheduled for November 6 and was conducted during Run
November 5, 1987. The portable unit heatup was started at
05:35 hours and feed was introduced to the unit at 07:55. Run
3, under an oxidizing atmosphere, was started at 08:16 hours
the operating parameters were retained at the previous
settings of 20-min residence time, a bed depth of 1 1/2-in a
primary combustion chamber temperature of 1600°F. and a
secondary combustion chamber temperature of 2200°F. With
the exception of the ash discharge screw tripping out
momentarily, Run 3 was problem-free and was completed at 18-37
hours. Unit cooldown began as soon as all of the waste
material had been discharged into the ash chute
41
-------
6. 1987. The portable unit heatup was started at
08-30 hours and feed was started to the unit at 09:55. The
testing program consisted of the sampling runs that remained
from Run 1 and Run 2 and was designated as Run 1-2; me _
operating parameters were left at the previous settings of
20-min residence time, a bed depth of 1 1/2-in, a primary
combustion chamber temperature of 1600°F, and a secondary
combustion chamber temperature of 2200°F. After another
delay caused by a leak in ttje continuous emission monitoring
(CEM) system, the test started at 10:32 hours. At 11:20
hours, the venturi recycle flow was lost for no apparent
reason. The test equipment was shut down, feeding was
resumed, and the test was restarted at 11:40 hours. The test
runs were finished at 15:31 hours, and cooldown began as soon
as all of the waste material had been discharged into the ash
chute.
November 7/8. 1987. The unit was shutdown during the weekend
November 9
1987. The portable unit heatup was
07:15 hours and feed was introduced to the unit
hours The anticipated test schedule consisted
14, and 12, all under an oxidizing atmosphere.
20-min residence time, a bed depth of 1 1/2-in,
combustion chamber temperature of 1200_F, and a
started at
at 08,: 55
of Runs 10,
Run 10, with
a 'primary
secondary
combustion chamber temperature of 1800°F, was started at
09:34 and completed at 10:35 hours. After changing the
primary combustion chamber material residence time to 15
minutes, Run 14 began at 11:26 and was completed at 12:27
hours? The secondary combustion chamber auxiliary heat^source
was changed to electrical glowbars for Run 12; however the
electrical rods would not hold the temperature in the chamber
at the specified 1800°F. After checking and f i ne-tum ng^the
secondary combustion chamber's heating element power^center
(HEPC) system, the electrical glowbars again failed to
maintain the temperature in the chamber. The propane burner
was used to increase the secondary combustion chamber to
2200°F and Run 5, under an oxidizing atmosphere, was carried
out to replace Run 12. The primary combustion chamber
temperature was increased to 1400°F, and the residence time
was verified at 20 minutes. Run 5 began at 13:45 hours and
was completed at 14:47 hours. After the testing was finished,
the secondary combustion chamber again was changed over to
electrical heating and the HEPC system was
effort to maintain the desired temperature
Unit cooldown was initiated at 16:00 hours
was secured for the night.
tuned further in
during operati.on .
and all equipment
an
November 10. 1987
The portable
feed was started
unit heatup
to the unit
07:55 hours and .
The test schedule consisted of Runs 6, 8
feed for these test runs
prior to the tests. The
was started at
at 08:,59 hours.
15, and 18. The
had been blended with 3 wt.% oil
method of transferring the waste to
42
-------
the incinerator was the same .as described above. Run 6, with
a 15-min residence time, a bed depth'of 1 1/2-in, a primary
combustion chamber temperature of 1600°F, a secondary
combustion chamber temperature of 1800°F, and an oxidizing
atmosphere was started at 09:30 and was completed at 10:30
hours. After changing to a non-oxidizing atmosphere, Run 8
began at 11:20 hours with the other parameters remaining the
same. Run 8 was completed at 12:20 hours. The primary
combustion chamber temperature was decreased to 1200°F for
the next run while the remaining variables were held
constant.. Run 15 began at 13:13 hours and was completed at
14:14 hours. For Run 18 the primary combustion chamber
temperature was reduced to 900°F, and the residence time was
increased to 20 minutes. The run commenced at 15:07 hours and
ended a.t. 16:07 hours. After the testing was completed and the
waste was totally off the belt, unit cooldown was initiated at
16:32 hours and all equipment was secured for the night.
November 11, 1987. The portable unit heatup was started- at
06:15 hours and feed was started to the unit at 08:40 hours
The test schedule consisted of Runs 7, 4, and the rescheduled
12. Run 7 began at 09:04 hours. The test parameters were set
at a 10-min residence time, a bed depth of 1 1/2-in, a primary
combustion chamber temperature of 1600°F, a secondary
combustion chamber temperature of 2200°F, and an oxidizing
atmosphere. The test was completed at 10:05 hours. In an
attempt to conduct Runs 4 and 12, the secondary combustion
chamber heat source was changed over from propane fuel to
electrical power. With the feed material low in organics, the
chamber temperature again failed to reach the desired limits
The propane burner was refired and the testing proceeded with
Runs 9, 11, and 13. Run 9, with the variables set at 25-min
residence time, a bed depth of 1 1/2-in, a primary combustion
chamber temperature of 1200°F, a secondary combustion
chamber temperature of 2200°F, and a non-oxidizing
atmosphere, began at 11:30 hours and ended at 12:31 hours.
The material residence time in the primary combustion chamber
was reduced for the next run to 20 minutes; Run 11 commenced
at 13:20 hours and was completed at 14:20 hours. For Run 13
the residence time was further reduced to 15 minutes. The run
began at 15:10 hours and ended at 16:10 hours. After the
testing was finished and the feed was completely off the belt,
unit cooldown was started and all equipment was secured for
the night.
November 12, 1987. The portable unit heatup was started at
08:45 hours and feed was started to the unit at 09:48 hours.
The test schedule consisted of Runs 16 and 17. For Run 16,
the parameters were set at a 25-min residence time, a bed
depth of 1 1/2-in, a primary combustion chamber temperature of
900 F, a secondary combustion chamber temperature of
2200 F, and a non-oxidizing atmosphere. The run started at
10:27 hours and ended at 11:27 hours. The residence time in
the primary combustion chamber was reduced to 20 min, and
43
-------
secondary combustion chamber temperature reduced to 1800 F.
Run 17 commenced at 12:35 hours and was completed at 13:35
hours. After the testing was finished and the feed was
completely off the belt, the unit was cooled and all support
equipment secured for the night.
November 13. 1987
^___ ____ Run 19 was added to the matrix Runs 4 and
12 that were dropped due to the inability to maintain the
temperature in the secondary combustion chamber with
electrical power and a desire to extend the test operations
matrix with the remaining oil-blended soil. The unit heatup
at 08:25 hours and feed was started to the unit at
, The parameters were set at a 15-min residence
depth of one inch, a primary combustion chamber
of 1600°F, a secondary combustion chamber
of 1800°F, and an oxidizing atmosphere. The run
10:12 hours and ended at 11:12 hours.
was started
09:40 hours
time, a bed
temperature
temperature
started at
Run
bed
the
the
bed.
19 was identical to Run 6 except for a reduction;in PCC
depth from 1 1/2 in to one inch to examine the eiFfect on
decontamination of the solid waste feed in the PCC with
more intimate heat effect on the 1-in deep incinerator
With the completion of Run 19, the test matrix for the SITE
demonstration program was completed. The Shirco Portable
Demonstration Unit was baked out and decontaminated according
to the site safety plan. Site equipment was decontaminated
and removed from the job site. The remaining contaminated
waste, the residual ash, and the scrubber water were stored
securely in 55-gal drums, labeled, and set aside on the test
site for future disposal. The drums were transported and
placed within the MDNR-designated fenced hazardous waste site,
Posttest Activities. Shirco personnel remained on site
through November 16, 1987 to complete the decontamination and
removal of the Shirco Unit and all support equipment. The
Portable Demonstration Unit departed the job site on November
16, 1987.
4.2.3.3
Changes In Operation - Proposed Program Versus Actual
Operations
During the second week of testing, the test matrix was
modified by Shirco. The test schedule was rearranged into
groups of tests with parameters that ensured the most
efficient and satisfactory operation of the unit as conditions
were varied from test to test.
The scheduled length of time for each run also was shortened
to approximately 1 hr from the proposed range of 1.5 to 4 hrs
for individual runs. The 1-hr steady-state operation provided
sufficient sampling time to ensure representative analytical
44
-------
results for each test
run. The unit was
operated
for
»
r
In addition to the changes
run, the following changes
as defined in the proposed
in the scheduled length of each
also were made to individual runs
test program.
Runs 4 and 12
attain an SCC
the heat source
were aborted because of an inability
operating temperature of 1800°F when
T 4. . was changed over from propane fuel to
electrical power via the infrared '
in the SCC.
to
heating rods located
??
12.
reduction in
the^Jcc6 w t\h
the PCC with the
deep incinerator
4 and
19 was added to the matrix in place of Runs
Run 19 was identical to Run 6 except for a
the PCC bed depth from 1 1/2 in to 1 in
on solid waste decontamination in
more intimate heat effect on the 1-in
bed.
to
aJ °Perated With a PCC ^sidence time of 20 min
PCC t-6 ProP°sed 25 min- Run 5 was operated at
a PCC operating temperature of 1400°F instead of thP
nPrnnPnSeH 1™° *' JheSe ch^es in operation f?om the
SI?S h6? Ki3Sef W6re not Planned a^ can only be
attributable to an inaccurate interpretation of the
proposed operating conditions.
4.3 OPERATING LOG DATA
The unit log data
staff is included
attached Tab! (
as inputted by the Shirco unit operations
the
operati ng
4.3.1 Primary Combustion Chamber Waste Feed Rates
The weight of material fed during all operating periods was
[ From°thra i"9 ]°? data included in Appendix A,
test ?ondnion°wasacalcuUtVera9e feedrate dUring a
feedrate values shown on Table 7. ^ 1$ presented as the
The actual test program operated at test conditions for 51 hrs
11 mm and processed 1,799 (3,967.1bs) of contaminated waste
45
-------
feed. The total unit operating time including heatup and
cooldown periods without waste feed to the unit, and startup,
sSSldowl'and transi tional. periods betweeirrirns at^non-test
conditions was 74 hrs 21 mm. For 66 hrs 48 min of that
overall -operating period a total of 2,274 kg (5,015 Ibs) ot
Contaminated waste feed was processed through the unit.,,
During each of the emissions sampling test periods, a, new pail
Sf material was fed to the unit as emissions sampling was
initiated. A series of pails were completely fed to the
furnace through the end of the sampling period The total
of material fed to the furnace was adjusted for the
1
for the test run.
4.3.2 Primary Combustion Chamber Residence Time
Recorded on the logsheets included in Appendix A, Volume II
and on Table 7 are the material residence times in the primary
combust on chamber. The operator adjusted the speed of the
fTrnTceTonveyor belt for 'each test Condition using electronic
rontrol for the motor/gear reducer, a stop watch, and tne
calibrated scale mounted on the end of the feed end terminal
drum shaft. This iterative adjustment is made until the belt
sjeed produces the nominal specified residence time tor the
test run.
4.3.3 System Operating Temperatures
The average operating temperatures of the primary and
A, Volume
the
and the
operating log data included in
temperature recorder charts.
4.3.4 Power and Fuel Usage
4.3.4.1 Primary Combustion Chamber
A s.immarv of the primary combustion chamber power usage is
M en?ed li Table 8. The data is based on the compre ensive
log data found in Appendix A, Volume II. Note that this data
not be used as a direct scale-up for a full-scale system.
may
The portable unit has a much greater surface area per
material processed than does a large commerci al -seal e
Pheat loss per pound of feed is proporti onately
!!! isTmaK
°
energy retirement. Full-scale
proportionately smaller.
pound
unit.
of
in the
ng
larger-scale system in which
percentage of the operating
power usage therefore would be
46
-------
4.3.4.2 Secondary Combustion Chamber
A summary of the propane fuel consumption rates for the
secondary combustion chamber is presented in Table 8 The
47
-------
(Phase I)
discussed
were made
three-day
SECTION 5
SAMPLING AND ANALYSIS PROGRAM
The SITE program for the Shirco Pilot-Scale Infrared
Incineration System at the Demode Road Superfund Site was
conducted in two phases: under normal/optimum conditions
and varied operating conditions (Phase 11), as
in Section 4. During the first phase measurements
for three identical test runs conducted over a
period. In the second phase runs, parametric
factors affecting incinerator performance were evaluated.
Tables 9 and 10 present sampling and analytical program .
summaries for the test runs conducted in each phase, including
sampling frequencies, sampling methods, and analytical
parameters and methods for each sampling location. The
complete Sampling and Analytical report is presented in
Appendix B, Volume II. A separate report discussing the
results obtained during the continuous monitoring of the PCI
offgas for vaporous lead emissions is presented in Appendix h,
Volume II.
The demonstration plan for this program, dated October 23,
1987, is included in Appendix C, Volume II. The continuous
monitoring of the PCC offgas for vaporous lead emissions is
presented in Appendix E, Volume II. These documents provide
Sore detailed discussions and definitions of the overall
sampling and analytical procedures and methods discussed in
this section.
It should be noted that in the discussions that follow,
references to various sampling and analytical protocols are
included These recommended methods for sampling and
analyzing samples are coded to the following standards:
o "S" and "A" refer to Arthur D. Little, Inc., "Sampling and
Analysis Methods for Hazardous Waste Combustion,, EPA
600/8-84-002, PB84-155845, February, 1984.
o "ASTM" refers to American Society for Testing Materials,
"Annual Book of ASTM Standards," Philadelphia, Pennsylvania.
o "EPA Method" refers to Code of Federal Re9u]atjon*
40CFR Part 60, Appendix A, revised as of July 1, I
o "M" refers to U.S. EPA, "Methods for Chemical Analysis
of Water and Wastes," EPA-600/4-79-020, March, 19/9.
o "SW" refers to U.S. EPA, "Test Methods for Evaluating Solid
Waste-Physical/Chemical Methods," SW-846, Third Edition, ;
November, 1986.
48
-------
TABLE 9. SUMMARY OF SAMPLING AND ANALYTICAL PROGRAM, PHASE I
Source
Sample
collection frequency
Sampling method
Analysis parameters
Analysis method
Stack Gas
Composite over 3- to
6-hour period
EPA Method 5
with 0.1 N NaOH
10
Composite over 3- to
6-hour period
Composite over 3- to
6-hour period
Composite over 4 hour
period
6 pairs of samples over
2 hour period (one
aqueous condehsate)
Continuous
SASS with XAD-2 (SW0020)
Modified Method 5
(No filter/0.1 N NaOH)
Gas bag (Grab)
VOST (SW0030)
Continuous emission
monitors
Particulate Matter
HCl
Volumetric flowrate
Moisture
Metals (particulate
on filter)
SASS with XAD-2 (SW0020) PCB
PCDD/PCDF
Semivolatile Priority
Pollutants (plus 10
higher peaks)
Soluble Chromium
co2, o2
Volatile Priority
Pollutants (plus 10
highest peaks)
co2
CO
THC
EPA Method 5
Ion Chromatography
EPA Methods 1-4
EPA Method 4
SW 6010,7060,7041,7421
7740,7470/7471
EPA 680
SW 8280
SW 8270
M218.4
EPA Method 3
SW 8240
Paramagnetic
NDIR
NDIR
FID
Chemiluminescence
(continued)
-------
TABLE 9 (continued)
Source
Primary Furnace Offgas
01
o
Sample
collection frequency
Composite over 3- to
6-hour period
Composite over 3- to
6-hour period
Composite over 3- to
6-hour period
Composite over 4 hour
period
6 pairs of samples over
2 hour period (one
aqueous condensate)
Continuous
Sampling method
EPA Method 5
with 0.1 N NaOH
SASS with XAD-2 (SW0020)
Modified Method 5
(No filter/0.1 N NaOH)
Gas bag (Grab)
VOST (SW0030)
Cont i nuous emi ss i on
monitors
Analysis parameters
Particulate Matter
HCl
Volumetric flowrate
Moisture
Metals (particulate
on filter)
SASS with XAD-2 (SW0020) PCB
PCDD/PCDF
Semivolatile Priority
Pollutants (plus 10
higher peaks) •
Soluble Chromium
C02'°2 .,-.'
Volatile Priority
Pollutants (plus 10
highest peaks)
co2
oo ;
THC
Lead
Analysis method
EPA Method 5
Ion Chromatography
EPA Methods 1-4
EPA Method 4
SW 6010,7060,7041,7421
7740,7470/7471
EPA 680
SW 8280
SU 8270
M218.4
EPA Method 3
SW 8240
Paramagnetic
NOIR '
-NBIR
FID
Chemiluminescence
EPRI/DOE Special
(continued)
-------
TABLE 9 (continued)
Source
Solid Waste Feed
Sample
collection frequency
Grab sample every 30
minutes and composite
Sampling method
S007
Scrubber Solids
Sample at end of test
period and composite
S002
Analysis parameters
Chlorine
PCDD/PCDF
PC8
Metals
TCLP (Proposed)
EP Toxicity
Volatile Priority
Pollutants (plus 10
highest peaks)
Semivolatile Priority
Pollutants (plus 10
highest peaks)
Moisture, Ash
Ultimate
Higher Heating Valve
Density
PCB
PCDD'/PCDF
Chlorine
Metals
EP Toxicity
TCLP (Proposed)
Volatile Priority
Pollutants (plus 10
highest peaks)
Analysis method
A003
SW8280
EPA 680
SW 6010,7060,7041,
7421,7740,7470/7471
Fed. Reg. Vol. 51,
No. 114
C004,SW1310
-SW8240
SW8270
A001''
A003
A006
GRAV/VCi
EPA 680
SW8280 ' " ;
A003'' ! ' '''
'SW 6010,7060,7041
7421,7740,7470/7471
C004, SW1310
Fed. Reg. Vol. 51,
No, 114
SW 8240
(continued)
-------
TABLE 9 (continued)
Source
Sample
collection frequency
Sampling method
Scrubber Makeup Water
Sample at end of test
period and composite
S004
tn
rvs
Ambient Air
Continuous during unit
operation; One upwind
and one-downwind
General Metal Works
Model PS-1 Air Sampler
w/ Polyurethane Foam
(PDF) Plugs and Florisil
Sorbent
General Metal Works
Model 2000H High Volume
Sampler w/ glass fiber
filters
Analysis parameters
Semivolatile Priority
Pollutants (plus 10
highest peaks)
Ash
Ultimate
Density
PCB
PCDD/PCDF
pH
Chloride
Metals
Volatile Priority
Pollutants (plus 10
highest peaks)
Semivolatile Priority
Pollutants (plus 10
highest peaks)
Total Organic Carbon
Total Suspended Solids
Total Dissolved Solids
PCB
Metals
Analysis method
SW 8270
A001
A003
GRAV/VOL
EPA 680
EPA 8280
M150.1
Ion Chromatography
SW 6010,7060,7041,
7421,7740.. 7470/7471
SW 8240
SW 8270
M415.1
M160.1
M160.2
EPA 680
SW 6010,7060,7041
7421,7740,7470/7471
(continued)
-------
TABLE 9 (continued)
Source
Sample
collection frequency
Sampling method
Analysis parameters
Analysis method
Furnace Ash
Sample composite at end of
test period
S007
cn
Co
PCB
PCDD/PCDF
Metals
EP Toxicity
TCLP (Proposed)
Volatile Priority
Pollutants (plus 10
highest peaks)
Semivolatile Priority
Pollutants (plus 10
highest peaks)
EPA 680
SW 8280
SW 6010,7060,7041,7421
7740,7470/7471
C004, SW1310
Fed. Reg. Vol. 51,
No. 114
SW 8240
SW 8270
Scrubber Water
Sample at end of test
period
S002
Moisture, Ash
Chlorine
Density
PCB
PCDD/PCDF
PH
Chlorine
Metals
EP Toxicity
TCLP (Proposed)
A001
A003
GRAV/VOL
EPA 680
EPA 8280
M150.1
Ion Chromatography
SW 6010,7060,7041,
7421,7740,7470/7471
C004, SW1310
Fed. Reg. Vol. 51,
No. 114
(continued)
-------
TABLE 9 (continued)
Source
Sample
collection frequency
Sampling method
Analysis parameters
Analysis method
Volatile Priority SW 8240
Pollutants (plus 10
highest peaks)
Semivoiatile Priority SW 8270 •
Pollutants (plus 10
highest peaks)
Total Organic Carbon H415.1
Total Suspended Solids H160.1
Total Dissolved Solids M160.2
en
-------
Source
Stack Gas and
Primary Furnace Offgas
, Sample
collection frequency
Composite over 3- to
6-hour period
Sampling method
EPA Method 5
Analysis parameters
Particulate Matter
Analysis method
EPA Method 5
Solid Waste Feed
en
en
Scrubber Solids
Continuous
Grab sample every
30 minutes and composite
Grab sample once per
hour and composite
Continuous emission
monitors
S007
S002
Volumetric flowrate
Moisture
co2
CO
THC
NO
PCDD/PCDF
PC8
Metals
TCLP (Proposed)
EP Toxicity
Moisture, Ash
Ultimate
Density
PCB
PCDD/PCDF
Metals
EP Toxicity
TCLP (Proposed)
Ash
Ultimate
Density
EPA Methods 1-4
EPA Method 4
Paramagnetic
NDIR
NDIR
FID
Chemiluminescence
SU8280
EPA 680
SW 6010,7060,7041,
7431,7740,7470/7471
Fed. Reg. Vol. 51,
No. 114
C004.SW1310
A001
A003
GRAV/VOL
EPA 680
SW8280
SW 6010,7060,7041
7421,7740,7470/7471
C004, SW1310
Fed. Reg. Vol. 51,
No. 114 '
A001
A003
GRAV/VOL
(continued)
-------
TABLE 10 (continued)
Source
Sample
collection frequency
Sampling method
Analysis parameters
Analysis method
Ambient Air
Continuous during unit
operation; one upwind
and one downwind
General Metal Works PCB
Model PS-1 Air Sampler
w/ Polyurethane Foam
(PUT) Plugs and Florisil
Sorbent
General Metal Works Metals
Kodel 2000H High Volume
Sampler w/ glass fiber
filters
EPA 680
SW 6010,7060,7041,
7421.7740,7470/7471
oi
en
Furnace Ash
Sample at end of test
period and composite
S007
PCB
PCDD/PCDF
Metals
EPA 680
SW 8280
SU 6010,7060,7041,7421,
7740,7470/7471
EP Toxicity
TCLP (Proposed)
C004, SW1310
Fed. Reg. Vol. 51,
No. 114
Moisture, Ash
Chlorine
Density
A001
A003
GRAV/VOL
(continued)
-------
TABLE 10. (continued)
Source
Sample
collection frequency
Sampling method
Analysis parameters
Analysis method
.en
Scrubber Water Sample at end of test S002 RGB
period and composite PCDD/PCDF
PH
Metals
EP Toxicity
TCLP (Proposed)
Total Organic Carbon
Total Suspended Solids
Total Dissolved Solids
EPA 680
EPA 8280
M150.1
SW 6010,7060,7041,
7421^7740,7470/7471
C004, SW1310
Fed. Reg. Vol. 51,
No. 114
M415.1
M160.1
M160.2
-------
o "SASS" refers to U.S. EPA, "Modified Method 5 Train and
Source Assessment Sampling System Operator's Manual,
EPA-600/8-85-003, February, 1985.
o "VOST" refers to U.S. EPA, "Protocol for the Collection
and Analysis of Volatile POHCs Using VOST,"
EPA-600/8-84-007, March, 1984.
o "EPA" refers to U.S. EPA, "Methods for Organic Chemical
Analysis of Municipal and Industrial Wastewater,"
EPA-600/4-82-057.
5.1 SAMPLING PROCEDURES .
5.1.1 Sampling Locations
The streams that were sampled, at locations depicted in
Figures 5 and 6, are:
1. Stack Gases
2. Primary Furnace Offgas
3. Feed
4. Furnace Ash
5. Scrubber Water
6. Scrubber Solids
7. Scrubber Makeup Water
8. Ambient Air, upwind and downwind
5.1.1.1 Stack Gases ;
Secondary combustion chamber gases were drawn through the
scrubber unit by an induced draft fan and exhausted through a
4 0-in ID stack. The stack extended through the roof of the
trailer to an elevation of 23.6 feet above grade
above the trailer roof). The stack was equipped
ports accessible from the trailer roof. Because
of the exhaust stack, the duct was not traversed
were collected at a single point in the center of
(10 feet -.•
with sampling
of the size
Al1 samples
the pi'pe.
About 3 feet above the roof of the trailer was a 3-in flanged
port and a 1-in sample tap. Approximately 3 feet above these
ports was another 3-in flanged port. The two 3-in ports above
the trailer roof were used to collect source assessment
sampling system (SASS), Method 5, and Modified Method 5
samples! Prior to the point at which the exhaust stack passes
through the trailer roof was a 2-in port accessed through a
bulkhead in the trailer. Volatile organic sampling train
(VOST) samples were collected at this location.
The 1-in port above the roof had been projected as the CEM :
sampling tap. However, due to the potential for in-leakage
through the 3-in port at the same location during sampling
58
-------
FENCING
en
X—X—
EXCLUSION ZONE
DRUM STORAGE:AREA
'• WASTE FEED
• ASH ,
• SLOWDOWN WATER
EMPTY DRUMS
SHIRCO PILOT-SCALE INFRARED INCINERATOR SYSTEM
I
WASTE FEED
TRANSFER -
DRUMS TO
PAILS
£• WASTE FEED
WEIGH SCALE
CONTROL CABINET
BELT SPEED CONTROL
BURNER CONTROL
LIGHT PANEL .
MOTOR CONTROL CENTER
TRANSFORMER
ELECTRICAL SERVICE
HEPC
' -T * •» •» * «x
(J BELT CONVEYOR (") I
RIMARY COMBUSTION CH T
SECONDARY COMBUSTION CHAMBER
J COMBUSTION
AIR BLOWEfl
J CONTAMINATION,'
I REDUCTION I
I ZONE
AT GRADE
Figure 5. Sampling locations - system process flow.
MAKEUP WATER
FROM WATER
SUPPLY TRAILER.
1 STACK GASES
2 PRIMARY FURNACE OFFGAS
3 SOLID WASTE FEED
4 FURNACE ASH ;
5 SCRUBBER WATER
6 SCRUBBER SOLIDS
7 SCRUBBER MAKEUP WATER
-------
TO FENCED
HAZARDOUS
WASTE SITE
FENCING
• WASTE FEED
DRUM STORAGE AREA
• WASTE FEED
•ASH
• SLOWDOWN WATER
• EMPTY DRUMS
• WASTE FEED
WEIGH SCALE
METEOROLOGICAL
STATION
SHIRCO PILOT-SCALE INFRARED
INCINERATOR SYSTEM
CONTAMINATION
REDUCTION
ZONE
ELECTRICAL
SUPPLY-
DIESEL
GENERATORS
RADIAN ANALYTICAL
TRAILER
SHIRCO SUPPORT TRAILER
t
SLOPE
DOWN
EXISTING VEGETATION
SITE PROGRAM OFFICE TRAILER
STACK GASES
PRIMARY FURNACE OFFGAS
SOLID WASTE FEED
FURNACE ASH
SCRUBBER WATER
SCRUBBER SOLIDS
SCRUBBER MAKEUP WATER
83 AMBIENT AIR (UPWIND)
8b AMBIENT AIR (DOWNWIND)
—x— x—x—x—x—x—x— x—x—x—x
FENCING X
PARKING AREA
rT'
TO EXIT
I FROM SITE
Figure 6. Sampling locations - overall test site.
-------
activities, a sampling tap was installed in the exhaust pipe
upstream of the VOST sampling port.
In addition to the above ports, a 2-in tap was installed to
accommodate a fixed pitot tube and thermocouple in the exhaust
stack to continuously monitor stack flue gas velocity.
Because of the small exhaust duct size, following conventional
sampling protocol using a nozzle, pitot, and thermocouple at
the sampling point in the duct would overly obstruct flow and
potentially bias data. With this tap, flue gas velocity was
monitored upstream of the sampling locations in an
unobstructed flow region. These data were used to determine
isokinetic sampling rates.
5.1.1.2 Primary Furnace Offgas
The offgas from the primary furnace passed through a 2x2-ft
duct into the secondary combustion chamber. There were two
4-in 150-lb flanged ports available for sampling access
located on either side of the duct. An additional 1-inch port
also was available for collection of sampling gas for the
continuous monitors. Sampling access was via Ix2-ft bulkheads
on either side of the trailer and in line with the ports.
5.1.1.3 Feed
Grab samples were collected by Shirco personnel every 30
minutes during the tests from the incinerator feed pail using
a scoop. Two liters of sample were collected during each of
the runs. Samples for analysis were composited in 1-liter
amber glass jars with teflon-lined caps.
5.1.1.4 Furnace Ash
Ash samples
end of each
composi ted
were collected from the ash collection drum at the
test period. The samples were collected and
in 1-liter amber glass jars with teflon-lined lids.
5.1.1.5 Scrubber Water
The scrubber water was recirculated
outside of the incinerator trailer.
water were taken at the end of each
through a 50-gal drum
Samples of the scrubber
test period from the drum
using a dipper. Six liters of scrubber water were collected
jars with teflon-lined lids, along with three
i n amber glass
40-mL volatile
organic analysis (VOA) vials
5.1.1.6 Scrubber Sol ids
Particulate matter and salts were removed from the exhaust gas
by a venturi scrubber. These solids settled out of the
scrubber water and collected at the bottom of the 50-gal
recirculation drum. Scrubber solids were to be collected at
61
-------
the end of each test period using a dipper. Approximately
2,500 grams of sample were required to achieve all analytical
requirements; during the test period, insufficient solids were
collected to accommodate analytical requirements, and the
analysis of scrubber solids was eliminated. During each test,
several scrubber water sample's were collected and analyzed for
total suspended solids to evaluate the solids loading of the
scrubber water.
5.1.1.7 Scrubber Makeup Water
tap
Samples of the scrubber makeup water were collected from a
in the line running from the holding tank to the scrubber
intake port at the end of each test period. Six liters of
scrubber make-up water were collected in amber glass jars with
teflon-lined lids, along with three 40-mL VGA vials.
5.1.1.8 Ambient Air
PCB concentration in the ambient air and metals concentrations
in the ambient air particulate matter were measured upwind and
downwind of the incineration area during the demonstration
tests. Samples were collected continuously during the
operation of the unit.
5.1.2 Process Data
Shirco operating personnel recorded process data during the
test periods at hourly intervals. Selected process data is
included in Section 4. Actual operating log data;is included
in Appendix A, Volume II.
5.1.3 Stack Gas and
Procedures
Primary Furnace Offgas Samp!i
5.1.3.1 EPA Method 5
The stack gas and primary furnace offgas were sampled for
measurement of particulate matter, HC1, volumetric flowrate
moisture, and metals using an EPA Method 5 sampling train.
The method was modified by including 0.1 N NaOH in the
impingers to collect HC1.
Based on the EPA Method 5 technique, a s
particulate-1aden flue gas was withdrawn
a gooseneck nozzle and heat-traced, glas
particulate matter was collected on a gl
maintained at a temperature in the range
The particulate mass was determined grav
residues collected on the filter and in
associated glassware prior to the filter
the flue gas entered a chilled impinger
collected in the first two Greenburg-Smi
contained 200 ml of 0.1 N NaOH. A third
amp!e of :
i sokinetically using
s-lined probe. The
ass fiber f i1ter
of 248° + 25° F.
imetrically from the
the probe and
After the filter,
trai n where HC1 was
th Impingers, which
dry impinger was
62
-------
employed to collect condensate or mist carryover from the
previous impingers. The third impinger was a modified , .
Greenburg-Smith type. The fourth impinger contained a, known
weight of si 1 i ca. gel desi ccant to collect remaining moisture.
A pump and dry gas meter were used to control and monitor the
gas flowrate. .
During collection of EPA Method 5 samples, S-type pitot ' '.
measurements were taken in the flue gas duct to determine the
isokinetic sampling rate. The pitot differential pressure
measurements, along with the flue gas composition (C0?,
0?> N2, HpO), also were used to determine the volumetric
flue gas flowrate by. correl ati on to the cross-sectiona-1 area
of the duct at the sampling location. Grab samples of the
stack gas were collected to determine the concentrations of •
CO? and 0? directly., and No by difference, in accordance
with EPA Method 3 protocol. The moisture content of the
sample gas was measured during the runs following EPA Method 4
protocol .
At the end of the sampling period, the .nozzle, probe, liner,
and glassware preceding the filter housing were rinsed with
acetone and. deionized water to remove particulate matter. The
resulting wash was evaporated and the mass of particulate
residue was determined gravimetrically. The glass fiber
filter was removed from the filter holder, desiccated for 24
and weighed to determine the mass of particulate on the
Th.e total mass of particulate present on the filter
the probe wash then .was divided by the total .volume of
hours,
filter
and in
gas sampled to determine the particulate loading
The impingers used during particulate sampling were weighed
before and after sampling to .determine, the moisture content of
the flue gas. The HC1 concentration of the flue gas was
determined by analyzing two sodium hydroxide impingers for
chloride. Since the impinger solutions were caustic, COo
also was removed. To account for the C02 removal, the 071
NaOH impinger solutions also were analyzed for carbonate.
metered gas sample volume was -adjusted using the carbonate
analytical values. .
N
The
The particulate matter collected on the.glass fiber filter,wa^s
analyzed for metals. The measured metals concentration along
with the particulate loading and flue gas flowrate were used
to determine the emission rates of those metals..
and
5.1.3.2 Source Assessment Sampling System (SASS)
SASS trains were used to collect samples of the stack gas
primary furnace offgas for the determination of PCBs,
SV-PP+10, and PCDDs/PCDFs. Samples were collected in separate
SASS trains for PCBs, semivolatile priority pollutants
(identifying the ten highest other peaks), and PCDDs/PCDFs.
63
-------
The sampling system consisted of a heated probe, a heated
filter, a condenser, a sorbent module containing an organic
adsorption resin (XAD-2) used to efficiently collect vapor
phase organics, and a pumping and metering unit. Because of
the low particulate loading in the gas stream, the three
cyclones of the SASS were removed from the train for
sampling. The probe was a stainless steel sheath, which
contained a heat-traced stainless steel .sample liner. A
gooseneck nozzle of proper size to allow near-isokinetic
sample collection was attached to the probe. The probe was
fixed to the heated enclosure, which housed a high-efficiency
glass fiber filter. The enclosure was maintained at a
temperature of 400°F.
From the heated filter, the sample gas entered a water-cooled
condenser followed by the XAD-2 sorbent module. A condensate
trap followed the sorbent module, which collected the aqueous
condensate.
After the condensate trap were three dry impingers to collect
any mist carry-over from the condensate trap and a final
impinger containing a desiccant to dry the sample gas prior to
metering. The sample gas was drawn by two double diaphragm
pumps, and the sample gas volume was measured using a, dry gas
meter.
The design of the SASS train precluded traversing of the
stack. Sample collection was performed at a point of average
qas velocity that was selected based on previously .determined
velocity traverse data. The SASS probe included a fixed pitot
tube and thermocouple in the exhaust stack to continuously
monitor stack gas velocity. ?
5.1.3.3 Soluble Chromium • :
Soluble chromium (hexavalent chromium) sampling of the stack
gas and primary furnace offgas was conducted according to the
procedures (with modifications) currently being used by the
EPA's Emission Measurement Branch (EMB) of the Office of Air .
Quality, Planning, and Standards (OAQPS), Research Triangle
Park, NC for sampling hexavalent chromium emissions from
municipal waste incinerators. This procedure involves the use
of an EPA Method 5 sampling train with the following ,;;
modifications:
o 0.1 N NaOH impingers in place of water.
o No filter. :
o A glass nozzle in place of stainless steel. ; j
o 0.1 N NaOH rinse to recover the sample. ;
64
-------
o Minimal 0.1 N NaOH in the sample recovery
process
^ 3°Jzl?i P™b<: 1iner' and pre-impinger glassware rinse were
added to the impinger catches and the sample analyzed by
atomic absorption spectroscopy. The soluble chromium sampling
train was run approximately 4 hours at a point of average flue
gas velocity to achieve adequate analytical sensitivity.
5.1.3.4 Volatile Organic Sampling Train (VOST)
The stack
(plus the
was designed to
points less than
gas and primary furnace offgas were sampled for
volatile organic compounds and priority pollutants
10 highest peaks) using the VOST. The VOST
collect volatile organics with boiling
100 C using a pair of absorbent resin traps in series.
Volatile organics were removed from the gas in sorbent resin
coo£S C°ntain1n9 Tenax and Tenax-charcoal maintained at
68 F. The first resin trap contained Tenax, and the second
trap contained Tenax followed by petroleum-based charcoal
After sampling, the resin traps were sealed and returned to
the laboratory for analysis. A 20-L sample of gaseous
effluent was collected at a flowrate of 1.0 L/min using a
glass-lined probe. A dry gas meter was used to measure the
volume of gas passed through the pair of traps
During the test, the VOST
pairs of traps, with each
for 20 minutes at the 1.0
sampling, two 40-mL VOA vi
condensate collected in th
performed on the six resin
aqueous condensate vials.
fixed point of average gas
sampling was not required
gas phase.
5.1.3.5 Molecular Weight
run consisted of collecting six
pair of traps exposed to sample gas
L/min flowrate. After daily
als were used to collect the aqueous
e condenser. Three analyses were
trap pairs and on one of the
The samples were collected at a
velocity in the duct. Isokinetic
since the volatile POHCs were in the
Stack gas and primary furnace offgas were collected at a
single point in the stack in tedlar gas bags for determination
ot 02 and C02 concentrations. The samples were extracted
through a stainless steel probe and passed through a silica
gel impinger to dry the gas before collection in the qas bag
Analysis was conducted by EPA Method 3.
5.1.3.6 Continuous Emission Monitors (CEMs)
CEMs were used during the demonstration test to
monitor the concentrations of CO, C02, 0?, NO
in the stack gas or primary furnace offgas using one set of
instruments, which were switched between the two sources every
continuously
and THC
65
-------
30 minutes. A stainless steel probe was inserted at the stack
gas and primary furnace offgas sampling locations. Gases were
withdrawn and transported via separate heat-traced,(at
300°C) Teflon@ sample lines to the instrumentation area.
There the stack gas and primary furnace offgas sample lines
were fed into a three-way valve. The selected stream was
conditioned prior to analysis to remove both particulate
matter and water.
Gases first entered an impinger train having a series of
short-stemmed impingers (as condensers) immersed in an ice
bath. After the impinger train, particulate matter was
removed by a glass fiber filter. After filtration, the gases
were further dried using a Perma-Pure dryer, which utilizes a
water xapor permeable membrane. The gases were drawn by a
TeflonR coated diaphragm pump located between the filter and
the Perma-Pure dryer. Gases for the five instruments;
(discussed below) were drawn from a manifold downstream of the
pump.
A Bendix Model 85-105CA analyzer was used to measure CO
concentration in the gases., This instrument is a
nondispersive infrared (NDIR) analyzer, which measures the _
concentration of CO by infrared absorption at a characteristic
wavelength. To measure the C02 concentration in the gases,
an MSA Model 303 NDIR analyzer was used. This instrument
measures the concentration of C02 by infrared absorption at
a characteristic wavelength.
oxygen analyzer
the gases. The
was used to
Taylor 540A
determine the
measures
A Taylor Model 540A
Oo concentration of <,,,^ 3 . .-•- - -„ ---
oxygen concentrations on the basis of the strong paramagnetic
properties of Oo compared to other.compounds present in
combustion gases. In the presence of a strong magnetic
Oo molecules become temporary magnets. The Taylor,540A
determines the sample gas 02 concentration by detecting
field
the
displacement torque of the sample
a magnetic field.
test body in the presence of
A TECO
of NO
NO
used to measure the concentration
This instrument determines
the
Model 10 analyzer was
Y present in the gases.
v concentrations by converting all nitrogen oxides in
sample gas to nitric oxide and then reacting the nitric oxide
with ozone. The reaction produces a chemilumlnescence
proportional to the NOX concentration in the sample gas.
The chemilumlnescence is measured using a high-sensitivity
photomultiplier.
A Beckman Model 40OA was used to continuously measure the.
concentration of hydrocarbons present in the gases. The
analyzer utilizes a hydrogen flame ionization detector. ine
sensor is a burner in which a regulated flow of sample gas
passes through a flame sustained by regulated flows of a^fuei
gas and air. Within the flame, the hydrocarbon components of,
the sample stream undergo a complex ionization that produces
66
-------
,„
5-'-4
The Test
sampling
Lead
Plan for the experimental primary furnace offaas
^Sthm 1S ?^ernted 1n APPendix E, Vo?um" ?l.9a t was
m the fiei-d to accomodate the port configuration on
an
a Type-se stam
n1ess
, * r-
i$ a probe "^isting
covered by a qlass "sork"
pump, and then to
_. . „ -• The samp!e line
zones. The first zone extended from
e port to approximately t
»F
bS?ner
for 1 ntroduct ion no the
was
tror
introduct
nebulzatTon
th that samp e
to the oxidant side negatively influenced
rate and produced back-pressures in the sample
line.) To prevent changes in the flame characteristics from
one type of sample to another, all gases (?allb?at1oJ blend
sample) were introduced into the full side^eed of the burner
i
?9 the GBC-900 atomic adsorption
67
-------
an impact bead nebulizer and pre-mix air-acetylene burner
an MM p«\. u _ " _._j.j j_ 4-..,^ .p/-. VMYI a •»• c • numerical outou
to
air and
blend
originanyWchoserhara^certified composition of 5.0 percent
C02, 8.0 percent 02, and 87 percent N2. . ,
5.1.5 Solid and Liquid Sampling Procedures
Sampling procedures that were used to collect samples from
solid and liquid streams are described in this section.
5.1.5.1 Solid and Liquid Sample Container Preparation
S^e containers f.r,^^0^^ tnffi.15" ™
ties used for solid and liquid samples were amber
glass with Teflon1* cap liners.
Each ...PL bottl.,th.tj.»(«»adht.f,t.r.i,..PDl..ef.r9.rS.n1c
analysis
i
5.1.5.2 Solid Sampling Procedures
Samoles of the feed, furnace ash, and scrubber solids were
2 500 g of sample were necessary for analysis.
subsequent analysis.
5.1.5.3 Liquid Sampling Procedures
Scrubber water and scrubber makeup water samples, were
68
-------
he VOA samPles were composited at the time of
"
5.1.6 Ambient Air Sampling Procedures
Ambient air both upwind and downwind of the test site was
jsj ;".:.; ^^^r^ .-& ° If I
Sh rco unit The upwind and downwind samplers were located
using on-site, continuous meteorological data i e w?nH
hour LT The Wind ^ection ^s checked at'last'once per
ha be n' ^n"sampl ers should not be moved after s mpl ng
Qn° fSSIont the average wind direction deviated by more tha
90 , amblent .sampling was terminated for that period.
5.1.6.1 PCBs
5.1.6.2 Metals
Ambient
H Jh
8xlS n
concentrations of metals upwind and downwind of the
USinn9 a Ge"eral Metal Works Sodel 2000H
o er Particulate matter was collected on
1 .
5.1.6.3 Meteorological Measurements
During the siting of the ambient air sampling stations a
location for the meteorological monitoring station also was
operated Jortab e^J091'?1 dat? W3S Capt"red ^ing a battery
operated portable meteorological station (Meteoroloqical
M°de1 1072) P^itioned at the iJ-fi
ion and wind speed were recorded on a
stnpGhart recorder. Temperature measured by the
meteorological station was recorded on a strfpchart recorder;
69
-------
all other temperature measurements were recorded by hand and
entered on the data sheet. '
5.1.7 Sampling Equipment Calibration Procedures
au
results have been properly documented and retained.
5.1.7.1 S-Type Pitot Tube
The EPA has specified guidelines, as presented in Section
31 1 Sf EPA Document 600/4-77-027b ("Quality Assurance .
Handbook for Air Pollution Measurement Systems," August, 1977)
-
*
and documented as meeting EPA specifications.
5.1.7.2 Samp! ing Nozzle
5.1.7.3 Differential Pressure Gauge
gauges were used during this project to measure
agneeicR is described. The Magnehel i c« gauges were -
calibrated prior to field sampling and checked at a single
representative value following the field sampling.
5.1.7.4 Temperature Measuring Device
mirina source sampling, accurate temperature measurements are
i SceSueu§L^KrnusL^sr3%wr^^
600/4-77-027b? All sensors were calibrated prior to fiel
samp! ing.
5.1.7.5 Dry Gas Meter
70
-------
DHor to ?hpCHrre°,tl0n fa.Ct?r at standard conditions) just
nnc?t S the departure of the equipment to the field A
and Dostt^ Vbariath°n;C'heCk alS°,Was ^formed. The pretest
and posttest calibrations agreed to within 5 percent.
The DGMs used in the SASS, Modified Method 5, and Method
5
'
Method^ o<
dSnng t5heevsi testing9"
5.1.7.6 Analytical Balance
the Sflss' Modified Method 5 and
°™-115- lo-fl..' DGM was used
9 ?•!! fleld measurempnt program, the analytical balances
!NBS na?r^the 6XPec^d range of use with standard
C
5.1.7.7 CEMs
Calibrations of all continuous monitors were accomplished bv
introducing standard gases at the front end of the CEM
an™lHVr0^ Pr1°r to and after dai1^ sampling. This
all rnnA°r ^ assessment of any impact caused by the sample
fine ™1thT;n?iTtri'K1ncluding the heat-tracedysample P
line, on the pollutants being monitored. All instruments
underwent multipoint linearity checks (two points plus zero)
bracketing the predicted sample values These checks werp''
performed at the beginning and end of the simp! iSg per? oSv
^tanH^HtiCa1 b1ank 5^ a Sin9le-Point response factor (RF)
standard was analyzed daily prior to testing for all
t?rS: A fin9le-Point drift check also was
analyzing the same standard used for the
RF determination at the end of each day of
•
DPrf™Hh
performed by
single-point
is
5.1.7.8 PUF 'Sampler Calibration
Calibration of the General Metal Works (GMW) PS-1 sampler
.3 GMW Mode1 40 orifice calibration unit
1^31^-15 calibrated ^ the manufacturer
K a 1inear regressions analysis of the
ation coefficient of at least 0.9998. The
and
s
S
5.1.7.9 Hi-Volume Sampler Calibration • ,
Multipoint flowrate calibrations of the Hi-Vol sampler flow
71
-------
rate recorders were performed using the procedures outlined in
40 CFR? Pan 50 11, Appendix B, July 1, 1975. A calibrated
orifice and a series of five resistance plates were used to
calibrate the flow recorder response.
5.1.7.10 Meteorological Equipment Calibration
The following calibration procedures for the meteorological
senses were performed once in the field prior to sampling:
o Wind Direction--The wind sensor was set at north, south,
east, and west. The recorder was checked at each setting
for correct response. The setting for north was
determined using a compass. A correction for the site
declination was made during data analysis.
o Wind Speed--The chart speed was checked for consistent
movement.
o Temperature--The thermocouples were calibrated by
comparison of three separate measurements against an ASTM
reference thermocouple at different times of day. The
melsuHng thermocouple was positioned in cl ose Proximity
to the temperature sensor of the meteorological station
The temperature readout of the ^tripchart recorder on the
meteorological station then was compared to the reference
thermocouple.
All calibration data and
were recorded on meteorological
forms.
5.1.8 Sample Custody
sensors
test data from meteorological
instrumentation calibration
program were based on
samples were analyzed on
facilities, the custody
documentation of
field analytical data
Sample custody procedures for this
EPA-recommended procedures. Since
site, as well as at the laboratory
procedures used emphasized careful
monitoring, sample collection, and . . _. _ -... „
generation, and the use of chain-of-custody records for
samples being transported.
ThP field samolinq leader was responsible for ensuring that
Jroper custody an9d documentation procedures were; foil owed for
the field sampling and field analytical efforts He was
assisted in this effort by the sampling personnel involved in
sample recovery.
All sampling data, including sampling times, locations, and
any specific considerations associated with sample
acauisition, were recorded on preformatted data sheets.
Follow ng sample collection, all samples were ogged into a ;
master logbook (bound notebook) and given a unique
72
-------
"» P"..nn.l
In
•'
C°°lln9 requirements
were employed for all s-ample transfer activities.
5.2 ANALYTICAL PROCEDURES
^nanal*t1Cal ««°<* a- P-enlJ a^n°-fo?^r°nS
5.2.1 Solid Streams Analysis
"""er
'
5.2.2
Liquid Streams Analysis
5.2.3 Stack Gas an-d Primary Furnace Offgas Analysis
Toxicity
systems rrFMci f«;~ usjng continuous emission monitoring
systems (CEMs) for carbon monoxide, carbon dioxide, oxygen,
73
-------
eco
dioxide and oxygen using an Orsat analyzer
Three EPA Method 5 samples were collected for analysis of
particulate matter, moisture, flowrate, and HC1 .
condensate vial also was analyzed.
Three EPA Modified Method 5 (MM5) samples were collected for
analysis of soluble chromium.
for PCDD/PCDF and SV-PP+10.
5.2.4 Ambient Air
Ambient air samples were collected daily upwind
^nVal^a^icSla^ ma'itJ M! £ J 1
and PUF samples were analyzed for PCBs.
5.2.5 V-PP+10 Analysis
«t,ls,
liquid incinerator samples included:
o Feed
o Furnace Ash
o Scrubber Water
o Scrubber Makeup Water
o Scrubber Solids
s
If sample used the following
5.2.5.1 Stack Gas and Primary Furnace Offgas Analysis for
V-PP+10 ' . ••
74
-------
ninnr/c Vola^'le 5omP°unds were separated and detected
using GC/MS as outlined in SW-8240.
5.2.5.2 Liquid and Solid Sample Analysis for V-PP+10
V-PP+10 compounds in liquid and solid samples were analyzed
using SW-8240. The methods detailed the purge and trap
procedure for preparing field samples for GC/MS analysis.
5.2.6 SV-PP+10 Analysis
SV-PP+10 analyses were conducted on all samples streams
including:
o
o
o
o
o
o
o
Feed
Furnace Ash
Scrubber Water
Scrubber Makeup Water
Scrubber Sol ids
Primary Furnace Offgas
StackGases
5.2.6.1 Stack Gas and Primary Furnace Offgas Analysis for
SV-PP+10 Analysis ..,-_..-
SV-PP+10 analysis using SW-8270 was performed on the stack gas
15 PpIiTry/P™n/DrSrfgaS samPles collected using the SASS
hv'.nt ?t- PCDD/PCDF were analyzed in the same SASS sample
by splitting the solvent extract for the two analyses
Surrogates applicable to both analyses were injected into the
Dr^r%Vri%r-^eXtraCti°n' SV-PP+1° analysis was completed
prior to initiation of cleanup steps for the PCDD/PCDF
analysis. ' '
5.2.6.2 Liquid and Solid Sample Analysis for SV-PP+10
caJnlhS °f ^ feed, scrubber water, scrubber makeup water,
scrubber solids, and furnace ash were analyzed by SW-8270
Liquid samples were extracted using SW-3520. Solid samples
were extracted using SW-3540. Extracts of liquid and solid
3nalyZed for semivolatile organic contaminants
5.2.7 PCB Analysis
PUF ^lrS "^^o analyze stack gas, primary furnace offgas,
PUF samples (ambient air), and solid and liquid samples for
75
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PCBs by GC/MS. GC/MS analysis using selected ion morCoring
is superior for PCB analysis of gas samples. This type of
analysis monitors for ions indicative of biphenyls with two
chlorines, three chlorines, etc. The results are presented as
the sum of individual chlorinated blphenyl congener instead of
mixtures of such congeners, as defined by Aroclor number,
which is most common in GC/ECD analysis.
5.2.7.1 Stack Gas and Primary Furnace Offgas Analysis for PCBs
Samoles of the stack gas and primary furnace offgas were
collected using a SASS train with XAD-2 as the adsorbent resin
for PCB analysis. The samples were recovered using methanol
and methvlene chloride. The SASS train provides three
subsamDles- (1) the glass fiber filter; (2) methanol and
methyUne chloride rinses of the probe, filter holder, and the
condenser/resin trap; and (3) the aqueous conden ate Each
subsample was extracted separately and then combined for
analysis.
5.2.7.2
Liquid
PCBs
and Solid, and Ambient Air Sample Analysis for
EPA 680 was followed for PCB analysis of the feed, furnace
ash, scrubber water, scrubber water makeup, scrubber sol ids,
and ambient air particulates. Solid samples were;
Soxhlet-extracted using SW-3540. Liquid samples were
extracted using SW-3520.
5.2.8 PCDDs and PCDF Analysis
All sampled streams were analyzed for polychlorinated
dibenzo-p-dioxins (PCDDs) and polychlorinated dibenzofurans
(PCDFs) using SW-8280.
5.2.8.1 Stack Gas and Primary Furnace Offgas Analysis for
PCDDs and PCDFs
Stack aas and primary furnace offgas samples for analysis of
PCDDs Ind PCDFs were collected using a SASS train and were
analyzed according to SW-8280. PCDD/PCDF analyses were
performed on the same SASS samples as SV-PP+10 by splitting
the SASS sample extract for each analysis.
5.2.8.2 Liquid and Solid Samples Analysis for PCDDs and PCDFs
The liquid and solid samples collected for
measurements were analyzed using SW-8280.
were extracted by continuous 1iquid/Iiquid
according to SW-3520. SW-3540, which is a
technique, was used to extract solids.
PCDD and PCDF
Aqueous samples
extraction
Soxhlet extraction
76
-------
5.2.9 Metals
t 93S' Binary furnace offgas and ambient
m • .™atter' sollds> and liquids were analyzed for
metals by inductively coupled argon plasma emission
spectroscopy (ICAP) using SW-6010, and by atomic absorption
°ma SP
-re
The samples were analyzed for a total of thirty-one elements
The volatile -elements (lead, arsenic, antimony selen urn and
mercury) were analyzed by AAS. Arsenic, antimony? iSad and
(sl67060 "yo^l^y^r'"6^^]^ 9«ph1tef furnace techni ues
(*u 7060, 7041, 7421, and 7740, respectively) Mercurv was
determined by the cold vapor technique (SW - 7470/7471 )
Aqueous samples (SW-7470) were acidified prior to analysis.
5.2.9.1 Continuous Monitoring - Vaporous Lead
Radian Corporation, through work with the Electric Power
Research.lnstltute and the Department of Energy, has dlvel ooed
an experimenta continuous vapor phase monltorfor lellcted
metals .including lead. The monitor was not defined by an
approved EPA method or QAPP review but was incorporated ?n the
overall program to study the monitoring system's ability to
conatroimofd:PtafiWh1C^ "" all°" 3 pr°C «s evlluJtlSn
vooroi ?!«5 3n Ih S emi^sions- Continuous monitoring of
vaporous lead n the primary furnace offgas was conducted to
desternvntehth6 1ncinera+tor operating conditions required to
destroy the organic material while minimizing the
volatilization of lead from the contaminated soi 1 . The
n the P?fSnifS ld "^ det?Ct Vap°r phase lead concentrations
i" „?? offgas samples at levels less than 2.7 ppb; the
Tes? Pl.nT 1^onc1u!ive and the program was aborted! The
Test Plan for this activity, as proposed and defined by Radian
Corp., is included in Appendix E, Volume II. The results of
these monitoring studies are included in Appendix F? Volume
5.2.10 Soluble Chromium
^ia°l!i9aSuand.pr1'!'ary furnace offgas samples were analyzed for
soluble chromium (hexavalent chromium) using EPA M218.4 By
this method, the hexavalent chromium is chelated using
ammonium pyrrolidine di thi o'carbamate . The chelated chromium
kS?nnpS e^ract?d from the sample medium using methyl isobutyl
ketone The solvent extract then is analyzed by flame atomic
absorption spectroscopy. • nine atomic
77
-------
sol id
EP
The stability of hexavalent chromium is not completely
understood, and the method recommends that chelation
extraction be carried out as soon as possible. The stack gas
samples for soluble chromium analysis were chelated and
exacted on site after sample collection. The results did
not detect soluble chromium concentrations at levels less than
264 ppb and were inconclusive.
5.2.11 EP Toxicity Leaching Procedure :
The feed, furnace ash, scrubber water, and scrubber solids
were analyzed by the RCRA Characteristic of EP Toxicity
(SW-1310). The method involves the acidic extraction of
samples followed by analysis of specific trace metals The
Toxicity analysis was performed for trace metals only.
specifically, arsenic, barium, cadmium, chromium, lead,
mercury, selenium, and silver.
5.2.12 Toxicity Characteristic Leaching Procedure
The feed, furnace ash, scrubber water, and scrubber sol ids
were analyzed by the proposed Toxic Characteristic Leaching
Procedure (TCLP). TCLP was proposed by EPA to expand the
?oxicity cnaracieristic to Delude additional chemica-ls and to
incorporate a new extraction procedure. Extracj!°*M^0
volatiles involves acidic extraction in a zero-head ace
extractor which is rotated in an end-over-end fashion at 30+2
rpm Extract on for metals and semivolati1es uses the same
pTScedure except that it is done in a glass container rather
than the zero-headspace. The metals were analyzed a:^
described for EP Toxicity. The organic contaminants were
analyzed using SW-8240 and 8270.
5.2.13 Other Analyses !
The feed furnace ash, and scrubber solids were analyzed for
chlorine', ash and ultimate analysis, and the feed for higher
heating value.
ash, and scrubber
The samples were
an alkaline solution.
chlorine (as chloride)
5.2.13.1 Chlorine Analysis
Chlorine analyses of the feed, furnace
solids were performed using ASTM D808.
combusted in an oxygen bomb containing
The alkaline solution was analyzed for
using titration.
5.2.13.2 Ash Analysis
The ash content of .the.feed^furnac^ash,^ scru bb.r^.l ids..
were determined using ASTM 03174^
after burning, was ashed at 1427 F
residue then was weighed.
in a
muffle furnace. The
78
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5.2.13.3 Ultimate Analysis (C, H, Ov S, N, Moisture)
solids were analyzed for
for ultimate analysis
of carbon, hydrogen
deteJmTneHy
of ASTM methods. ASTM
The feed, furnace ash, and scrubber
elemental concentrations using A003
The procedure involves the analysis
d1ffU?PnrpSUll!!n* '^ moisture-
difference. A003 is a conglomerate
D3178 analyzes for carbon and hydrogen by burning the samples
rLhnT UStl°n Sy^tem followed by fixation of the products of
combustion in an absorption train for analysis Nitroaen is
ann!yZtdHb? AS™ D3179« The nitrogen in the "ample IV
converted to ammonium salts by destructive digestion. Ammonia
is recovered and analyzed ti trimetrically . ASTM D3177 is used
to measure sulfur using bomb calorimetry! The recovered
sulfur is precipitated as BaS04 and determined
gravimetrically. Moisture is determined by ASTM D3173 which
is a gravimetric technique involving drying of the sample.
5.2.13.4 Higher Heating Value Analysis
The higher heating
determined using a
D2015-77 for solid
value (HHV) of the solid waste
bomb calorimeter, according to
waste.
feed
ASTM
was
5.2.14 TSS and TDS Analysis
The concentration of Total Suspended Solids (TSS) and Total
Dissolved Solids (TDS) present in the scrubber 1 quid effluent
and scrubber water inlet was determined using gravimetric
procedures EPA M160.1 and M160. 2, respectively
5.2.15 pHAnalysis
™%PKi°f uhe fcrubber liquid samples was determined using a .
portable pH meter and combination electrode with temperature
compensation in accordance with EPA M150.1.
5.2.16 Density
n dei?si^ °f the ^ed, furnace ash, and scrubber sol i ds
were determined .using a gravimetric/volumetric method.
5.2.17 Particulate Matter
Particulate material was measured in the stack gas and primary
furnace offgas using EPA Method 5. primary
5.2.18 Flue Gas Moisture
The moisture content of the gas streams was determined using
the technique specified in EPA Method 4.
79
-------
5.2.19 HC1 Determination
For the determination of HC1 in the stack gas and primary
furnace offgas, samples of gas were passed through a series of
impingers immersed in an ice bath. The first two jmpingers
contained 200 ml of 0.1 N NaOH and were Greenburg-Smith type
impinqers. Following the first two impingers are a dry,
modified Greenburg-Smith impinger and an impinger containing a
desiccant. The sample was analyzed using an ion chromatograpn
following Method 27 from the "FGD Chemistry and Analytical
Methods Handbook," Volume 2, Radian Corporation, July 1984.
5.2.20 Carbon Dioxide
During the sampling for HC1 in the stack gas and primary
furnace offgas, the collection of C02 in the 0.1 N NaOH
impinger is a consideration that had^to be addressed. Because
the impinger solutions are caustic, C02 also was removed
from the stack gas. Thus, the metered sample gas volume was
low by the amount of C02 removed by the impinger solutions.
To account for
solutions were
was corrected.
the CO? removal, the 0.1 N NaOH impinger
analyzed for carbonate; total gas volume then
5.2.21 Oxygen and Carbon Dioxide Analysis
Grab bag samples of the stack gas and primary furnace offgas
were collected in the field according to EPA Method 3 for
COo and 02. These samples were analyzed within 3 :hours ot
collection using an Orsat analyzer.
5.2.22 Total Organic Carbon
Total carbon was measured using a carbonaceous analyzer by
quantitatively converting the organic and inorganic carbon in
a sample to carbon dioxide, which then was measured by an
infrared detector. Total inorganic carbon is determined by
sparging carbonates from the sample as C02, which is
measured by IR. The UV-catalyzed oxidation of organics is not
used. Total organic carbon is calculated from the difference
of total carbon/total inorganic carbon.
5.3 SAMPLING AND ANALYTICAL REPORT /
The Sampling and Analytical Report is included as Appendix B,
Volume II.
80
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SECTION 6
PERFORMANCE DATA EVALUATION
6.1 INTRODUCTION
Based on the operating data presented in Section 4 and Appen-
dix A, and the analytical results presented in Appendix B, and
Appendices D-G, an evaluation was conducted to determine the
effectiveness of the Shirco Pilot-scale Infrared Incineration
System in treating the feed at the Demode Road Superfund Site
under a series of varied operating conditions.
A total of 17 runs, were conducted. Three runs were performed
under design operating conditions to assess overall unit
operation and system performance (Phase I). These runs were
conducted at 1600°F PCC temperature, a 2200°F SCC temperature,
and a PCC residence time of 20 min. Each of the three runs
was sufficiently long (6 to 10 hours) to gather a large enough
sample of stack gas to analyze it for PCBs. An additional run
was conducted at the same operating conditions to obtain spe-
cific stack samples that had not been successfully collected
during two of the previous runs.
Fourteen runs were conducted under varying operational para-
meters to evaluate their effect on system performance and
energy consumption. These runs were conducted for approxi-
mately one hour under varied operating conditions that
included the PCC temperature (900, 1200, 1400, and 1600°F),
SCC temperature (1800 and 2200°F), PCC feed residence time
(10, 15, 20, and 25 minutes), and PCC combustion air flow (on
or off to simulate oxidizing or non-oxidizing/pyrolytic PCC
atmosphere). Specific discussions addressing the field
operations of each run and the operating conditions under
which it was carried out are provided in Section 4.
This section addresses the Shirco unit's ability under the
various operating conditions to meet specific evaluation
objectives that have been set in the following areas:
o ORE levels for PCBs and the presence of PICs in the stack
gas. The regulatory standards are 99.99% DRE under the
Resource Conservation and Recovery Act (RCRA) and 99.9999%
DRE under the Toxic Substances and Control Act (TSCA).
81
-------
o Level of hydrogen chloride (HC1) and particulars in the
stack gas. The RCRA standard for HC1 in the stack gas is
1.8 kg/hr (4 Ib/hr) or 99 wt% HC1 removal efficiency. The
RCRA standard for participate emissions in the stack gas is
180 mg/dscm (0.08 gr/dscf).
o Level of residual PCBs in the furnace ash at normal and
varied operating conditions.
o Mobility of heavy metals, particularly lead, in the furnace
ash as compared to the feed.
o Mobility of heavy metals in the furnace ash as compared to
the RCRA Extraction Procedure Toxicity (EP Tox) Character-
istic (as measured by the EP Tox test) and the proposed -
toxicity characteristic (as measured by the Toxicity
Characteristic Leaching Procedure (TCLP)).
o Level of residual heavy metals and organic compounds, and
other physical and chemical characteristics in the scrubber
water discharged from the unit.
o The operating conditions that reduce energy consumption
without decreasing soil decontamination effectiveness.
o Effect of varying operating conditions on residual levels
of heavy metals and organics in the furnace ash versus the
levels in the feed.
o Adherence of the quality assurance (QA) procedures to the
requirements of the RREL-approved QA Project Plan (Category
II), as defined by the Document No. PA QAPP-0007-GFS,
"Preparation Aid for HWERL's Category II Quality Assurance
Project Plans," June 1987.
6.2 CHARACTERISTICS OF THE FEED
The results of the analyses of the composites of the grab
samples of feed taken during each of the test runs are
reported in Appendix B and summarized in Table 11. Highlights
of these results are as follows:
o During the runs conducted on soil feed mixed with 3 wt%
fuel oil, the analyses of the feed samples showed the
expected trend of increased HHV, moisture content and
carbon, hydrogen, and oxygen contents, and decreased ash
content, as compared to the excavated soil feed with no
fuel oil addition. ,'...;',,
o Total PCBs concentration ranged from 10.2 to 669 ppm and
averaged 272 ppm.
82
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TABLE 11. FEED CHARACTERISTICS (b,c)
Characterization
Density, g/cc
High Heating Value
Moi sture, wt%
Carbon, wt% (a)
Hydrogen, wt% (a)
Oxygen, wt% (a)
Nitrogen, wt% (a)
Sulfur,.wt% (a) . .
Chlorine, wt% (a)
Ash, wt% (a) .
(HHV), Btu/lb
Average
w/o Fuel Oil
2.31
210
10:81
2.45
1.48
11.87
0.10
0.02
0.11
83.98
Average
w/Fuel Oil
2.23
588
12.68
3.54
1.64
12.86
0.11
0.03
0.09
81.75
Orqanics
Total PCBs, ppm .
Total PCDD, ppb
Total PCDF (TCDF),
Semivolatiles, ppm
Bis(2-ethylhexyl)phthalate
Volatiles, ppm
Methyl ethyl ketone
Trichloroethene
ppb
Range (d) Average fe)
10.2-669
ND
ND-0.1
<.1.0-5. 5
31-34
<2.0-17
272
ND
0.065
5,5
32
10.2
Metals, ppm Range(d). Avg(e) J Metals.
Antimony
Arsenic
Barium
Beryl 1ium
Cadmium
Chromium
Copper
Lead
<0.3-26
9.8-13
390-940
<0.097
2.6-11
59-180
15-34
290-3000
2.7
10.6
591
<0.097
4.4
84.9
18.1
778
4>pm Ranqefd) Avgfe)
Mercury
Nickel
Selenium
Silver
Thai 1i urn
Vanadium
Zinc
<0.005-0.3 0.11
19-110 30.8
<0.3 <0.3
<0.87-6.2 2.3
<8.7 <8.7
16-26 20.4
200-590 301
» *
(d)
(e)
U) Jl!!IS;ital+Jna1?ses'iwtX) are on a mo^ture-free basis.
/ui Average wt% values do not total to 100%.
(b) ND indicates not detected, or less than detection limits
which vary for each.PCDD/PCDF homolog.
(c) < indicates ND at detection limit (as indicated)
Range values shown represent all data
Average values shown represent the average of all data
aair™beJ°?hdeJeJt12? liraits were Deluded in t e
average at the detection limit.
83
-------
o Several samples of the feed contained small quantities of
TCDFs ranging from 0.04 to 0.1 ppb.
o Volatile and semivolatile organic compounds including
methyl ethyl ketone, trichloroethene, and bi s (Z-ethy I -
hexyl)phthalate were measured in feed samples at concen-
?rat ins less than 50 ppm, Methyl ethyl ketone and
trichloroethene were also detected in solvent blanks and
are attributed to analytical laboratory contamination.
o In addition to lead, the primary heavy metal contaminant,
whose concentrations ranged from 290 to 3,000 ppm and
averaged 778 ppm, several other metals were present at
average concentrations exceeding 50 ppm including barium
(591 ppm), zinc (301 ppm), and chromium (85 ppm). Other
heavy metals were present in lesser concentrations, as
reported in the table.
6.3 CHARACTERISTICS OF THE FURNACE ASH
The results of the analyses of the composites of the grab
samples of furnace ash taken during each of the test runs are
reported in Appendix B and summarized in Tables 12 and 13.
Highlights of these results are as follows:
o The total concentration of PCBs ranged from 0.004 to 3.396
ppm. Additional discussion on the residual PCBs in the
furnace ash is presented in Section 6.4.
o Two samples of furnace ash contained 0.07 and 0.3 ppb of
TCDF during Runs 17 and 18 conducted at a 900°F PCC oper-
ating temperature; the normal PCC operating temperature is
1 600°F These runs were also conducted without the input
of PCC combustion air to simulate non-oxidizing or pyro-
lytic combustion conditions. The low PCC temperature and
pyrolytic environment could have led to the incomplete
desorption or incineration of TCDF present in the feed or
to the production of TCDF from the incomplete combustion of
PCBs in the feed.
The ultimate analysis data tend to substantiate the incom-
plete desorption of contaminants from the feed, as dis-
cussed above for TCDF desorption, and in Section ^4 for
PCBs At the low PCC operating temperature of 900 F and
nyrolytic combustion conditions, the presence of higher
TCDF and PCB concentrations in the furnace ash .is comple-
mented by higher carbon contents and lower noncombusti bl e
ash contents in the furnace ash that are indicative of an
incomplete desorption or incineration process. For the
three runs conducted at a PCC operating temperature of
900°F, carbon contents averaged 2.08 wt%, vs. 0.80 wU
for the other runs; noncombusti bl e ash contents averaged
93 88 wt% vs. 98.04 wt% for the remaining runs.
84
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TABLE 12. CHARACTERISTICS OF THE FURNACE ASH - ORGANICS AND METALS ANALYSES
PCC Oraanics
Residence PCDF (g)
Run Temp. Time PCB (TCDF) MeC
No- <°F) (min.) (ppm) (ppb) (ppm)
18 900(a,b) 20 2.079 0.07
17 9QO(b) 20 3.396 0.30
16 900(b) 25 0.168 ND
1.0 1200 20 0.115(d) ND
14 1200 15 0.077 ND
9 1200(b) 25 0.108(d) ND
11 1200(b) 20 0.066(d) ND
13 12QO(b) 15 0.025(d) ND
15 1200(a,b) 15 0.066(d) ND
5 1400 20 0.087(d) ND
1 1600 20 0.037 ND ND
2 1600 ,20 0.112 ND 980
3 1600 20 0.003 ND ND
1-2 1600(f) 20 (f) ND
7 1600 10 0.045 15 0.061(d) ND
(a) Waste feed blended with 3 wt% fuel oil.
(b) Non-oxidizing atmosphere.
(c) PCC bed depth at 1 inch. All other tests at
(d) PCB levels below analytical detection limits.
limits indicated in analyses.
(e) ND - nondetectable value.
Metals (i)
(g) (g) (g)
MEK TeCE TrCE Pb Ba Zn
(ppm) (ppm) (ppm) (ppm) (ppm) (ppm)
1,000 720 380
1,400 940 410
860 940 410
1,100 970 380
1,000 1,000 420
1,200 1,000 360
1,200 760 510
2,000 690 350
1,000 1,800 640
1,600 950 420
36 ND 5 1,100 1,400 360
64 6.4 3.9 1,300 1,200 410
40 ND ND 1,100 1,000 340
420 1,100 350
1,700 . 940 400
840 790 380
1,500 1,800 440
800 1,100 420
1-1/2 inches.
Total shown is sum of detectable
Cr
(ppm)
86
94
85
77
100
78
76
74
84
81
78
79
110
71
75
62
79
68
(f) Run was conducted to make up for incomplete semivotatile organics, PCDD/PCDF,
soluble chromium and stack gas particulate samplings during Runs 1 and 2.
(g) MeC: Methylene chloride; HER: Methyl ethyl ketone; TeCE: Tetrachloroethylene;
TpCE: Trichloroethene.
(h) Reported data is presented. For runs with no
were not conducted.
(i) Only heavy metals with concentrations greater
values shown, organic analyses
than 50 ppm are shown.
85
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TABLE 13. CHARACTERISTICS OF THE FURNACE ASH - ULTIMATE ANALYSES
Operating Conditions
PCC
Run
No.
18
17
16
10
14
9
11
13
15
5
1
2
3
1-2
7
6
19
8
(a)
Cb>
(c)
Residence
Temp. Time
<°F) (min)
900(a,b)
900(b)
900
-------
For the Phase I Runs 1-3, volatile and semivolati1e organic
analyses were conducted on the furnace ash samples. No semi-
volatile organics were detected. Volatile compounds includ-
ing methylene chloride, methyl ethyl ketone, tetrachloro-
ethene, and trichloroethene were measured in the furnace ash
samples in concentrations ranging from 3.9 to 64 ppm with one
sample containing 980 ppm of methylene chloride. Methyl ethyl
ketone and trichloroethene were also detected in solvent
blanks and methylene chloride is commonly employed in labora-
tory procedures; therefore, these compounds may be products
of incomplete combustion and/or the result of laboratory
contamination.
o In addition to lead, for which concentrations ranged from 420
to 2,000 ppm and averaged 1,173 ppm, several other metals
were present at average concentrations exceeding 50 ppm
including barium (1061 ppm), zinc (410 ppm), and chromii
ppm).
6.4 RESIDUAL PCBs IN FURNACE ASH
turn (81
During the demonstration test, a total of 17 runs were conducted
at varying operating conditions. In addition to the ORE levels
which are an indication of the performance of the Shirco Pilot-'
c5/e I^irared Incineration System and its ability to meet RCRA
and/or TSCA regulatory standards, the reduction of PCB concentra-
tion from the feed to the furnace ash is also a measure of the
unit s ability to effectively destroy PCBs and produce a furnace
ash with a PCB concentration below the TSCA guidance level of 2
ppm.
As shown by the data presented in Table 12, two samples of
furnace ash exceeded the TSCA guidance levels and contained
3.396 and 2.079 ppm of total residual PCBs. The samples were
produced during Runs 17 and 18 conducted at a 900°F PCC
operating temperature (20 minutes residence time), which is
fl^OrCaTJly lower than the normal PCC operating temperature of
1600 F. These runs were also conducted without the input of
PCC combustion air to simulate non-oxidizing or pyrolytic
combustion conditions. At this low PCC temperature and
pyrolytic condition, these higher total residual PCB levels in
the furnace ash may be the result of the incomplete combustion
of PCBs in the feed. This is further substantiated by the
residual TCDF present in the furnace ash samples from these same
two runs, as discussed in Section 6.3. The remaining runs
conducted at 1200°F, 1400°F, and 1600°F resulted in total
lal PCB concentrations in the furnace ash ranging from
onnor nrr°'117 P?1"' Run 16' wnich was also conducted at a
900 F PCC operating temperature, but with an increased PCC
residence time of 25 minutes, resulted in a total furnace ash
PCB concentration of 0.168 ppm with no detectable TCDF. It is
P?!S1?'?uthnat the jncreased residence time in the PCC may have
offset the low 900°F PCC operating temperature and provided
87
-------
the additional processing time for the satisfactory;destruction
of the PCBs in the feed.
6.5 MOBILITY OF HEAVY METALS
EP Tox and TCLP tests were conducted on the feed, furnace ash,
scrubber water, and scrubber solids. The tests were conducted
to document any trend or evidence which, as a result ot the
thermal treatment, shows reduced mobility of heavy metals in
effluent streams based on the toxicity characteristic standards,
as compared to the feed. The results of these tests are
reported in Appendix B and Appendix G. Table 14 summarizes the
data reported for the heavy metal of particular concern in these
tests, lead, as analyzed in the leachate fronf the feed and the
furnace ash. Highlights of the results are as follows:
6.5.1 Mobility of Heavy Metals -'Feed and Furnace Ash
In order to determine whether heavy metals, particularly lead,
would leach from the furnace ash produced in the Shirco Pilot-
Scale Infrared Incineration System, EP Tox and TCLP tests were
conducted to determine the mobility of heavy metals from the
furnace ash as compared to the feed.
o The initial EP Tox analyses for lead in the leachate ranged
from 0.05 to 0.67 ppm for the feed and 0.05 to 4.1 ppm for
the furnace ash. The initial TCLP analyses ranged from 0.35
to 1.80 ppm (with one sample at 7.0 ppm) for the feed and
0.05 to 4.1 ppm (with one sample at 6.2 ppm) for the furnace
ash.
A comparison of
furnace ash and
that indicates
versus the feed
comparison did
TCLP leachates
consistently hi
results on the
the EP Tox and TCLP analyses conducted on the
the feed does not show any trend or evidence
reduced mobility of lead from the furnace ash
as a result of the thermal treatment. The
reveal that the concentrations of lead in the
from both the feed and the furnace ash were
gher than the corresponding EP Tox test
same samples. , , , -
When several samples were retested to verify the results, the
concentrations of lead in the EP Tox leachates (4.9 ppm feed,
3 0 pm furnace ash) were higher than during the initial
tests, and in direct reversal from the original data,
exceeded corresponding TCLP leachate concentrations (2.8 ppm
feed, 1.4 ppm furnace ash). The results of the retest again
did not indicate reduced mobility of lead from the furnace
ash versus the feed as a result of the thermal treatment.
88
-------
TABLE 14. COMPARISON OF LEACHABLE LEAD IN THE FEED AND FURNACE ASH
Operating Conditions
PCC
Run
No.
18
17
16
10
14
9
11
13
15
5
1
2
3
1-2
7
6
19
8
ND =
(a)
(b)
(c)
(d)
(e)
(g)
Residence
Temp. Time
( F) (min.)
900 ( a, b.)
900(b)
900(b)
1200
1200
1200(b)
1200(b)
1200(b)
1200(a,b)
1400
1600
1600
1600
1600(d)
1600
1600(a)
1600(a)
1600(a,b)
Not Detected.
20
20
25
20
15
25
20
15
15
20
20
20
20
20
10
15
15(c)
15
Waste feed blended with 3
Non-oxidizing
atmosphere.
EP Toxicitv
Feed
(mg/L)
(ppm)(f)
0.29
0.67
0.32
0.05
0.20
0.12
0.20
0.18
0.21
0.07
0.15
0.20
0.23
0.14
0.25
ND
0.53
0.07
3.00(e)
wt% fuel oil .
Ash
(mg/L)
(Ppm)(f)
0.38
0.89
0.88
4.10
0.38
0.14
0.06
4.90(e)
(g)
0.46
ND
0.05
ND
0.13
0.28
ND
0.43
0.27
1.10
PCC bed depth at 1 inch. All other tests at 1-1/2
Run was conducted to make up for incomplete semi vol
PCDD/PCDF, soluble chromium, and stack gas parti cul
other runs.
in P
Feed
(mg/L)
(ppm)(f)
0.81
0.88
7.00
0.56
0.44
0.53
0.71
0.53
0.96
0.89
0.67
0.35
1.30
0.49
1.73
0.66
1.80
0.55
1.40(e)
Ash
(mg/L) ,
(Ppm)(f)
2.90 -
6.20
3.80
1.60
3.60
0.05
4.10
2.80(e)
(g)
0.82
0.15
ND
ND
0.05
1.80
1.00
0.17
0.23
2.40
inches.
atile organics,
ate samplings on
Data from additional EP Tox and TCLP tests as presented in Appendix G
Nn £? 3Hd PtrOPKSed- TCLP tox1city Characteristic standard Is 5 mg/L
No data due to broken sample container.
89
-------
6 5 2 Mobility of Heavy Metals - EP Tox and Proposed TCLP
Toxicity Characteristic Standards
The results of the EP Tox and TCLP tests conducted on the feed,
furnace ash, and scrubber water were below the EP Tox and
e^d is no at.
thermal treatment.
6.6 DESTRUCTION AND REMOVAL EFFICIENCY (ORE) OF PCBs
The Phase I Runs 1-3 were designed to operate for a suffi-
balance of PCBs during these runs.
The. PPR analyses performed on the feed indicated detectable but
l«.J-th"-«pUtSdrpCB Uvehs based on the "-
ees P o o
comoared to the analyses of the feed employed during Runs 1-3,
which varied from VzOO ng/g to 35,200 ng/g as shown on Table
15 These low-feed PCB concentrations contributed to stack gas
PCB cJSclntra?ions that were less than th%a^1/tf^alRlJJe]eCtl °n
limit for Runs 1 and 2 and minimally detectable for Run 3.
However! the PCBs were destroyed and not found in the furnace
ash or the stack gas.
? ! ' IS
s s •:! his?
UEIo^co^^t^ln^rat^^ha/l^rretroa SIS
a hSmogeneSus waste feed source, the results discussed above
did not confirm our expectations.
In order to provide the most conservative ORE values, the
detectable levels of PCBs in the feed along with the sum of the
an
90
-------
detection limits for each PCB congener in the stack gas (as
reported in Appendix B) were employed. ORE levels for PCBs
during the Phase I runs were calculated based on the above
?uan In1n«-,and ra"9ed from greater than 99.9922% to greater
than 99.9976%, as shown in Table 15.
With a RCRA ORE standard of 99.99%, the runs indicated ORE
levels in excess of the RCRA standard. In order
the unit's ability to meet
99.9999%, the feed
to have proved
or exceed the TSCA ORE standard of
required higher PCB concentrations.
For Run 3, where a detectable PCB concentration in the stack
gas also was obtained, a ORE of 99.9982% was calculated This
value, however, may be suspect because of apparent concentra-
tions of similar PCB congeners in a reagent blank. Thus the
detectable PCB concentration in 'the stack gas may have been the
result of contamination during analysis.
The Phase I runs indicated ORE levels in excess of the RCRA
standard of 99.99% Based on the operating and sampling and
3 ifnnn a*a' ^ feed required a PCB concentration exceed-
ing 1000 ppm in order to calculate a ORE of 99.9999%. With an
average PCB concentration of 626 ppm in the ten-sector compos-
ite sample and actual PCB concentrations ranging from 10 2 to
35.2 ppm during Runs 1-3, as discussed above, the waste feed
required spiking with additional PCB material to the 1000 ppm
concentration level in order to have ensured a unit operation
that would have met the TSCA ORE standard of 99.9999%. ;
was
MnnnnH- p
(Appendix C)
di?9ussions concerning the ORE calculations
anallcal me™°<* employed for the determina-
H-°n5 1n.,the feed and stack 9as samples
Aas + d.(rfined and aPProved in the program's QAPP
At this time, however, it appears that the two
nH MfthnHa«n«analytlCal meth°ds for measuring PCBs, Method 680
and Method 8080 may not be adequate for a treatment process
involving thermal destruction of PCBs, such as the tested
Shirco technology. Method 680 presents difficulties with
detection limits .for individual PCB congeners, and Method 8080
is not applicable to samples that have had their Arochlor
patterns altered due to thermal treatment. Without a specific
PCB analytical procedure to follow, Method 680 was employed and
conservative ORE values were obtained utilizing the resulting
analytical data and a defined calculation method, as discussed
aDove.
91
-------
TABLE 15. DESTRUCTION AND REMOVAL EFFICIENCY OF.PCBs
Date
(Time)
PCB concentration
in waste feed
Ufl<:te feedrate (q/hr)
1
11/3/87
(1228-1800)
10200
30178
Run
2
11/4/87
(1608-1924)
35200
33163
No.
3(a) :
11/5/87
(0938-1330)
20400
35113
3(b)
11/5/87
(0938-1330)
20400
35113
PCB Mass feedrate
(ng/hr x 10a)
PCB concentration in
stack gas (ng/nr)
Stack gas flowrate
(dscmm)
PCB mass emission rate
(ng/hr x 104)
ORE (%)
3.078
3.60
<2.391
>99.9922
11.673
<142.9
3.26
<2.795
>99.9976
7.163
<177.5
3.14
<3.344
>99.9953
7.163
68.0
3.14
1.281
99.9982
(a) Calculated ORE for Run 3 based on the sum of the detection limits
for each PCB congener in the stack gas. This calculated DRt is
consistent with the ORE calculation method for Runs 1 and 2,,
(b) Calculated ORE for Run 3 based on a detectable PCB concentration in
the stack gas.
92
-------
6.7 OTHER ORGANIC STACK GAS AND PCC OFFGAS EMISSIONS
The results of the analyses of the stack gas and PCC offgas
samples obtained from the SASS and VOST sampling trains during
the Phase I runs are presented in Appendix B and summarized in
Table 16. Highlights of these results are as follows:
o Several volatile and semivolatile organic compounds were
detected in the stack gas at concentrations less than 100
ppb and below established standards for direct inhalation.
o Low levels of several phthalate compounds were also detected
in blank samples and may be traced to contamination from
process, sampling equipment, or
plastic components in the
laboratory apparatus.
o Several volatile organic compounds including benzene and
toluene were detected in the stack gas and the scrubber
makeup water and may be attributable to contamination from
the makeup water, although PIC formation is a possibility.
o Other volatile and semivolatile organic compounds, which
probably represent PICs, were detected. They include
halomethanes; chlorinated species including chlorobenzene
and methylene chloride; volatile organics including xylenes,
styrene and ethyl benzene; oxygenated hydrocarbons including
acetone and acrolein; carbon disulfide; and
p-chloro-m-cresol.
Dioxins and
samp!es.
furans were not detected in the stack gas
o The majority of the organic compounds present in the PCC
offgas samples at levels less than 500 ppb were also present
in the stack gas. The additional destruction and removal of
organics that takes place in the SCC and emissions scrubbing
systems reduced the concentration of these organic compounds
in the corresponding stack gas samples.
6.8 ACID GAS REMOVAL
The concentration
the EPA Method 5
1-3. During Run
results were obta
additional set of
was obtained from
taken during each
EPA Method 5 and
and summarized in
fol1ows:
of HC1 in the stack gas was measured during
sampling conducted during the Phase I Runs
2, the sampling train malfunctioned and no
ined. Run 1-2 was conducted to obtain the
data. The chlorine concentration in the feed
the ultimate analyses of the feed samples
of the runs. The complete results of these
ultimate analyses are reported in Appendix B
Table 17. Highlights of these results are as
93
-------
TABLE 16. PCC OFFGAS AND STACK GAS ORGANIC EMISSIONS
Average Concentration*
PCC Offgas Stack Gas
ppb
Semivolatile oraanics,
Benzole acid
Bis(2-ethylhexyl)phthalate
p-Chloro-m-cresol
Diethylphthalate
Di-n-butylphthalate
ppb
Volatile orqanics,
Acetone
Acrolein
Benzene
Bromomethane
2-Butanone
Carbon di sulfide
Carbon tetrachloride
Chlorobenzene
Chloroform
Chloromethane . . .
l,4-Dichloro-2-butene
Ethyl benzene
lodomethane
Methylene chloride
Styrene
Tetrachloroethene ....
To!uene
1,1,1-Trichloroethane
Trichlorofluoromethane
Vinyl chloride
Xylenes
2.5
2.0
1.4
24.0
4.4
7
86
200
4
2
2
0
10
0
74
6
5
16
6
12
0
34
0
1
4
3
.9
.7
.0
.7
.6
.6
.4
.4
.7
.7
.6
.7
.6
,6
.5
.2
.2
.3
.2
.6
.3
6.5
2.4
9.1
9.3
4.7
4.0
16.0
0.7
9.3
0.2
1.4
0.1
8.3
0.4
2.3
14.4
3.7
0.3
1.3
0.2
0.2
0.7
* Average values shown represent the
Values below detection limits were
at the detection limit.
average of all data.
included in the average
94
-------
TABLE 17. ACID GAS REMOVAL EFFICIENCY
Date
Time 16
Stack gas flowrate (dscfm)
HC1 cone, (ppmv)
HC1 emission rate (g/hr)
Waste feedrate (g/hr)
Ultimate analysis
waste feed (wt% Cl)
HC1 to scrubber (g/hr)
HC1 removal efficiency (wt%)
1
11/3/87
:30-17:50
139
0.4
0.181
30178
0.09
27.93
99.35
Run No.
3
11/5/87 ,;
13:01-13:54
119
2.0
0.590
35113
0.09
32.49
98.18
: ======
1-2*
11/6/87
10:57-12:55
132
3.0
0.998
31856
0.11
36.03
97.23
------ _ _ . . vt M vwil^vlWV^-tVit W V III Vl l\ G ' M is I \J I
EPA Method 5 sampling run for Run 2.
95
-------
Based on measured stack gas flowrates and HC1 concentra-
tions, HC1 emission rates were calculated and ranged from
0 181 to 0.998 g/hr. These values are below the RCRA per-
formance standard of 1.8 kg/hr (1800 g/hr) of HC1 or a 99
wt% removal efficiency.
Based on
trations
flowrate
the ultimate analyses of the feed, chlorine concen-
ranged from 0.09 to 0.11 wt%, equivalent to an HC1
to the scrubber ranging from 27.93 to 36.03 g/hr.
From the above, calculated HC1 or acid gas
cies ranged from 97.23 to 99.35 wt%.
removal efficien-
o With the HC1 emissions rate being below the RCRA performance
standard and the scrubber water being maintained at a
neutral pH of 7.25-8.65 with no caustic addition, the unit
satisfactorily met acid gas removal requirements and dis-
played sufficient capacity to process higher acid gas
loadings.
The impinger train of the EPA Method 5 runs was not analyzed
for sulfate to determine the concentration of SOo in the
stack qas; therefore, SOo removal efficiency could not, be
calculated. For the Phase I tests, sulfur concentrations in
the waste feed were less than 0.01 wt% as presented in Appendix
B. At these low levels, total S02 flows and loadings on the
scrubber system were minimal. \
6.9 PARTICULATE EMISSIONS
Mass particulate loadings in the stack were measured ;during the
EPA Method 5 sampling conducted during the test program. The
results are reported in Appendix B and summarized ,in Tab! e 18.
The data indicate that for the entire demonstration, particu-
late emissions ranged from 7 to 69 mg/dscm, which is lower than
the RCRA standard of 180 mg/dscm and indicative of satisfactory
particulate emissions control at a conservative venturi pres-
sure drop of less than 20 inches WC.
10 ANALYSIS OF SCRUBBER MAKEUP WATER, SCRUBBER WATER,
SCRUBBER SOLIDS
AND
The results of the analyses of the samples of scrubber makeup
water, scrubber water, and scrubber solids taken durung the
test runs are reported in Appendix B and summarized in Tables
19 and 20. Highlights of these results are as follows:
o Scrubber makeup water was transported to the site in a tank
truck that may have contained some residual contamination
prior to fill up. Samples of scrubber makeup water were
taken at the end of each run. No PCBs, dioxins, furans, or
semivolatile organic compounds were detected. Several
96
-------
TABLE 18. PARTICULATE EMISSIONS
Run
No.
1
2
1-2*
10
14
5
6
8
15
18
7
9
11
13
16
17
19
Date
11/03/87
11/05/87
11/06/87
11/09/87
11/09/87
11/09/87
11/10/87
11/10/87
11/10/87
11/10/87
11/11/87
11/11/87
11/11/87
11/11/87
11/12/87
11/12/87
11/13/87
Stack Gas
Fl owrate
Time (dscfm)
1630-1750
1301-1354
1057-1255
1936-1036
1126-1226
1346-1446
0931-1031
1121-1221
1313-1413
1508-1608
0904-1004
1132-1422
1322-1422
1511-1611
1028-1128
1235-1335
1010-1110
139
119
132
131
122
120
127
119
99
136
140
129
100
109
125
109
112
Oxygen
Content
(wt%)
8.5
9.8
7.2
!10.7
12;3
7.5
8.6
8.3
9.8
11.1
8.9
9.8
9.2
9.0
9.0
11.4
9.3
Participate Emissions
Concentration
Measured
(gr/dscf)
0.0093
0.024
0.015
0.0061
0.0042
0.0048
0.0045
0.0029
0.0035
0.0028
0.0073
0.0082
0.0078
0.0078
0.0071
0.0055
0.0055
7% 02 7% 0?
(gr/dscf) (mg/dscm)
0.010
0.030
0.015
0.0083
0.0068
0.0050
0.0051
0.0032
0.0044
0.0040
0.0084
0.0100
0.0093
0.0091
0.0083
0.0080
0.0066
23
69
34
19
16
11
12
7
10
9
19
23
21
21
19
18
15
* Run 1-2 was conducted to make up for incomplete samplings on
Runs 1 and 2, that include the particulate sampling for Run 2.
97
-------
volatile organics including benzene, toluene, and trichloro-
ethene were measured at concentrations less than 15 ppm.
The concentrations of heavy metals were all less than 0.2
ppm. Scrubber makeup water was also analyzed for pH, total
suspended solids (TSS), total dissolved solids (IDS),
chloride, and total organic carbon (TOC). Average values
were 7.94 pH, 0.12 mg/L TSS, 339 mg/L TDS, 25.7 mg/L
chlorides, and 2.3 mg/L TOC.
o Samples of the water recirculation through the venturi
scrubber system, referred to as scrubber water, were also
taken at the end of each run. PCB concentrations were less
than 200 ppt and no dioxins, furans, or semivolatile organic
compounds were detected. Small quantities of benzene (2 ppm)
and toluene (5.7 to 11 ppm) were measured in several of the
samples and are attributable to the similar contaminants in
the scrubber makeup water. The concentrations of heavy
metals in the scrubber water were all less than 1 ppm except
for barium, which ranged from 0.2 to 2.2 ppm, and lead,
which ranged from 0.12 to 1.8 ppm. Scrubber water was also
analyzed for pH, TSS, TDS, chloride, and TOC. Average
values were 7.7i pH, 116.1 mg/L TSS, 1272 mg/L TDS 6309
mg/L chlorides, and 2.7 mg/L TOC. A comparison of the high
TSS, TDS, and chloride values as compared to the scrubber
makeup water illustrate the effect of the venturi scrubber
system on removing particulate carryover from the vapor
stream prior to its exit at the stack. . ,
o Insufficient quantities of scrubber solids in the scrubber
water were available for representative analyses.
6.11 OVERALL DISPOSITION OF METALS ,
Total metals analyses were conducted on samples from each of
the test runs of the feed, furnace ash, scrubber makeup water,
and scrubber water. Metals analyses on the scrubber sol ids
were incomplete and suspended due to the small quantity of
recoverable solids.
Total metals analyses were also conducted on the particulate
material and probe and nozzle washes collected on the EPA
Method 5 sampling trains from the PCC offgas and stack gas
streams during Phase I Runs 1, 3, and 1-2. Run 1-2 was con-
ducted to make up for incomplete samplings during Runs 1 and 2
and, in particular, the malfunctioned EPA Method 5 sampling
during Run 2.
The results of these analyses are reported in Appendix B and
summarized in preceding tables. An overall mass balance of
lead through the unit and a breakdown of the calculated lead
concentration in the feed, furnace ash, and PCC offgas and
stack gas particulates, is summarized in Tables 21 and 22.
Highlights of these results are as follows:
98
-------
TABLE 19, SCRUBBER MAKEUP WATER ANALYSIS
Characterization
Organi cs
Metals
Range Tc) Average (d)
pH ..:...
TSS, mg/L
TDS, mg/L ............
Cl , mg/L . .
TOC, mg/L
7 O.R
0'
. . . . 3 n fi
. . . . 2 4 ft
:• . . < 1
Q ^ O
- p . oo
n 8 A
U . OH
- 7fiK
J 0 0
- 9fi Q
£. D . y
- fi
. 94
. 1 2
O O rt
do 9
0 C 7
dO . /
9 •?
Total PCBs, ppt
Total PCDD/PCDF, ppt ...!!!!."'.'.'.*•
Semivolatiles, ppb ;.!.'
Volatiles, ppm '
Benzene
Tol uene <
Trichloroethene . .' <
ND (a)
ND (a)
ND (a)
2.0
2.0
2.0
13.0
5.3
7.1
All metals concentrations less than 0.2 ppm.
ND (a)
ND (a)
ND (a)
6.3
3.2
3.7
(a) ND indicates not detected or less than detection limits
which vary for each PCB congener, PCDD/PCDF homolog, and
organic compound. a
(b) < indicates ND at detectionlimit (as indicated).
(c) Range values shown represent all data.
(d) Average values shown represent the average of all data
' average
99
-------
TABLE 20. SCRUBBER WATER ANALYSIS
Range (c) Averaae (d)
Characterization
nu 6.19 - 8.65 7.71
TSS 'mq/L*"". '.'.'.'.'. '.'.'.'. '•'• 49.4 - 557 : ,116.1
TDS mq/L 722 - 2653 1272
c??'•;?( .::::.... -513.7 - 575.3 *3o.9
TOC, mg/L < 1 - 6 Z *'
Oraanics
Total PCBs, ppt ND (a) ND (a)
Total PCDD/PCDF, ppt ND a ND a
Semivolatiles, ppb ND .(a) ND(a)
Volatiles, ppm r • •
Benzene • < 2.0 - 2.0 z.o
Toluene < 2.0 - 11.0 6.2
Metals, ppm
Barium 0.2 - ,2.2 0.8
Barium n 19 10 n?
|_ea(j O.lt - l.o u./
All other metals concentrations less than 1,ppm and,average
concentrations less than 0.3 ppm.
fa) ND indicates not detected or less than detection limits
which vary for each PCB congener, PCDD/PCDF homolog, and
organic compound.
(b) < indicates ND at,detection limit (as indicated).
(c) Range values shown represent all data. :
(d) Average values shown represent the average of all data.
Values below detection limits were included in the average
at the detection limit.
100
-------
The data indicate that a
of the heavy metals that
with the furnace ash.
high concentration of the majority
enter the unit with the feed remain
An overall mass balance of lead through the unit was calcu-
lated based on the analysis of lead in the samples, the
measured fe.ed.rate as weighed during the runs' operating
periods, -the calculated furnace ash flow based on the ulti-
mate analysis of ash in the feed sample, and the measured
particle mass and gas volume obtained from the Method 5
sampling trains. The balance shows that the majority of the
lead entering the unit with the feed also remained with the
Phase I results indicate an average lead mass flowrate of
n,t • r».innJ>e f!ed) 37'° g/hr in the furnace ash, 0.206
g/nr in the PCC offgas parti cul ates , and 0.109 g/hr in the
stack gas particulates. The quantity of lead leaving the
unit with scrubber water effluent is approximately 01204
g/hr based on the maximum measured concentration of 1 8 ppm
Howrate^f 30rUber ^^ ^ *" overa11 approximate 'water
In contrast to the high mass flowrates of lead in the feed
and furnace ash as compared to the particul ates , the PCC off
gas particulates sampled during the Phase I runs contained
an average of 5364 ppm of lead and the stack gas particu
lates contained an average of 15,830 ppm of lead. By
?S£nrn™' ^fjjverage concentration of lead in the feed was
1550 ppm. Although the concentration of lead in the
particulate matter increases as the process flow progresses
through the unit, the actual mass flow of lead decreases as
the gas stream is cooled and treated through the emissions
contro I system .
rnnrf JhJSe * i™"? samPlin9 and analysis procedures were
conducted to evaluate vaporous lead concentrations in the
rut orrgas and soluble chromium concentrations in the PCC
offgas and stack gas particulates. The special sampling for
vapor phase lead and soluble chromium were unable to detect
any of either metal 'at levels less than 2.7 ppb and 264 ppb
respectively; -therefore, the evaluations were inconclusive
Other heavy metals, particularly barium and zinc, with aver-
age concentrations exceeding 100 ppm in the feed (barium 591
ppm, zinc 301 ppm) were also present in high concentrations
inli in6 to.othernheavy metals, in the furnace ash (barium
1061 ppm, zinc 410 ppm) and scrubber water (barium 0 8 DDm
zinc 0.3 ppm) . r K '
101
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TABLE 21. LEAD FLOWS THROUGH THE SYSTEM
Test
1
3
1-2*
2
10
14
5
6
8
15
18
7
9
11
13
16
17
1 Q
j. y
Averaqe
Feed
g/hr
90.6
19.3
35.1
46.5
22.9
37.7
22.1
36.2
27.2
16.8
21.4
32.1
16.9
20.4
18.8
8.6
21.0
15 6
jL */ • \y
28.3
PCC Stack
Ash particulates participates
g/hr g/hr g/hr
28.7 0.039 0.122
32.1 0.278 0.098
11.2 0.302 0.108
36.0
33.4 ..-.•;
36.5
39.4
34.8
35.8
37.2
29.8
73.4
29.5 ,
33.5 .
67.3 .-..'.
21.2
37.4
49.0
37.0 0,206 0.109
Run 1-2 was conducted to make up for incomplete samplings
on Runs 1 and 2 that include the PCC offgas and stack gas
particulate sampling for Run 2.
102
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TABLE 22. LEAD CONCENTRATIONS IN FEED, ASH, AND PARTICULATES
Test
Feed
ppm
Ash
ppm
PCC
particulates
ppm
Stack
particul.ates
PPm
1
3
1-2*
Average
3000
550
1100
1550
1100
1100
420
873
3939
6114
6040
5364
24493
8990
14017
15830
Run 1-2 was conducted to make up
on Runs 1 and 2 that include the
particulate sampling for Run 2.
for incomplete
PCC offgas and
samplings
stack gas
6.12 OPTIMUM OPERATING CONDITIONS
Phase II was designed to examine over varying operating
conditions the energy consumption and changes in the residual
leve s of heavy metals and organics in the furnace ash versus
tne levels in the feed.
Based
the
of
8 rspr??nn & S"? f? cSn * umP J } on dat* Presented in Tables 7 a-nti
8 (Section 4.2.3.2), Table 23 presents a comparative summary
power and energy consumption of the unit at varied
0"!'!!!?* 51? n0t affect the Performance1 of the
of this data are as follows:
uit
unit
° ' - r°n n tne PCC operating
temperature from
power usage 48%
1600°F
from'
° J r?o^0r°n !n the SCC operating temperature from 2200°F
The use of 3 wt% fuel oil to supplement the heating value of
the feed further decreased PCC power usage by 26% to 67% at
PCC operating temperatures of 1600°F and 1200°F respec-
y h accomPanying increases in overall feedrate of
103
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o Based on the data presented in Table 11 (Section 6 2) the
addition of the fuel oil increased the average HHV of the
feed from 210 to 588 Btu/lb, This increase in heating value
is equivalent to a savings of 0.11 kwhr/lb feed. Based on
the data presented in Table 23, reductions or savings in
power when fuel oil was added to the feed were 0.07 and 0.09
kwhr/lb feed, which closely approximates the calculated
value of 0.11 kwhr/lb feed based on heating value.
o The costs for fuel oil and its attendant facilities still
must be examined for specific applications to determine the
cost effectiveness of a fuel oil additive to the feed. The
cost of power, the moisture content of the feed, the total
heating value of the feed, PCC residence time, and the
overall PCC design heating input will all impact on the
necessity for and the quantity of the addition of fuel oil
to the feed.
As discussed in previous sections, the results did not provide
any trend or change in the residual levels of the heavy metals
and organics in the furnace ash versus the levels in the feed
as the operating conditions were varied and PCC operating tem-
peratures were maintained at 1200° to 1600°F. At an abnormally
low PCC operating temperature of 900°F, without the input of
combustion air to simulate non-oxidizing or pyrolytic combustion
conditions, total PCB and TCDF concentrations in the furnace ash
increased. The increases may indicate that these PCC conditions
led to incomplete desorption or incineration of PCB and TCDF and to
the production of TCDF from the incomplete combustion of PCBs in
the feed.
6.13 QA SUMMARY
The Phase I and II runs had a we!1-defined quality assurance/
Quality control program to ensure the collection of accurate data.
This program was developed as part of the test program preparation
activities and was formalized in the RREL-approved QA Project Plan
(Category II). All of the sampling and analytical work was
conducted in accordance with this QA Project Plan, and the results
include data quality credibility statements and information that
confirm the satisfactory precision and accuracy of the data
reported.
Overall, the QA/QC data indicate that the measurement data are
acceptable and defensible. Samples were analyzed for PCBs, dioxins
and furans, volatiles, semivolatiles, metals, TCLP extracts
(volatiles, semivolatiles, and metals), EP extract metals, chloride
in filters, hexavalent chromium, total organic carbon, and solids
characterization. The most significant problems noted, from a
QA/QC standpoint, were that the analyses for PCBs and semiyolat-1les
were not carried out within the holding time specified by the QAPP
and selenium was not recovered in the matrix spike samples for
solids, TCLP and EP extracts, and filters.
104
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TABLE 23. OPTIMUM OPERATING CONDITIONS - ENERGY CONSUMPTION
Run
No.
1
2
3
1-2
7
Avg
Feed'-.'
rate
(Ib/hr)
66.53
73.11
77.41
70.23
114.10
80.28
1600°
PCC temp.
power
(kwhr/lb feed)
0.2975
0.2495
0.2497
0.2919
0.1827
0.2543
w/fuel oil
6
8
19 .,
Avg
110.77
120.00
88.29
106.35
Overal 1
0.1914
0.1367
0.2356
0.1879
Avg 0.2294
2200°F
SCC temp.
Propane fuel
(Btu/lb feed)
4458
3914
4560
3847
3210
'
3997
1800° SCC
1819
1608
2428
1952
Run
No.
10
14
9
11
13
Avg
Feed-
rate
(Ib/hr)
78.68
95.41
62.95
73.85
88.29
79.84
1200°F
PCC temp.
power
(kwhr/lb feed)
0.1913
0.1608
0.1360
0.0678
0.1189
0.1350
w/fuel oil
15
Avg
100.33
100.33
Overal 1
0.0451
0 0451
Avg 0.1200
105
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Analyses of solid, liquid, and filter samples for PCBs met most
of the specifications in the QAPP, except for holding time
Blank recoveries were acceptable for all matrices. Surrogate
spike recoveries tended to be low for feed, higher weight PCBs
in liquids, and ambient air filters. Recoveries were generally
low for matrix spike/matrix spike duplicate compounds for fur-
nace ash, scrubber makeup water, and the filter blank sample.
Repeatability of the matrix spike/matrix spike duplicate
samples was excellent except for one sample of scrubber makeup
water? Recovery for the other sample of scrubber makeup water
was within specifications.
sp;ike compounds
are probably
Low recoveries for the PCB surrogate and matrix
suggest that reported results for field samples
lower than the true concentrations.
Analyses of dioxins and furans .in solid and 1 }j|"^j"mPrl
most of the acceptance criteria specified in the QAPP. Blank
sample analyses showed no contamination from analytical
sources. Although surrogate recoveries were low for the higher
molecular weight .dioxins, and furans for both types of matrices-,
none of the native dioxins and furans were detected-in field
samples. Surrogates were recovered at about 30% which suggests
that actual field sample concentrations are probably no greater
than about three times the laboratory-stated detect!on- limit.
Repeatability for the compounds reported in two pairs ot
duplicates was excellent.
Quality control data for volatiles in solids, liquids, VOST
samples, and TCLP extracts showed no significant problems in
these analyses. Some common laboratory contaminants (methyl
ethyl ketone, l,2-dibromo-3-chloropropane, and xylene.s) were
detected in more than one blank analyzed with the solid
samples. None of these compounds should be considered a sig-
nificant contaminant since they were detected at less than five
times the method detection limit. Recoveries of surrogate
spike and matrix spike compounds was excellent for all four
matrix types.
No quality control problems were detected with the se'mivol atile
analyses except for the holding time violation. Surrogate and
matrix spike recoveries are acceptable for almost all com-
pounds. Surrogate recovery was low for 2-fluorophenyl in TCLP
extracts of feed and furnace ash samples. This may have been
due to exceeded holding time; however, recovery of the other
five surrogate compounds was acceptable.
Analyses of metals were performed on solids, liquids,, TCLP and
EP extracts, and filter samples. Several elements (arsenic,
barium, beryllium, cadmium, chromium, copper,
vanadium, and zinc) were detected in the . ulani,
However, only one element (barium), in one blank
recovered at greater than five times the detection
lead, silver,
blanks above the detec-
tion limit.
sample, was
106
-------
ike
the data.
,
q
1
s and Inavr,..
^^
,
ny control. No problems were detected in
* U.S. GOVERNMENT PRINTING OFFICE: 1989-648-163/87097
107
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