vyEPA
United States
Environmental Protection
Agency
Research and
Development
(RD681)
EPA/540/AR-92/017
August 1992
Babcock & Wilcox
Cyclone Furnace Vitrification
Technology
Applications Analysis Report
SUPERFUND INNOVATIVE
TECHNOLOGY EVALUATION
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EPA/540/AR-92/017
August 1992
Babcock & Wilcox Cyclone Furnace
Vitrification Technology
Applications Analysis Report
Risk Reduction Engineering Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, Ohio 45268
Printed on Recycled Paper
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Notice
The information in this document has been funded by the U.S. Environmental Protection Agency (EPA) under the
auspices of the Superfund Innovative Technology Evaluation (SITE) Program under Contract No. 68-CO-0048 to Science
Applications International Corporation (SAIC). 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 Innovative Technology Evaluation (SITE) Program was authorized in the 1986 Superfund Amendments.
The Program is a joint effort between EPA's Office of Research and Development and Office of Solid Waste and Emergency
Response. The purpose of the program is to enhance the development of hazardous waste treatment technologies necessary
for implementing new cleanup standards that require greater reliance on permanent remedies. This is accomplished by
performing technology demonstrations designed to provide engineering and economic data on selected technologies.
This project consists of an analysis of the Babcock & Wilcox (B&W) Cyclone Furnace Vitrification Technology. The
Demonstration Test took place at the B abcock & Wilcox Research and Development pilot facility located in Alliance, Ohio.
The goals of the study, summarized in this Applications Analysis Report, are: 1) to evaluate the technical effectiveness and
economics of this technology relative to its ability to treat soils contaminated with heavy metals, radionuclides, and
organics; and 2) to establish the potential applicability of the process to other wastes and Superfund sites. The primary
technical objective of this project is to determine the ability of the process to produce a non-leachable vitrified material that
immobilizes heavy metals and radionuclides. The process is also being evaluated for its ability to destroy any organic
contaminants present in the Synthetic Soil Matrix (SSM).
Additional copies of this report may be obtained at no charge from the 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 Building, Springfield, Virginia, 22161 (703) 487-4650. Reference copies will be available in the
Hazardous Waste Collection at EPA libraries.
E. Timothy Oppelt, Director
Risk Reduction Engineering Laboratory
111
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Abstract
This document is an evaluation of the performance of the Babcock & Wilcox (B&W) Cyclone Furnace Vitrification
Technology and its applicability as a treatment technique for soils contaminated with heavy metals, radionuclides, and
organics. Both the technical and economic aspects of the technology were examined.
A demonstration of the B&W vitrification technology was conducted in the fall of 1991 using B&W's pilot-scale unit
located at its Alliance Research Center in Alliance, Ohio. Operational data and sampling and analysis information were
carefully compiled to establish a database against which other available data, as well as the vendor's claims for the
technology, could be compared and evaluated. Conclusions concerning the technology's suitability for use in immobilizing
metal and radionuclides in soils as well as destroying organic contaminants were reached. Extrapolations regarding
applications to different contaminants and soil types were made.
The following conclusions were derived primarily from the Demonstration Test results and supported by other available
data: (1) the treated soil did not leach any metals at levels above the regulatory limits; (2) the process achieved a
Destruction and Removal Efficiency (DRE) of greater than 99.99 percent for each Principal Organic Hazardous
Constituent (POHC); (3) particulate emissions were below the regulatory limit; (4) the non-volatile metals were retained
in the slag; and (5) simulated radionuclides were immobilized.
IV
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Contents
Section
Notice ii
Foreword iii
Abstract iv
Contents v
Tables viii
Figure x
Abbreviations xi
Acknowledgments xiii
1. Executive Summary 1
1.1 Introduction 1
1.2 Conclusions 1
1.3 Results 1
2. Introduction 3
2.1 The SITE Program 3
2.2 SITE Program Reports 3
2.3 Key Contacts 4
3. Technology Applications Analysis 5
3.1 Introduction 5
3.2 Conclusions 5
3.3 Technology Evaluation 5
3.3.1 Slag Characteristics 6
3.3.2 Metals Partitioning 7
3.3.3 Air Emissions 8
3.3.4 . Quench Water 9
3.4 Ranges of Site Characteristics Suitable for the Technology 10
3.4.1 Site Selection 10
3.4.2 Surface, Subsurface, and Clearance Requirements 10
3.4.3 Topographical Characteristics 10
3.4.4 Site Area Requirements 10
3.4.5 Climate Characteristics 10
3.4.6 Geological Characteristics 10
3.4.7 Utility Requirements 10
3.4.8 Size of Operation . 11
3.5 Applicable Media 11
3.6 Regulatory Requirements 11
3.6.1 Federal EPA Regulations 12
3.6.2 State and Local Regulations 14
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Contents (Continued)
3.7 Personnel Issues 14
3.7.1 Training 14
3.7.2 Health and Safety 14
3.7.3 Emergency Response 14
3.8 References ; 14
4. Economic Analysis 15
4.1 Introduction 15
4.2 Conclusions 15
4.3 Issues and Assumptions 15
4.3.1 Costs Excluded from Estimate 15
4.3.2 Maximizing Treatment Rate 16
4.3.3 Utilities ...... 16
4.3.4 Operating Times 16
4.3.5 Labor Requirements 16
4.3.6 Capital Costs 16
4.3.7 Equipment and Fixed Costs 16
4.4 Basis of Economic Analysis 16
4.4.1 Site Preparation Costs 17
4.4.2 Permitting and Regulatory Costs 17
4.4.3 Equipment Costs 17
4.4.4 Startup and Fixed Costs 18
4.4.5 Labor Costs 18
4.4.6 Supplies Costs 19
4.4.7 Consumables Costs 19
4.4.8 Effluent Treatment and Disposal Costs 19
4.4.9 Residuals and Waste Shipping, Handling, and Transport Costs 19
4.4.10 Analytical Costs 19
4.4.11 Facility Modification, Repair, and Replacement Costs 19
4.4.12 Site Demobilization Costs , 20
4.5 Results of Economic Analysis 20
4.6 References 22
Appendix A-Process Description 23
A.I Introduction 23
A.2 The Cyclone Furnace 23
Appendix B - Vendor's Claims 25
B.I Site Demonstration Vendor's Claims 25
B.2 Comparison of Performance Results from the Two SITE Emerging Technologies Projects
with the Vendor's Claims 25
B.2.1 Synthetic Soil Matrix and Feed Conditions 25
B.2.2 Performance Results 26
B.3 Comparison of Performance Results from the SITE Demonstration with the Vendor's Claims 26
B.3.1 Synthetic Soil Matrix and Feed Conditions 26
B.3.2 Performance Results 26
B.4 Summary 27
B.5 Reference 27
VI
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Contents (Continued)
Appendix C - SITE Demonstration Results 28
C.I Introduction 28
C.2 Slag Characteristics 28
C.2.1 Leachability 28
C.2.2 Volume Reduction 29
C.3 Metals Partitioning.... 30
C.4 Air Emissions 31
C.4.1 Particulate 31
C.4.2 DRE 31
0.4.3 PICs ! 31
0.4.4 CEMs 32
C.5 Quench Water 32
Appendix D - Case Studies 33
D.I Municipal Solid Waste, (MSW) Ash Testing 33
D.2 Emerging Technologies Testing 33
D.2.1 Introduction 33
D.2.2 Phase I 33
D.2.3 Phase II 34
VII
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Tables
Number Page
1 B&W SITE Demonstration Test Results and Potential Incineration ARARs 2
2 Total Concentrations of Spiked Components Measured in the SSM 6
3 Total Concentrations of Spiked Components Measured in the Slag 6
4 TCLP Results 7
5 Metals Partitioning from the Cyclone Vitrification Process 8
6 Summary of Particulate Emissions 8
7 Excavation Costs 17
8 Treatment Costs for 3.3 tph Cyclone Furnace Vitrification System
Treating 20,000 Tons of Contaminated Soil 20
9 Treatment Costs as Percentages of Total Costs for 3.3 tph Cyclone Furnace
Treating 20,000 Tons of Contaminated Soil 20
10 Treatment Costs for 3.3 tph Cyclone Furnace Vitrification System
Operating with a 60% Online Factor 21
11 Treatment Costs as % of Total Costs for 3.3 tph Cyclone Furnace Vitrification
System Operating with a 60% Online Factor 22
12 Treatment Costs for the Remediation of 100,000 Tons of Contaminated Soil Using
Cyclone Furnace Vitrification System Operating with a 60% Online Factor 22
13 Treatment Costs as Percentages of Total Costs for Cyclone Furnaces
Treating 100,000 Tons of Contaminated Soil 22
B-l B&W Claims for Cyclone Vitrification Technology 25
B-2 Phase I & Phase n Performance vs. Vendor Claims 26
B-3 SITE Demonstration Performance vs. Vendor Claims 26
C-l Averages TCLP Results from B&W SITE Demonstration Runs 29
C-2 Percent of Leachable Metals from B&W Cyclone Furnace 29
vm
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Tables (Continued)
C-3 Leachability Index of Simulated Radionuclides
C-4 Volume Reduction
C-5 Summary of Metals Emissions
C-6 DREs
C-7 Summary of Volatile Organic Concentrations in Stack Gas from B&W SITE Demonstration
C-8 Summary of NOX, CO, and THC CEM Data
C-9 Summary of CO2 and O2 CEM Data
C-10 Quench Water from B&W SITE Demonstration
D-l Total Metals in Soil, Slag, and Multiple Metals Train Particulates
29
30
30
31
31
32
32
32
34
IX
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Figure
Number
A-l Cyclone Test Facility 23
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Abbreviations
AAR Applications Analysis Report
ANS American Nuclear Society
ARAR Applicable or Relevant and Appropriate
Requirements
ASTM American Society for Testing and Materials
B&W Babcock and Wilcox
CAA Clean Air Act
CEM Continuous Emission Monitor
CERCLA Comprehensive Environmental Response,
Compensation, and Liability Act
CO Carbon Monoxide
CO2 Carbon Dioxide
CPR Cardiopulmonary Resuscitation
CWA Clean Water Act
DOD U.S. Department of Defense
DOE U.S. Department of Energy
DRE Destruction and Removal Efficiency
EPA Environmental Protection Agency
gr/dscf grains per dry standard cubic foot
gpm gallons per minute
MSW Municipal Solid Waste
NPDES National Pollutant Discharge Elimination
System
NOX Nitrogen Oxides
O2 Oxygen
ORD Office of Research and Development
OSHA Occupational Safety and Health Act
OSWER Office of Solid Waste and Emergency
Response
PIC Products of Incomplete Combustion
POHC Principal Organic Hazardous Constituent
ppm parts per million
POTW Publicly-Owned Treatment Works
psig pounds per square inch gauge
RCRA Resource Conservation and Recovery Act
RREL Risk Reduction Engineering Laboratory
SARA Superfund Amendments & Reauthorization
Act
scf standard cubic feet
scfm standard cubic feet per minute
SDWA Safe Drinking Water Act
SITE Superfund Innovative Technology Evaluation
SSM Synthetic Soil Matrix
SVOC Semi-Volatile Organic Compounds
TCLP Toxicity Characteristic Leaching Procedure
XI
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Abbreviations (Continued)
TER Technology Evaluation Report
THC Total Hydrocarbons
tph tons per hour
tpd tons per day
TSD Treatment, Storage, and Disposal
VOC Volatile Organic Compounds
VOST Volatile Organic Sampling Train
xu
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Acknowledgments
This report was prepared under the direction and coordination of Ms. Laurel Staley, EPA Superfund Innovative
Technology Evaluation (SITE) Program Manager in the Risk Reduction Engineering Laboratory (RREL), Cincinnati,
Ohio. EPA-RREL contributors and reviewers for this report were Robert Stenburg, Randy Parker, and Kim Lisa
Kreiton. Babcock and Wilcox contributors and reviewers were Jean Czuczwa, Dan Rowley, Hamid Farzan, William
Musiol, James Warchol, and Stanley Vecci.
This report was prepared for EPA's SITE Program by the Technology Evaluation Division of Science Applications
International Corporation (SAIC) in Cincinnati, Ohio for the U.S. EPA under Contract No. 68-CO-0048. The Work
Assignment Manager for this project was Ms. Margaret M. Groeber.
xui
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Section 1
Executive Summary
1.1 Introduction
This report summarizes the findings of an evaluation of
the Cyclone Furnace Vitrification Technology developed
by Babcock & Wilcox (B&W). The study was conducted
under the Superfund Innovative Technology Evaluation
(SITE) Program. A Demonstration Test of the technology
was performed by U.S. Environmental Protection Agency
(EPA) as part of this program. The results of this test
and supporting data from other testing performed by
B&W constitute the basis for this report.
1.2 Conclusions
A number of conclusions may be drawn from the
evaluation of this innovative technology. The most
extensive data were obtained during the SITE Demon-
stration Test. Data from other testing activities have been
evaluated in relation to SITE Program objectives. The
conclusions drawn are:
• The slag produced complied with Toxicity
Characteristic Leaching Procedure (TCLP)
regulatory requirements for cadmium, chromium,
and lead.
• Ninety-four percent of the non-combustible
portion of the soil was incorporated within the
slag.
• Most of the non-volatile metals remained in the
slag. On the average, the percentages for
chromium, strontium, and zirconium retained in
the slag were 76, 88, and 97 percent, respectively.
Metals which partitioned to the flue gas were
captured by the baghouse.
• A volume reduction of 29 percent from the feed
Synthetic Soil Matrix (SSM) to the slag was
achieved on a dry weight basis.
Destruction and Removal Efficiencies (DREs)
for each Principal Organic Hazardous Consti-
tuent (POHC) were greater than 99.99 percent.
An average of 0.001 grains per dry standard cubic
foot (gr/dscf) of particulate (corrected to 7
percent O2) was emitted, which is less than the
Resources Conservation and Recovery Act
(RCRA) regulatory limit of 0.08 gr/dscf at 7
percent O2.
The simulated radionuclides were immobilized
within the slag according to American Nuclear
Society Method 16.1.
The process formed products of incomplete
combustion; however, concentrations were in the
parts per trillion range.
The cost to remediate 20,000 tons of
contaminated soil using a 3.3-ton per hour
cyclone furnace vitrification system is estimated
at $465 per ton if the system is online 80 percent
of the time or $529 per ton if the system is online
60 percent of the time.
1.3 Results
The objectives of this Applications Analysis are to assess
the ability of the process to comply with Applicable or
Relevant and Appropriate Requirements (ARARs) and to
estimate the cost of using this technology to remediate a
Superfund site. This analysis includes determining if the
cyclone furnace can produce a non-leachable vitrified
material that immobilizes a significant percentage of the
metals, particularly chromium. It also includes
determining DREs and air emissions from the process.
Table 1 lists the unit's performance as it relates to
ARARs.
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Table I. B&W SITE Demonstration Test Results and Potential Incineration ARARs
Contaminant Average Range
ARARs
TCLP frng/L)
SSM
Cadmium
Chromium
Lead
Sag
Cadmium
Chromium
Lead
ORE (%)
Anthracene
Dimethylphthalatc
Slack Emissions
Particulatc matter
Nitrogen oxides (NO,, ppm)
Carbon monoxide (ppm)
Total hydrocarbons (ppm)
Cadmium (Ib/hr)
Chromium (Ib/hr)
Lead 0b/hr)
49.9
2.64
97.3
0.12
0.22
0.31
> 99.997
> 99.998
0.0008
a
a
a
3.27X10'6
2.70xlO'5
1.88xlO's
31.0 - 75.3
1.30 - 4.32
72.2 - 128
0.03 - 0.30
0.07 - 0.81
<0.25 - 0.66
> 99.996 -> 99.997
> 99.998 - > 99.998
0.003 - 0.0014
310 - 435
4.8 - >54.1
<5.9 - 18.2
9.4xlO'6 - 1.5xlO'4
2.1X10'5 - 1.9xlO'4
4.8xlO's - 7-lxlO"4
1.0
5.0
5.0
1.0
5.0
5.0
99.99
99.99
0.08
b
<100
<20
c
c
' c
a Average concentration for each run is presented in Appendix C. Average concentration for the entire Demonstration was not calculated.
b Allowable emissions limits established on a case-by-case basis as per the requirements of the Clean Air Act.
C Less than those established by EPA Guidance on Metal Emissions from Hazardous Waste Incinerators.
Other results regarding the ratio of slag-to-flyash, metal
partitioning, volume reduction, and characterization of
feed soil and baghouse solids are also addressed.
A full discussion of the SITE Demonstration Test results
is included in Appendix C and supported in
Appendix D, Case Studies.
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Section!
Introduction
2.1 The SITE Program
In 1986, the U.S. Environmental Protection Agency (EPA)
Office of Solid Waste and Emergency Response
(OSWER) and Office of Research and Development
(ORD) established the Superfund Innovative Technology
Evaluation (SITE) Program to promote the development
and use of innovative technologies to clean up Superfund
sites across the country. Now in its fifth year, SITE is
helping to provide the treatment technologies necessary to
implement new Federal and State cleanup standards aimed
at permanent remedies rather than quick fixes. The SITE
Program is composed of three major elements: the Dem-
onstration Program, the Emerging Technologies Program,
and the Measurement and Monitoring Technologies
Program.
The major focus has been on the Demonstration Program,
which is designed to provide engineering and cost data for
selected technologies. To date, the Demonstration
Program projects have not involved funding for technology
developers. EPA and developers participating in the
program share the cost of the demonstration. Developers
are responsible for demonstrating then- innovative systems
at chosen sites, usually Superfund sites. The EPA is
responsible for sampling, analyzing, and evaluating all test
results. The result is an assessment of the technology's
performance, reliability, and costs. This information is
used hi conjunction with other data to select the most
appropriate technologies for the cleanup of Superfund
sites.
Developers of innovative technologies apply to the
Demonstration Program by responding to EPA's annual
solicitation. EPA also accepts proposals any time a
developer has a Superfund waste treatment project
scheduled. To qualify for the program, a new technology
must be at the pilot- or full- scale and offer some advan-
tage over existing technologies. Mobile technologies are
of particular interest to EPA.
Once EPA has accepted a proposal, EPA and the
developer work with the EPA regional offices and state
agencies to identify a site containing waste suitable for
testing the capabilities of the technology. EPA prepares
a detailed sampling and analysis plan designed to evaluate
the technology thoroughly and to ensure that the resulting
data are reliable. The duration of a demonstration varies
from a few days to several months, depending on the
length of time and quantity of waste needed to assess the
technology. After the completion of a technology
demonstration, EPA prepares two reports, which are
explained in more detail in the following paragraphs.
Ultimately, the Demonstration Program leads to an
analysis of the technology's overall applicability to
Superfund problems.
The second principal element of the SITE Program is the
Emerging Technologies Program, which fosters the further
investigation and development of treatment technologies
that are still at the laboratory scale. Successful validation
of these technologies could lead to the development of a
system ready for field demonstration and participation in
the Demonstration Program. The third component of the
SITE Program, the Measurement and Monitoring
Technologies Program, provides assistance in the
development and demonstration of innovative technologies
to characterize Superfund sites better.
2.2 SITE Program Reports
The analysis of technologies participating in the
Demonstration Program is contained in two documents:
the Technology Evaluation Report (TER) and the
Applications Analysis Report (AAR). The TER contains
a comprehensive description of the demonstration
sponsored by the SITE program and its results. It gives
detailed descriptions of the technology, the waste used for
the demonstration, sampling and analysis during the test,
the data generated, and the quality assurance program.
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The scope of the AAR is broader than the TER and
encompasses estimation of the Superfund applications and
costs of a technology based on all available data. This
report compiles and summarizes the results of the SITE
demonstration, the vendor's design and test data, and
other laboratory and field applications of the technology.
It discusses the advantages, disadvantages, and limitations
of the technology.
Costs of the technology for different applications are
estimated based on available data on pilot- and full-scale
applications. The AAR discusses the factors, such as site
and waste characteristics, that have a major impact on
costs and performance.
The amount of available data for the evaluation of an
innovative technology varies widely. Data may be limited
to laboratory tests on synthetic waste or may include
performance data on actual wastes treated at the pilot- or
full-scale level. In addition, there are limits to conclusions
regarding Superfund applications that can be drawn from
a single field demonstration. A successful field demon-
stration does not necessarily ensure that a technology will
be widely applicable or fully developed to the commercial
scale. The AAR attempts to synthesize whatever inform-
ation is available and draw reasonable conclusions. This
document is very useful to those considering a technology
for Superfund cleanups and represents a critical step in the
development and commercialization of the treatment
technology.
2.3 Key Contacts
For more information on the demonstration of the B&W
technology, please contact:
1. EPA Project Manager for the SITE
Demonstration Test:
Ms. Laurel Staley
U.S. Environmental Protection Agency
Risk Reduction Engineering Laboratory
26 W. Martin Luther King Drive
Cincinnati, Ohio 45268
(513) 569-7863
2. Process Vendor :
Mr. Lawrence P. King
Research and Development Division
Babcock & Wilcox
1562 Beeson Street
Alliance, Ohio 44601
(216) 829-7576
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Section 3
Technology Applications Analysis
3.1 Introduction
This section addresses the applicability of the Babcock &
Wilcox (B&W) Cyclone Furnace Vitrification Technology
to various contaminated soil matrices where heavy metals,
radionuclides, and various organics are the pollutants of
primary interest. Recommendations are based on the
results obtained from the SITE demonstration as well as
additional data from B&W. The results of the demonstra-
tion provide the most extensive database, conclusions on
the technology's effectiveness, and its applicability to other
potential cleanups. Additional information on the B&W
technology, including a brief process "description, vendor's
claims, and a summary of the demonstration results are
provided in Appendices A through C.
3.2 Conclusions
Soil contaminants are either immobilized, thermally
destroyed (oxidized), or volatilized in B&W's cyclone
furnace. It successfully produced a non-leachable, vitrified
slag that immobilized heavy metals and radionuclides. The
technology also destroyed the organic contaminants
present in the soil.
A review of the Demonstration Test indicates the
following results:
• The slag produced complied with Toxicity
Characteristic Leaching Procedure (TCLP)
regulatory requirements for cadmium, chromium,
and lead.
• Ninety-four percent of the non-combustible
portion of the soil was incorporated within the
slag.
• Most of the non-volatile metals remained in the
slag. On the average, the percentages for
chromium, strontium, and zirconium retained in
the slag were 76, 88, and 97 percent, respectively.
Metals which partitioned to the flue gas were
captured by the baghouse.
The volume of slag produced was 29 percent
smaller than the feed soil on a dry weight basis.
Destruction and Removal Efficiencies (DREs)
for Semi-Volatile Organic Compounds (SVOCs)
were greater than 99.99 percent.
An average of 0.001 grains per dry standard cubic
foot (gr/dscf) of particulate corrected to 7
percent O2 was emitted, which is less than the
Resource Conservation and Recovery Act
(RCRA) regulatory limit of 0.08 gr/dscf at 7
percent O2.
The simulated radionuclides (strontium,
zirconium, and bismuth) were immobilized within
the slag according to American Nuclear Society
(ANS) Method 16.1.
The process formed products of incomplete
combustion; however, concentrations were in the
parts per trillion range.
3.3 Technology Evaluation
The 6-million Btu/hr pilot-scale furnace used in this
demonstration is a scaled-down version of the B&W
commercial coal combustion cyclone furnace. This unit
employs high temperatures to vitrify high inorganic
hazardous wastes (e.g., soils) that may also contain organic
constituents. The technology was demonstrated using a
Synthetic Soil Matrix (SSM) provided by the EPA Risk
Reduction Engineering Laboratory (RREL) in Edison,
New Jersey. The contaminants used to spike the SSM
were chosen in order to produce a feed with con-
tamination problems similar to those encountered at
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Supcrfund sites, Department of Defense (DOD) facilities,
and Department of Energy (DOE) facilities. The SSM is
a well characterized, clean material used for technology
evaluations which has been spiked with heavy metals,
SVOCs, and simulated radionuclides [1].
Simulated radionuclides are non-radioactive metals, the
behavior of which in the cyclone furnace will simulate true
radionuclidc species. The simulated radionuclides selected
were strontium, bismuth, and zirconium. Bismuth was
used as a surrogate for volatile radionuclides found at
DOE/DOD sites such as cesium (cold cesium was origin-
ally proposed but found to be excessively expensive). Cold
strontium was used as a surrogate for radioactive
strontium (the cold version of the radionuclide is the best
possible surrogate). Zirconium was considered an
excellent surrogate for radioactive thorium and uranium
from the standpoint of both volatility and chemical
behavior.
Data regarding simulated radionuclides are suspect
because the method has not been validated for these
metals. Since the method accuracy and precision ar& not
well quantified, the data are used for informational
purposes only.
Table 2 is a summary of the spiked components and their
concentrations in the SSM. The chosen spikes allow for
proper evaluation of the technology without risk to
personnel safety and limit the generation of hazardous
products.
Table 2. Total Concentrations of Spiked Components Measured in
the SSM
Concentration (me/kg)
Analyte
Heavy Metals
Cadmium
Chromium
Lead
Simulated
Radionuclides
Bismuth
Strontium
Zirconium
Organic
Compounds
Average
1260
4350
6410
4180
3720
4070
Range
1000-1800
3800-4680
3880-7510
2810-7210
3300-4100
3660-5000
Anthracene
Dimethyl-
phthalatc
4710
8340
3300-7800
4800-10000
The following paragraphs present information available on
the B&W cyclone furnace and its performance and
summarize observations and conclusions on the process as
they relate to the SITE demonstration.
33.1 Slag Characteristics
3.3.1.1 Leachability
Ninety-four percent of the non-combustible portion of the
feed is transformed from loosely packed soil to a brittle,
glass-like slag. The remaining 6 percent becomes
particulate matter in the flue gas. Table 3 summarizes the
concentrations of the spiked components in the resultant
slag.
Table 3. Total Concentrations of Spiked Components Measured in
the Slag
Concentration (me/kg)
Anatyte
Heavy Metals
Cadmium
Chromium
Lead
Simulated
Radionuclides
Bismuth
Strontium
Zirconium
Organic
Compounds
Average
106
1610
1760
730
3210
3640
Range
62.7-177
922-2110
1270-2420
522-949
1890-3830
2080-4420
Anthracene
Dimethyl-
phthalate
<0.24"
<3.89"
(0.04)b-<0.34
<0.33-llc
a If a result was undetected, the detection limit was used in
calculations for averages. This represents worst case
scenario.
b Estimated value above instrument detection limit but below
method quantitation limit.
c The analysis of the field blank yielded similar values
indicating the sample may have been contaminated.
B&W claims its vitrification technology produces a non-
leachable, vitrified slag. For the demonstration, TCLPs
were performed on both the feed SSM and the slag. The
SSM was tested to determine the leachability of heavy
metals prior to treatment. The slag was tested to
demonstrate compliance with TCLP regulatory limits. The
teachabilities of the heavy metals in the feed soil and the
slag are summarized in Table 4, which includes TCLP
regulatory levels.
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Table 4. TCLP Results from B&W SITE Demonstration (mg/L)
Cadmium Chromium Lead
Regulatory
Limits
1.0
5.0
5.0
SSM
Average
Range'
Slag
Average
Range*
49.9
31.0-75.3
<0.12b
< 0.03-0.30
2.64
1.30-4.32
0.22
0.07-0.81
97.3
72.2-128
<0.31b
< 0.25-0.66
Range represents low-to-high values of the 27 samples taken
over the Demonstration period.
If a result was undetected, the detection limit was used in
calculations for averages. This represents worst case
scenario.
TCLP results for the slag indicate the cyclone furnace can
treat metal-contaminated soils to the extent that the
leachate from the resultant slag will comply with the
allowable limits. When TCLPs were performed on the
feed, the concentrations of lead and cadmium in the
leachate were greater than the regulatory limits; however,
this was not the case for chromium. It is not known why
chromium remains relatively fixed in the soil. TCLP
results from previous testing by B&W (refer to
Appendix D - Case Studies) also indicated the leachate
contained concentrations of chromium less than the
regulatory limit. For the demonstration, chromium
concentrations were triple that of levels from these
previous tests; however, the leachate still did not exceed
the regulatory limit.
The cyclone vitrification process not only produces a slag
that complies with TCLP requirements, but decreases the
leachability of metals in the slag. This decrease in
teachability is caused by the physical/chemical properties
of the SSM changing as it passes through the cyclone
furnace.
The leachability of the simulated radionuclides from the
slag was determined according to ANS 16.1 - "American
National Standard Measurement of the Leachability of
Solidified Low-Level Radioactive Wastes by a Short-Term
Test Procedure." This method provides a measure of the
release of simulated radionuclides from the slag at
ambient temperatures. A leachability index of six or
greater indicates these metals are immobilized within the
slag. In order to account for the irregular shape of the
slag material, the method used to quantify the external
surface area of the slag was modified.
Although all other equations and data reduction
procedures remain the same, the method has not been
validated for the material in question and accuracy and
precision are not well quantified; therefore the data are
suspect. The slag's leachability index for bismuth,
strontium, and zirconium were 13.4, 13.1, and 8.7,
respectively. These results indicate the simulated
radionuclides are immobilized.
3.3.1.2 Volume Reduction
The vitrification process reduces the volume of the feed
SSM. Approximately 20 percent of the SSM is made up
of materials that combust as they pass through the cyclone
furnace. These materials include carbonates, sulfates, and
organics. Their combustion results in a decrease in
volume. Percent volume reductions were determined by
comparing the volume of dry SSM introduced to the
furnace to the volume of dry slag produced. The average
volume reduction was 29 percent. Bulk densities of the
SSM and slag are almost equivalent; therefore any volume
reduction is the result of this combustion, not a change in
bulk density.
33.2 Metals Partitioning
As the SSM goes through the cyclone furnace, metals
partition to either the flyash or the slag. Their fate
depends on the relative volatility of the metal. The non-
volatile metals such as chromium, strontium, and
zirconium remain mainly in the slag. The more volatile
metals such as bismuth, cadmium, and lead tend to
partition to the flue gas where they are collected by the
baghouse. During the demonstration, over 75 percent (by
weight) of the chromium in the SSM was incorporated in
the vitrified slag. This percent of retention is consistent
with retentions obtained during previous tests (refer to
Appendix D - Case Studies). In addition, approximately
88 and 97 percent of the strontium and zirconium,
respectively, remained in the slag. The more volatile
bismuth, cadmium, and lead had lower retention (27, 12,
and 29 percent, respectively).
Almost all of the total mass of metals which partition to
the flue gas are captured by the baghouse. A very small
portion of the mass of metals pass through the baghouse
and out the stack. However, as long as these levels do not
exceed the furnace's permit limits (as determined by a
site-specific risk assessment), no significant changes to
emission treatment need be employed. Table 5
summarizes the distribution of the metals during the
demonstration.
Results from the TCLP analysis of the baghouse solids
indicate the TCLP limits for cadmium and chromium were
exceeded. The baghouse solids therefore require disposal
as a hazardous waste. During the demonstration, 6,000
pounds of SSM were treated and approximately 150
pounds of baghouse solids were collected. This is a
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Table 5. Metals Partitioning from the Cyclone Vitrification
Process (%)
Metal Slag Baghouse Stack gas
Bismuth*
Average
Range
Cadmium
Average
Range
Chromium
Average
Range
Lead
Average
Range
Strontium*
Average
Range
Zirconium*
Average
Range
26.8
25.7-28.4
11.8
113-12.7
75.8
73.7-793
29.2
24.3-33.2
87.8
85.0-893
965
95.7-97.4
73.1
71.6-743
88.1
87.3-88.8
24.2
20.7-26.3
70.8
66.8-75.7
12.2
10.7-15.0
35
2.6^.3
<0.08b
< 0.06-0.11
0.04
0.01-0.17
0.04
0.01-0.11
0.05
0.01-0.13
0.01
0.003-0.03
0.02
0.02-0.03
a These are included for informational purposes only since the
accuracy and precision of these data are suspect.
b If a result was undetected, the detection limit was used in
calculations for averages. This represents worst case
scenario.
significant decrease in the amount of material requiring
disposal as hazardous waste.
Modifications have been proposed that would recirculate
the baghouse solids through the furnace, allowing the
system additional opportunities to trap the metals within
the slag. This modification may eliminate the need to
dispose of or treat the flyash as a hazardous waste.
333 Air Emissions
3.3.3,1 Paniculate
During theDemonstration Test, particulate emissions were
measured directly after exiting the furnace outlet (prior to
the air pollution control equipment) and at the stack (after
the baghouse). Emissions out of the stack easily met the
RCRA emissions limit of 0.08 gr/dscf corrected to
7 percent oxygen (O2). Table 6 summarizes particulate
data from the Demonstration Test. The table includes
both measured values and values corrected to 7 percent
O2. The correction factor of 14 * (21 - percent O2) takes
into account the dilution factor in the stack gas caused by
excess air needed for combustion.
Table 6. Summary of Particulate Emissions
Concentration (gr/dscf)
Run No.
1
2
3
Location
Furnace Outlet
Stack
Furnace Outlet
Stack
Furnace Outlet
Stack
Measured
0.858
0.0016
0.864
0.0009
1.058
0.0003
7%O2
0.765
0.0014
0.817
0.0008
0.837
0.0003
Rate (Ib/h)
557
0.017
5.76
0.009
6.89
0.004
By comparing the particulate emission rate from the stack
test at the furnace outlet with the amount of slag produced
per hour by the cyclone furnace, the slag-to-flyash ratio
was determined for each run. The average slag to flyash
ratio from the Demonstration was 13.7. In addition to
providing a relationship from which baghouse solids
production can be estimated, this result demonstrates the
cyclone furnace is capable of treating the contaminated
soil without experiencing major losses as particulate
emissions.
3.3.3.2 ORE
The measure used to evaluate organic destruction during
the Demonstration Test is the DRE. This parameter is
determined by analyzing the concentration of the Principal
Organic Hazardous Constituent (POHC) in the feed SSM
and the stack gas. RCRA regulations define DRE for a
given POHC as follows:
DRE (%) =
Win -_Wout
Where:
W:n
= Mass feed rate of the POHC of interest in
the waste stream feed
= Mass emission rate of the same POHC
present in exhaust emissions prior to release
to the atmosphere
POHCs identified for the demonstration were anthracene
and dimethylphthalate. These compounds were selected
as representative stable compounds for the purpose of
evaluating the furnace's ability to destroy organic
compounds.
The cyclone furnace achieved DREs greater than 99.99
percent for both of these organics. This indicates the
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cyclone furnace is capable of achieving the DREs required
for a RCRA hazardous waste incinerator (99.99 percent).
Because the concentrations of both anthracene and
dimethylphthalate in the stack gas were below detection
limits, these results do not indicate the maximum DREs
the cyclone furnace is capable of achieving. Measurable
quantities of POHCs were expected in the stack gas since
high levels of POHCs were spiked in the SSM (refer to
Table 2) and their corresponding detection limits are low.
This indicates the furnace obtained better-than-expected
results.
For the Demonstration Test, the gas temperature exiting
the cyclone barrel was approximately 3000°F, while the gas
leaving the furnace had a temperature of over 2000°F and
a 2 second residence time. Similar operating conditions
are projected for the commercial-scale system. Because
anthracene and dimethylphthalate are relatively difficult
organics to destroy, it is projected that the commercial-
scale cyclone furnace will be capable of achieving DREs
of 99.99 percent or greater for all or nearly all organics. -
3.3.3.3 Products of Incomplete Combustion (PICs)
Volatile Organic Compound (VOC) emissions which
reflect the formation of PICs, were detected in the parts
per trillion range for the cyclone furnace. Organic
compounds spiked in the SSM were non-chlorinated;
therefore, PICs from this process should also be non-
chlorinated. However, several chlorinated compounds
were detected.
In order to account for these chlorinated compounds,
three samples of the feed SSM were analyzed for trace
levels of chlorine. The chlorine levels ranged from <0.01
percent to 0.03 percent. These trace amounts probably
resulted in the formation of chlorinated VOCs.
Higher concentrations of chlorinated VOCs may be
detected in the stack gas if a feed soil contains chlorinated
compounds; however, it is expected concentrations would
be very low. Soils contaminated with chlorinated organics
would also form hydrogen chloride (HC1) gas from the
cyclone vitrification process which would have to be
controlled by a scrubber.
3.3.3.4 Continuous Emission Monitors (CEMs)
CEMs were used to measure nitrogen oxides (NOX),
carbon monoxide (CO), total hydrocarbons (THC), carbon
dioxide (CO2), and O2 emissions during the Demonstration
Test.
NOX emissions are generally a result of the combustion
process rather than the nitrogen content of the feed. The
NOX concentrations from the demonstration were relatively
low; however, a unit larger than the pilot system may emit
significant levels of NOX, which may make it a major
source under the Clean Air Act. Allowable emissions of
NOX will be established on a case-by-case basis.
CO and THC emissions were relatively low and indicate
relatively complete combustion occurs within the cyclone
furnace, as also indicated by the low PIC concentrations
(refer to Section 3.3.3.3). Results from the demonstration
do not indicate the cyclone furnace will have difficulty in
meeting the RCRA limit of 100 parts per minion (ppm)
for CO. THC emissions from the demonstration, however,
were close to the RCRA limit of 20 ppm. Careful
monitoring of THC emissions from the furnace will be
required in order for the unit to operate in compliance.
CO2 and O2 in the stack gas were analyzed by CEMs and
Orsat analysis. Values obtained from both analyses
compared favorably with one another. O2 levels in the
stack gas indicate excess air values from the combustion
process. Operating at low excess air values may result in
incomplete combustion; too high values may reduce
combustion temperatures or increase fuel requirements.
O2 values obtained reflect typical excess air values for a
natural gas-fired furnace.
33.4 Quench Water
Slag exiting the cyclone furnace is cooled and collected in
a tank filled with quench water. Quench water samples
collected before and after each run were' analyzed to
determine if any of the metals present in the slag or
infusible matter leached into the quench water. Analyses
of the quench water from the baseline run and the three
test runs indicated minimal increases in the concentrations
of certain metals during the test runs. Concentrations of
cadmium, chromium, lead, and strontium were so close to
the detection limits that it cannot be determined if the
process causes any increase/decrease in concentrations.
Concentrations of bismuth and zirconium remained below
detection limits throughout the testing period.
Quench water samples collected before and after the
second and third test runs were analyzed for anthracene
and dimethyl phthalate to determine whether these
chemicals leached into the quench water. Concentrations
of both chemicals remained below method quantitation
limits throughout both test runs.
When the Demonstration Test was complete, the quench
water was found to be suitable for discharge to a sanitary
sewer and was disposed of in accordance with the terms of
B&W's wastewater discharge agreement with its local
Publicly-Owned Treatment Works (POTW). It is project-
ed that the quench water from the commercial-scale
system will be suitable for discharge to a sanitary sewer,
but this must be determined on a site-specific basis.
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Water that came in contact with the SSM (wash and rinse
water from demonstration equipment cleanup) was
collected, stored apart from other wastes, and disposed of
as a hazardous waste. The nature of the wash water and
rinse water will be site-specific. It may be a hazardous or
radioactive waste at some sites; at other sites it may be
suitable for discharge to a sanitary sewer.
In the commercial-scale cyclone furnace soil vitrification
system, the slag quench water, wash water, and rinse water
will only occasionally discharge. It is projected that the
commercial-scale system will continuously discharge water
from a quench tower, which will use water to cool the flue
gas (the pilot-scale system did not include a quench
tower). The water from the quench tower should be
suitable for discharge to a sanitary sewer.
equipment, such as the baghouse, scrubber, water quench
tower, heat exchanger, and feed system. A small building
must be constructed to house the controls for the system.
The lime required by the scrubber should be stored in this
building or in a separate facility.
3.4.4 Site Area Requirements
A minimum area of 3000 square feet is required for the
cyclone furnace vitrification system and the pad used to
support the system. Additionally, separate areas should be
provided where wastes generated during treatment may be
stored and where feed preparation activities can proceed
prior to treatment. Since the furnace can be configured
into any position, the shape of the site is inconsequential
except when it limits access to the equipment.
3.4 Ranges of Site Characteristics Suitable
for the Technology
3.4.1 Site Selection
The current pilot-scale cyclone furnace is not
transportable; however, it is projected the commercial-
scale unit will be able to be moved from site to site. The
following discussion of suitable site characteristics applies
only to the commercial-scale unit.
Although the geological features of a site have an effect on
the equipment that may be used within the contaminated
area, normally the cyclone furnace may be erected within
the confines of the contaminated area or positioned so
that the waste can be easily transported to the furnace.
Ultimately, in order for the furnace to be used onsite, the
characteristics of the site must allow for the construction
of a pad and the assembly of the system.
3.4.2 Surface, Subsurface, and Clearance
Requirements
A level graded area capable of supporting a pad holding
the equipment is needed. The foundation must be able to
support the weight of the cyclone furnace (at least 20
tons), heat exchanger, water quench tower, feed system,
baghouse, and scrubber. The total weight of all system
components is expected to be at least 200 tons. The site
must be cleared to allow construction and access to the
facility.
3.43 Topographical Characteristics
The topographical characteristics of the site should be
suitable for the assembly of the furnace and all ancillary
3.4.5 Climate Characteristics
This treatment technology may be used in a broad range
of different climates. Although prolonged periods of
freezing temperatures may interfere with soil excavation,
these temperatures would not affect the operation of the
furnace itself.
3.4.6 Geological Characteristics
Generally, any site that is sufficiently stable to handle the
weight of the furnace facility is suitable for this technology.
However, this B&W cyclone furnace should not be
employed in areas with landslide potential, volcanic
activity, and fragile geological formations that may be
disturbed by heavy loads or vibrational stress.
3.4.7 Utility Requirements
In order to operate the cyclone furnace, access must be
available to electrical power, water, compressed air, and
natural gas supplies. In order to install and operate the
furnace, a 3-phase electrical source capable of providing
440 volts at 140 amps is required. To maintain a sufficient
supply of water for the quench tower and scrubber, a
minimum water flowrate of 40 gallons per minute (gpm)
is needed. The baghouse will require approximately 85
standard cubic feet per minute (scfm) of compressed air
at 60 to 100 pounds per square inch gauge pressure (psig).
Natural gas must be provided to serve as a supplemental
fuel in the cyclone furnace, which consumes approximately
100,000 standard cubic feet (scf) of natural gas per hour of
operation. Oil and coal may also be used as supplemental
fuels.
10
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3.4.8 Size of Operation
The feed rate for the pilot-scale cyclone furnace soil vitri-
fication system utilized during the SITE demonstration was
approximately 170 Ib/hr of contaminated soil. The pilot-
scale system occupied an area measuring approximately 30
feet long by 30 feet wide.
The projected soil feed rate for the commercial-scale
cyclone furnace soil vitrification system is 80 tons per day
(tpd), or approximately 3.3 tons per hour (tph). The
layout of the commercial-scale system may be adjusted
somewhat to conform to an optimum facility design plan.
The area required for onsite construction of the system
will vary with the configuration, but it will require at least
2400 square feet.
3.5 Applicable Media
The B&W cyclone furnace can be used to treat soils,
sludges, liquids, and slurries contaminated with hazardous
inorganic and organic constituents, low level radioactive
solid wastes, or a combination of the two. The pollutant
concentrations which may be treated by this technology are
constrained by the characteristics (i.e., volatility, mobility,
etc.) of the individual pollutants and the ability of the
furnace to destroy or immobilize the different pollutants.
The Demonstration Test indicated that the furnace was
capable of destroying 99.99 percent of the SVOCs spiked
within the SSM (as demonstrated by DREs) and immobil-
izing approximately 12 percent of the cadmium, over 75
percent of the chromium, and approximately 29 percent of
the lead present within the feed. Since TCLP analyses of
the slag demonstrate acceptable teachability characteristics,
these metals are most likely trapped within the slag.
Metals analyses of the baghouse solids indicate that the
remainder of the metals are volatilized and collected with
the particulate by the baghouse.
Simulated radionuclides (bismuth, strontium, and
zirconium) from the feed were also immobilized in the
slag during the Demonstration Test. Approximately 27
percent of the bismuth, 88 percent of the strontium, and
97 percent of the zirconium were immobilized in the slag.
Simulated radionuclides not contained in the slag were
primarily recovered in the baghouse solids. Because actual
radionuclides are expected to behave similarly, this
technology can be used to treat radioactive soils to prevent
the migration of radionuclides from a site. Following
treatment, the slag and the baghouse solids will still be
radioactive, but it is projected that the slag will be
nonleachable.
3.6 Regulatory Requirements
Operation of the B&W Cyclone Vitrification Furnace
Technology for treatment of contaminated soil requires
compliance with certain Federal, state, and local regulatory
standards and guidelines. Section 121 of the
Comprehensive Environmental Response, Compensation,
and Liability Act (CERCLA) requires that, subject to
specified exceptions, remedial actions must be undertaken
in compliance with Applicable or Relevant and Appro-
priate Requirements (ARARs), Federal laws, and more
stringent promulgated state laws (in response to release or
threats of releases of hazardous substances, pollutants, or
contaminants) as necessary to protect human health and
the environment.
The ARARs which must be followed in treating contamin-
ated media onsite are outlined in the Interim Guidance on
Compliance with ARAR, Federal Register, Vol. 52, pp.
32496 et seq. These are:
• Performance, Design, or Action-Specific Require-
ments. Examples include RCRA incineration
standards and Clean Water Act (CWA) pretreat-
ment standards for discharge to POTWs. These
requirements are triggered by the particular
- remedial activity selected to clean a site.
• Ambient/Chemical-Specific Requirements.
These set health-risk-based concentration limits
based on pollutants and contaminants, e.g.,
emission limits and ambient ear quality standards.
The most stringent ARAR must be complied
with.
• Locational Requirements. These set restrictions
on activities because of site locations and
environs.
Deployment of the B&W cyclone furnace will be affected
by three main levels of regulation:
• Federal EPA air and water pollution regulations
• State air and water pollution regulations
• Local regulations, particularly Air Quality
Management District requirements
These regulations govern the operation of all technologies.
Other Federal, state, and local regulations are discussed in
detail in the following paragraphs as they apply to the
performance, emissions, and residues evaluated from
measurements taken during the Demonstration Test.
11
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3.6.1 Federal Regulations
3.6.1.1 Clean Air Act (CAA)
The CAA establishes primary and secondary ambient air
quality standards for the protection of public health and
emission limitations for certain hazardous air pollutants.
Because the cyclone furnace has the potential to emit
pollutants which are presently regulated under the CAA,
notably CO and NOX, operators of this system must pay
particular attention to the control of these emissions and
compliance with the ambient air quality standards. Other
regulated emissions may also be produced, depending on
the waste feed. During the Demonstration Test,
particulate matter, CO, and THC from the stack gas were
monitored relative to their effect on the emission limits
stipulated under 40 CFR 264. NOX emissions were also
evaluated.
3.6.1.2 CERCLA
CERCLA of 1980 as amended by the Superfund
Amendments and Reauthorization Act (SARA) of 1986
provides for Federal funding to respond to releases of
hazardous substances to air, water, and land. Section 121
of SARA, Cleanup Standards, states a strong statutory
preference for remedies that are highly reliable and
provide long-term protection. It strongly recommends that
remedial action use onsite treatment that "...permanently
and significantly reduces the volume, toxicity, or mobility
of hazardous substances." In addition, general factors
which must be addressed by CERCLA remedial actions
include:
• Overall protection of human health and the
environment
• Compliance with ARARs
• Long-term effectiveness and permanence
• Reduction of toxicity, mobility, or volume
• Short-term effectiveness
• Implementability
• Cost
• State acceptance
• Community acceptance
The ability of the B&W cyclone furnace to destroy the
majority of the organic contaminants originally present in
the feed, as demonstrated by DREs of 99.99 percent or
greater, indicates the cyclone furnace is capable of "perma-
nently and significantly" reducing the threat posed by the
organic compounds. TCLP analyses of the vitrified slag
demonstrated that the cyclone furnace is capable of
immobilizing heavy metal contaminants within the slag in
the short-term. However, the long-term effectiveness and
permanence of these results were not evaluated as part of
this project. It is anticipated, however, that the heavy
metals will be immobilized within the treated soil.
The short-term effectiveness of the B&W process may be
evaluated by examining analytical data obtained from the
stack gas and stack gas solids. Since the stack emissions
are well below the emission limits stipulated by 40 CFR
for particulates, CO, and THC, the data indicate that the
cyclone furnace is highly reliable in respect to the regulat-
ed emissions of concern.
Except for soil-bearing capacity requirements, very few site
characteristics can restrict the implementation of this
system. Unfortunately, the system is not easily or quickly
assembled or disassembled. Thus the cyclone furnace is
better suited for facilities where ongoing treatment is
required rather than for facilities where short-term or
small-scale treatment is required.
This technology may be used to treat media contaminated
with metals, radionuclides, and organics which are not
amenable to treatment using traditional techniques. If the
cyclone furnace were applied to such media, the organics
would be destroyed. A portion of the metals and
radionuclides would be immobilized in the slag; the
remainder would be contained in the baghouse solids.
Both the slag and the baghouse solids would be radioactive
and the baghouse solids would likely be hazardous. It is
projected that the metals and radionuclides in the slag
would be nonleachable since the slag generated during the
SITE demonstration was nonleachable. The slag would be
considered nonhazardous according to CERCLA
requirements.
3.6.1.3 RCRA
RCRA is the primary Federal legislation governing
hazardous waste activities. Under RCRA, various
incineration performance standards are established.
Although a RCRA permit is not required, the cyclone
furnace must meet all of its substantive requirements.
However, administrative RCRA requirements such as
reporting and recordkeeping are not applicable for onsite
action.
Subtitle C of RCRA contains requirements for generation,
transport, treatment, storage, and disposal of hazardous
waste. Compliance with these requirements is mandatory
for CERCLA sites producing hazardous waste onsite.
12
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Two potentially hazardous waste streams, the baghouse
solids and the treated slag, are produced by the B&W
cyclone furnace. Since a limited potential exists for the
heavy metals to leach from the slag, as demonstrated by
TCLP data, the flyash from the baghouse constitutes the
primary hazardous waste stream produced by this process.
This material is contaminated with metals which volatilized
or oxidized to form fumes or fine participates during the
treatment process. These metal fumes and particles were
removed from the gas stream by the baghouse.
In order to maintain compliance with RCRA, sites
employing the cyclone furnace must obtain ah EPA
generator identification number and observe storage
requirements stipulated under 40 CFR 262. Alternatively,
a Part B Treatment, Storage, and Disposal (TSD) permit
of interim status maybe obtained. Invariably, a hazardous
waste manifest must accompany offsite shipment of waste
and transport must comply with Federal Department of
Transportation hazardous waste transportation regulations.
Without exception, the receiving TSD facility must be
permitted and in compliance with RCRA standards.
The technology or treatment standards applicable to the
media produced by the B&W furnace (vitrified slag and
baghouse solids) will be determined by the characteristics
of the material treated and the waste generated. The
RCRA land disposal restrictions (40 CFR 268) preclude
the land disposal of hazardous wastes which fail to meet
the stipulated treatment standards. Wastes which do not
meet these standards must receive additional treatment to
bring the wastes into compliance with the standards prior
to land disposal, unless a variance is granted. The amount
of baghouse solids requiring treatment or disposal may be
eliminated if they are recycled through the furnace. This
modification has been proposed by B&W although it has
not been tested.
3.6.1.4 CWA
The CWA regulates direct discharges to surface water
through the National Pollutant Discharge Elimination
System (NPDES) regulations. These regulations require
point-source discharges of wastewater to meet established
water quality standards. The discharge of wastewater to
the sanitary sewer requires a discharge permit or, at least,
concurrence from state and local regulatory authorities
that the wastewater is in compliance with regulatory limits.
During the SITE demonstration, the water used to quench
the molten slag produced by the cyclone furnace was
disposed of in accordance with the terms of B&W's waste-
water discharge agreement with its local POTW. The
wash water from decontamination and rinse water from
demonstration equipment cleanups was collected, stored
separate from other wastes, and disposed of as a
hazardous waste. The nature of the wash and rinse water
will be site-specific; it may be a hazardous waste at some
sites. In the commercial-scale system, the slag quench
water, wash water, and rinse water will create only
occasional discharges. The water from the quench tower
will be discharged continuously during operation and
should be suitable for discharge to a sanitary sewer.
3.6.1.5 Safe Drinking Water Act (SDWA)
The SDWA establishes primary and secondary national
drinking water standards. CERCLA refers to these
standards and Section 121(d)(2) explicitly mentions two of
these standards for surface water or groundwater -
Maximum Contaminant Levels (MCLs) and Federal Water
Quality Criteria. Alternate Concentration Limits may be
used when conditions of Section 121 (d)(2)(B) are met
and cleanup to MCLs or other protective levels is not
practicable. Included in these sections is guidance on how
these requirements may be applied to Superfund remedial
actions. The guidance, which is based on Federal
requirements and policies, may be superseded by more
stringent promulgated state requirements, resulting in the
application of even stricter standards than those specified
in Federal regulations.
3.6.1.6 Atomic Energy Act (AEA)
Radioactive material treatment, storage, and disposal are
regulated under the AEA. For commercial and most
federal facilities, the Nuclear Regulatory Commission
(NRC) maintains the regulatory framework under which
use of radioactive material is controlled. For DOE
facilities, standards for the control of radioactive material
are established under a series of DOE Orders. Most
NRC regulations are not directly applied to DOE facilities,
since both agencies were founded under the auspices of
the AEA. However, some NRC regulations, particularly
in disposal of certain wastes, are directly applicable to
DOE operations.
Operation of the B&W furnace for treatment of
radioactive materials at a non-DOE facility must be
specifically authorized under a license issued by the NRC,
mandating compliance with the safety and health standards
contained hi 10 CFR 20. The license application will
define the conditions under which the furnace would be
operated to ensure health and safety protection of the
workers, the public, and the environment. At a DOE
facility, the comparable requirements for general radiation
protection will apply, although no license document would
be required.
Disposal of the treatment residuals from the furnace
would be regulated under 10 CFR 61 or DOE Order
5820.2A, depending of whether it is at a DOE facility.
Under either set of requirements, a defined upper
13
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concentration level has been established for near surface
disposal of certain radionuclides.
Certain regulations of the EPA also apply to some forms
of radioactive waste disposal. In general, the EPA
radioactivity standards would not apply to the B&W
furnace, unless it is used to treat high-level waste or
wastes from a uranium or thorium mill tailing site.
If treatment residues contain both RCRA regulated
constituents and radioactive material, they would be
classified as mixed waste. Since there are no currently
operating mixed waste disposal facilities, any mixed waste
resulting from operation of the furnace would have to
meet the RCRA land disposal regulations standards such
that it could be stored for the time required to develop an
acceptable disposal facility.
3.6.2 State and Local Regulations
Compliance with ARARs may require meeting state
standards that are more stringent than Federal standards
or that are the controlling standards in the case of non-
CERCLA treatment activities. Several types of state and
local regulations which may affect operation of the B&W
cyclone furnace are cited below:
• Permitting requirements for
construction/operation
* Limitations on emission levels
• Nuisance rules
3.7 Personnel Issues
3.7.1 Training
Since all personnel involved with sampling or working
dose to the furnace will be required to wear respiratory
protection, 40 hours of Occupational Safety and Health
Act (OSHA) training covering Personal Protective
Equipment Application, Safety and Health, Emergency
Response Procedures, and Quality Assurance/Quality
Control are required. Additional training addressing the
site activities, procedures, monitoring, and equipment
associated with the technology is also recommended.
Personnel should also be briefed when new operations are
planned, work practices change, or if the site or environ-
mental conditions change.
3.72 Health and Safety
Personnel should be instructed on the potential hazards
associated with the operation of the cyclone furnace,
recommended safe work practices, and standard
emergency plans and procedures. Health and Safety
Training covering the potential hazards and provisions for
exposure, monitoring, and the use and care of personal
protective equipment should be required. When
appropriate, workers should have medical exams. Medical
exams are particularly appropriate if the cyclone furnace
is being used for the remediation of radioactive media.
All workers should be routinely monitored for exposure to
radiation. Health and safety monitoring and incident
reports should be routinely filed and records of
occupational illnesses and injuries (OSHA Forms 102
and 200) should be maintained. Audits ensuring
compliance with the health and safety plan should be
carried out.
Proper personal protective equipment should be available
and properly utilized by all onsite personnel. Different
levels of personal protection will be required based on the
potential hazard associated with the site and the work
activities.
Site monitoring should be conducted to identify the extent
of hazards and to document exposures at the site. The
monitoring results should be maintained and posted.
3.73 Emergency Response
In the event of an accident, illness, explosion, hazardous
situation at the site, or intentional acts of harm, assistance
should be immediately sought from the local emergency
response teams and first aid or decontamination should be
employed where appropriate. To ensure a timely response
in the case of an emergency, workers should review the
evacuation plan, firefighting procedures, cardiopulmonary
resuscitation (CPR) techniques, and emergency decon-
tamination procedures before operating the system. Fire
extinguishers, spill cleanup kits, alarms, evacuation
vehicles, and an extensive first aid kit should be onsite at
all times.
For sites with radioactive media, bioassay urine samples
should be collected whenever an intake above allowable
limits may have occurred.
3.8 References
1. Procedures Manual for Preparation of Synthetic
Soils Matrix (SSM 019) Samples for B&W SITE
Program. Prepared by Foster Wheeler Envire-
sponse, Inc. for the U.S. Environmental
Protection Agency, September 1991.
14
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Section 4
Economic Analysis
4.1 Introduction
The primary purpose of this economic analysis is to
estimate costs (not including profits) for a commercial
treatment system utilizing the B&W cyclone furnace
vitrification process. This analysis is based on the results
of a SITE demonstration which utilized a pilot-scale
cyclone furnace vitrification system. The pilot-scale unit
operated at a feed rate of 170 Ibs/hr of contaminated soil
and utilized energy at a rate of 5 million Btu/hr. It is
projected the commercial unit will be capable of beating
approximately 3.3 tons per hour (tph) of contaminated soil
and will require an energy input of 100 million Btu/hr.
The daily feed rate for the pilot-scale system was
approximately 2 tons per day (tpd), while it is projected
the commercial system will be capable of treating 80 tpd.
4.2 Conclusions
The commercial-scale cyclone furnace vitrification system
proposed by B&W appears to be applicable to the
remediation of soils and other solid wastes contaminated
with organics, metals, and radionuclides. Treatment costs
appear to be competitive with other available technologies.
The cost to remediate 20,000 tons of contaminated soil
using a 3.3 tph cyclone furnace vitrification system is
estimated at $465 per ton if the system is online 80
percent of the tune or $529 per ton if the system is online
60 percent of the time. Projected unit costs for a smaller
site (less than 20,000 tons of contaminated soil) are slightly
higher; projected unit costs for a larger site are slightly
lower.
4.3 Issues and Assumptions
Because the B&W cyclone furnace vitrification process
appears to be capable of effectively treating soils
contaminated with organics, metals, and radionuclides, it
is considered potentially applicable to the remediation of
DOE and DOD sites as well as typical Superfund sites. In
the following economic analysis, the costs associated with
this technology are calculated based on the treatment of
20,000 tons of contaminated soil. This basis was chosen
because a small to medium DOE or DOD site may have
approximately 20,000 tons of contaminated soil suitable for
treatment by cyclone furnace vitrification. Approximately
3 tons of contaminated soil were treated during the SITE
demonstration.
Costs which are assumed to be the obligation of the
responsible party or site owner have been omitted from
this cost estimate and are indicated by a line (—) in all
tables.
Important assumptions regarding operating conditions and
task responsibilities that could significantly affect the cost
estimate results are presented in the following paragraphs.
43.1 Costs Excluded from Estimate
The cost estimates presented are representative of the
charges typically assessed to the client by the vendor but
do not include profit.
Many other actual or potential costs were not included as
part of this estimate. These costs were omitted because
site-specific engineering designs beyond the scope of this
SITE project would be required to determine those costs.
As a result, certain functions were assumed to be the
obligation of the responsible party or site owner and were
not included in this estimate.
Costs such as preliminary site preparation, permits,
regulatory requirements, initiation of monitoring programs,
waste disposal, sampling and analyses, and post-treatment
site cleanup and restoration are considered to be the re-
sponsible party's (or site owner's) obligation and are not
included. These costs tend to be site-specific and it is left
to the reader to perform calculations relevant to each
specific case. Whenever possible, applicable information
15
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is provided on these topics so the reader may perform
calculations to obtain relevant economic data.
based on the treatment of a total of 20,000 tons of waste
using a 3.3 tph system.
Maximizing Treatment Rate
Factors limiting the treatment rate include the feed rate
and the online percentage. Increasing the feed rate
and/or the online percentage can reduce the unit treat-
ment cost. Increasing the feed rate of the commercial unit
beyond 33 tph, however, may result hi less effective
reduction of contaminants.
433 Utilities
To support the operation of the cyclone furnace vitrifica-
tion system, a site must have clean water available at a
flow rate of at least 40 gpm. The majority of this water
(34 gpm) will be used in the water quench tower to cool
the flue gas. The remainder of the water will be used in
the scrubber and in other miscellaneous onsite applications
such as cleaning and rinsing.
A natural gas source and the required piping must be
available and accessible to accommodate a natural gas
usage of approximately 100,000 cubic feet per hour at
standard conditions (60°F and 30 inches of mercury). The
natural gas will serve as a supplemental fuel for the
cyclone furnace. Alternatively, provisions may be made
for the use of oil or coal as a supplemental fuel.
Electrical power is required for the operation of the fan,
the baghousc, the scrubber, and many smaller pieces of
equipment. The baghouse also requires compressed air,
which must be supplied at a pressure of 60 to 100 pounds
per square inch gauge (psig) and a flow rate of at least 85
standard cubic feet per minute (scfm).
For these cost calculations, it is assumed the site will
support all of these requirements. The cost of preparing
a site to meet these requirements can be high and is not
included in this analysis.
43A Operating Times
It is assumed the treatment operations will be conducted
24 hours a day, 5 days a week. It is further assumed site
preparation, assembly, shakedown and testing, and
disassembly operations will be conducted 12 hours a day,
5 days a week. Excavation activities for site preparation
will be concurrent with treatment (and may be concurrent
with assembly and shakedown and testing as well).
Assembly, shakedown and testing, and disassembly are
assumed to require 6 weeks, 6 weeks, and 3 weeks,
respectively. Except where noted, these calculations are
43.5 Labor Requirements
Treatment operations for a typical shift are assumed to
require ten workers: four feed operators, two mainten-
ance operators, and four system operators. Each shift is
assumed to be 8 hours long.
43.6 Capital Costs
Capital costs for equipment consist of the cost of the
furnace and additional equipment such as a heat
exchanger, a water quench tower, a feed system, a
baghouse, and a scrubber.
43.7 Equipment and Fixed Costs
Annualized equipment cost and costs that are estimated as
percentages of equipment costs on an annual basis have
been prorated for the duration of time that the equipment
is onsite. The costs for equipment, contingency, insurance,
and taxes accrue during assembly, shakedown and testing,
treatment, and disassembly; scheduled maintenance costs
accrue during treatment only.
4.4 Basis of Economic Analysis
The cost analysis was prepared by breaking down the
overall cost into 12 categories. The categories, some of
which do not have costs associated with them for this
particular technology, are:
• Site preparation costs
• Permitting and regulatory costs
• Equipment costs
• Startup and fixed costs
• Labor costs
• Supplies costs
• Consumables costs
• Effluent treatment and disposal costs
• Residuals and waste shipping, handling, and
transport costs
• Analytical costs
• Facility modification, repair, and replacement
costs
• Site demobilization costs
The 12 cost factors examined as they apply to the B&W
cyclone furnace vitrification process, along with the as-
sumptions employed, are described in the following
paragraphs.
16
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4.4.1 Site Preparation Costs
It is assumed that preliminary site preparation will be
performed by the responsible party (or site owner). The
amount of preliminary site preparation will depend on the
site. Site preparation responsibilities include site design
and layout, surveys and site logistics, legal searches, access
rights and roads, preparations for support and decontamin-
ation facilities, utility connections, and auxiliary buildings.
Since these costs are site-specific, they are not included as
part of the site preparation costs in this cost estimate.
Certain site preparation activities, such as excavating
hazardous waste from the contaminated site, will be
required at all sites and are therefore included in this
estimate. Cost estimates for site preparation are based on
rental costs for operated heavy equipment, labor charges,
and equipment fuel costs.
An excavation rate of 9.1 tph is assumed for all cleanup
scenarios using the 3.3 tph cyclone furnace. It is assumed
the minimum rental equipment required to achieve an
excavation rate of approximately 9.1 tph includes three
excavators, one box dump truck, and one backhoe. The
operation of this equipment will consume approximately 14
gallons of diesel fuel per hour. It is also assumed
excavation activities will be conducted 12 hours a day, 5
days a week. An excavation rate of 45.5 tph is assumed
for the cost estimate based on the use of a larger cyclone
furnace (capable of treating 20 tph). It is further assumed
that an excavation rate of 45.5 tph will require five times
as much equipment, labor, and diesel fuel as an excavation
rate of 9.1 tph. Excavation costs are itemized in Table 7.
Table 7. Excavation Costs
Item
Excavator
Box dump truck
Backhoe
Supervisor
Excavator operator
Dump truck operator
Backhoe operator
Diesel fuel
Cost
$l,260/week
$525/week
$585/week
$40/hour
$30/hour
$30/hour
$30/hour
Si/gallon
4.4.2 Permitting and Regulatory Costs
Permitting and regulatory costs are generally the
obligation of the responsible party (or site owner), not of
the vendor. These costs may include actual permit costs,
system monitoring requirements, and/or the development
of monitoring and analytical protocols. Permitting and
regulatory costs can vary greatly because they are site- and
waste-specific. No permitting or regulatory costs are
included in this analysis. Depending on the treatment site
however, this may be a significant factor since permitting
activities can be both expensive and time consuming.
4.43 Equipment Costs
Major pieces of equipment include the:
Cyclone furnace
Heat exchanger
Feed system
Baghouse
Quench tower
Scrubber
The cyclone furnace cost supplied by B&W was used. It
was comparable to an independent cost estimate. All
other equipment costs were estimated from various
references. The primary references used were the third
edition of Plant Design and Economics for Chemical
Engineers by M.S. Peters and K.D. Timmerhaus [1] and
the fourth edition of the Office of Air Quality Planning and
Standards Cost Control Manual [2]. Total equipment costs
for the 3.3 tph cyclone furnace vitrification system are
estimated to be approximately $3,500,000; equipment
costs for the 20 tph system are estimated to be
approximately $11,600,000. For each system, a useful life
of 15 years and an interest rate of 10 percent are assumed.
It is assumed no rental equipment or purchased support
equipment will be required for operation. Support
equipment refers to pieces of purchased equipment
necessary for operation but not integral to the system.
The commercial-scale cyclone furnace will be capable of
treating 3.3 tph of contaminated soil and will require
approximately 100 million Btu/hr. System accessories will
include a feed system (holding tank, mixer, and feed
nozzle) and an air pollution control system. The effluent
flue gas flows through an air-to-air heat exchanger where
it is cooled from 2000°F to BOOT while heating the
influent combustion air from ambient temperature to
800°F. Following the heat exchanger, the flue gas is
cooled to 200°F in a water quench tower. The cooled gas
flows to a lime spray dryer for acid gas removal and then
to a pulse-jet baghouse for particulate removal.
The total equipment cost is calculated and is annualized
using the following formula:
A = C * i * fl + iV
(1 + i)n - 1
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where: A = annualized cost, $
C = capitalized cost, $
i = interest rate, %
n = useful life, years
The annualized cost (rather than depreciation) is used to
calculate equipment costs incurred by a site. The
annualized equipment cost is prorated to the actual time
the reactor is commissioned to treat a hazardous waste
(including assembly, shakedown and testing, treatment,
and disassembly). The prorated cost is then normalized
relative to tons of soil treated.
4.4.4 Startup and Fixed Costs
Mobilization includes both transportation and assembly.
The cyclone furnace vitrification system will be difficult to
transport and its relocation will require a great deal of
time and planning. For the purpose of this estimate,
transportation costs are included with mobilization rather
than demobilization. Transportation activities include
moving the system and the workers to the site. As a
rough estimate, it is assumed that ten tractor-trailers will
be required to transport the commercial-scale cyclone
furnace soil vitrification system. A 1,000 mile basis is
assumed at a rate of $1.65 per mile per legal load
(including drivers). Transportation costs for the 30
workers are based on a $300 one-way airfare per person.
The accuracy of this airfare estimate was confirmed by an
examination of one-way airfares for flights from Akron,
Ohio (near Alliance) to Dallas-Fort Worth and to Fort
Laudcrdale, both of which are approximately 1000 miles
from Akron.
Assembly consists of unloading the system from the trucks
and trailers and reassembling the furnace. It is assumed
that unloading the equipment will require the use of an
operated 50-ton crane for 6 weeks at a cost of $6,360 per
week. Assembly is assumed to require 30 people working
12 hours per day, 5 days per week, for 6 weeks. Labor
charges during assembly consist of wages ($40 per hour)
and living expenses (refer to subsection 4.4.5).
This cost estimate assumes that 6 weeks of shakedown and
testing will be required after assembly and prior to the
commencement of treatment. During this tune, the system
components are tested individually. It is estimated that 15
workers will be required for 12 hours per day, 5 days per
week during shakedown and testing. Labor costs consist
of wages ($40 per hour) and living expenses (refer to
subsection 4.4.5).
Working capital consists of the amount of money currently
invested in supplies, energy, and spare parts kept on
hand [1]. The working capital for this system is based on
maintaining a 1-month inventory of these items. For the
calculation of working capital, 1 month is defined as one-
twelfth of a year, or approximately 21.7 working days.
Insurance is approximately 1 percent of the total
equipment capital costs, while taxes are 2 to 4 percent.
The cost of insurance for a hazardous waste process can
be several times more than this. Insurance and taxes
together are assumed, for the purposes of this estimate, to
be 10 percent of the equipment capital costs [1]. These
costs have been prorated to the actual time the cyclone
furnace is commissioned to treat contaminated waste on
a site (including assembly, shakedown and testing,
treatment, and disassembly).
The cost for the initiation of monitoring programs has not
been included in this estimate. Depending on the site,
local authorities may impose specific guidelines for
monitoring programs. The stringency and frequency of
monitoring required may have a significant impact on the
project costs.
An annual contingency cost of 10 percent of the annual-
ized equipment capital costs is allowed to cover additional
costs caused by unforeseen or unpredictable events, such
as strikes, storms, floods, and, price variations [1]. The
annual contingency cost has been prorated to the actual
time the reactor is commissioned to treat hazardous waste
(including assembly, shakedown and testing, treatment,
and disassembly).
4.4.5 Labor Costs
Labor costs consist of wages and living expenses.
Personnel requirements per shift during treatment are
estimated at: four feed operators at $25 per hour, two
maintenance operators at $30 per hour, and four system
operators at $40 per hour. Rates include overhead and
administrative costs. It is assumed that personnel will
work an average of 40 hours per week at three shifts for
a 24-hour, 5-day-per-week operation.
Living expenses depend on several factors: the duration
of the project, the number of local workers hired, and the
geographical location of the project. Living expenses for
all personnel who are not local hires consist of per diem
and rental cars, both charged at 7 days per week for the
duration of the treatment. Per diem varies by location,
but for the purposes of this report is assumed to be $60
per day per person. Six rental cars are required for a 24-
hour operation and are available for $30 per day per car.
Depending on the length of the project, B&W may elect
to hire local personnel and train them hi the operation of
the furnace, thus eliminating living expenses.
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4.4.6 Supplies Costs
For this estimate, supplies consists of chemicals and spare
parts. Lime requirements for scrubber operation are
estimated to cost approximately $28,500 per year of
operation (a year of operation is defined as a year of time
spent actually processing waste). Spare parts consist of
baghouse bags, which cost approximately $12,800 per set
and are assumed to require annual replacement during
periods of treatment.
4.4.7 Consumables Costs
The cyclone furnace consumes natural gas at a rate of
approximately 100 million Btu/hr. The cost of natural gas
is estimated as $5.10 per million Btu with no monthly fee,
yielding a fuel cost of approximately $510 per hour of
operation.
The projected air usage for the baghouse is approximately
85 scfm of 60 to 100 psig air; air costs are estimated at
$0.20 per 1000 standard cubic feet (scf).
The electricity requirement for the baghouse fans is
approximately 414,600 kilowatt-hours (kWh) per year of
operation. It is estimated that the electrical requirements
for the scrubber will have an associated cost of
approximately $5 per hour of operation. The cost estimate
assumes that electricity can be obtained for a flat rate of
$0.06 per kWh with no monthly charge.
The quench tower requires 34 gpm of water. Smaller
quantities of water are used in the scrubber and in
miscellaneous other applications yielding an estimated
total water usage rate of 40 gpm. Water costs are
estimated at $1.10 per 1000 gallons.
4.4.8 Effluent Treatment and Disposal Costs
B&W is currently investigating the feasibility of mixing the
baghouse solids into the feed and recycling them through
the system. If this process change is found to be feasible,
it will be implemented in the commercial-scale system and
it will not be necessary to dispose of the baghouse solids.
The baghouse solids generated during the SITE
demonstration were found to be hazardous and will
therefore require disposal as a hazardous waste and/or
additional treatment.
The water from the quench tower should be suitable for
discharge to a municipal sewer system. The responsible
party or site owner should obtain a discharge permit from
the local municipality if possible. If no sewer service is
available, the site owner or responsible party must obtain
a direct discharge permit or arrange for disposal by other
means. It should not be necessary to treat the water prior
to discharge, but this must be determined on a site-specific
basis.
Onsite treatment and disposal costs are restricted to onsite
storage (if necessary) of the water from the quench tower
and are assumed to be the obligation of the site owner or
responsible party. Offsite treatment and disposal costs
consist of wastewater disposal fees and are assumed to be
the obligation of the responsible party (or site owner).
These costs may significantly add to the total cleanup cost.
4.4.9 Residuals and Waste Shipping, Handling, and
Transport Costs
It is assumed that the only residual generated by this
process will be the slag. The slag generated during the
SITE demonstration passed the TCLP test; as a result, it
is anticipated that the slag will be disposed of in a sanitary
landfill. The teachability of the slag from actual wastes
must be determined on a site-specific basis. Potential
waste disposal costs include storage, transportation, and
treatment costs and are assumed to be the obligation of
the responsible party (or site owner). These costs could
significantly add to the total cleanup cost.
4.4.10 Analytical Costs
No analytical costs are included in this cost estimate.
Standard operating procedures for B&W do not require
sampling or analytical activities. The client may elect or
may be required by local authorities to initiate a sampling
and analytical program at then- own expense. If specific
sampling and monitoring criteria are imposed by local
authorities, these analytical requirements could contribute
significantly to the cost of the project.
4.4.11 Facility Modification, Repair, and
Replacement Costs
Maintenance labor and material costs vary with the nature
of the waste and the performance of the equipment. For
estimating purposes, total annual maintenance costs (labor
and materials) are assumed to be 10 percent of annualized
equipment costs. Maintenance labor typically accounts for
two thirds of the total maintenance costs and has
previously been accounted for under in subsection 4.4.5.
Maintenance material costs are estimated at one third of
the total maintenance cost and are prorated to the entire
period of treatment. Costs for design adjustments, facility
modifications, and equipment replacements are included
in the maintenance costs.
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4.4.12 Site Demobilization Costs
Demobilization costs are limited to disassembly costs;
transportation costs are accounted for under mobilization.
Disassembly consists of taking the cyclone furnace apart
and loading it onto ten trailers for transportation. It
requires the use of an operated 50-ton crane, available at
$6,360 per week, for 3 weeks. Additionally, disassembly
requires a 30-person crew working 12-hour days, 5 days a
week, for 3 weeks. Labor costs consist of wages ($40 per
hour per person) and living expenses (refer to
subsection 4.4.5).
Site cleanup and restoration are limited to the removal of
all equipment from the site. These costs have been
previously incorporated into the disassembly costs.
Requirements regarding the filling, grading, or
rccompaction of the soil will vary depending on the future
use of the site and are assumed to be the obligation of the
responsible party (or site owner).
4.5 Results of Economic Analysis
The costs associated with the operation of the cyclone
furnace, as presented in this economic analysis, are defined
by 12 cost categories that reflect typical cleanup activities
encountered on Superfund sites. Each of these cleanup
activities is defined and discussed, forming the bases for
the cost analysis presented in Table 8.
TableS. Treatment Costs for 3.3 tph Cyclone furnace
Vitrification System Treating 20,000 Tons of
Contaminated Soil
Item
60%
online
Cost (S/ton)
70%
online
80%
online
Site Preparation
Permitting and
Regulatory Costs
Equipment Cost Incurred
Startup and Fixed Costs
Labor
Supplies
Consumables
Effluent Treatment
and Disposal
Residuals Handling
and Transport
Analytical Costs
Facility Modification,
Repair and Replacement
Site Demobilization
Total Operating Costs
31.37
43.83
58.67
219.95
2.02
157.96
31.37
31.37
38.52 34.53
58.94 59.48
188.53 164.96
1.87 1.76
157.96 157.96
1.24 1.06 0.93
13.83 13.83 13.83
528.88 492.09 464.84
The percentage of the total cost contributed by each of the
12 cost categories is shown in Table 9.
Table 9. Treatment Costs as Percentages of Total Costs
for 3.3 tph Cyclone Furnace Treating 20,000
Tons of Contaminated Soil
Cost (as % of total cost)
Item
Site Preparation
Permitting and
Regulatory Costs
Equipment Cost
Incurred
Startup and Fixed Costs
Labor
Supplies
Consumables
60%
online
5.9
—
8.3
11.1
41.6
0.4
29.9
70%
online
6.4
—
7.8
12.0
38.3
0.4
32.1
80%
online
6.7
—
7.4
12.8,
35.5
0.4
34.0
Effluent Treatment and
Disposal
Residuals Handling and
Transport
Analytical Costs
Facility Modification,
Repair and Replacement
Site Demobilization
Total Operating Costs
0.2
2.6
100.0
0.2
2.8
100.0
0.2
3.0
100.0
B&W states that coal-fired cyclone furnaces frequently
operate with online factors of over 90 percent. The online
factor for a cyclone furnace being used to vitrify soil is
unknown, so online factors of 60 percent, 70 percent, and
80 percent were used to estimate the cost of cyclone
furnace vitrification. The online factor is used to adjust
the unit treatment cost to compensate for the fact that the
system is not online constantly because of maintenance
requirements, breakdowns, and unforeseeable delays.
Through the use of the online factor, costs incurred while
the system is not operating are incorporated into the unit
cost.
The B&W cyclone furnace vitrification system is expected
to be capable of a week of continuous operation; only one
startup should be required each week unless problems
arise. In fact, the system is believed to be capable of
operating continuously (24 hours per day, 7 days per week)
for extended periods of time and B&W will most likely
choose to conduct site remediations in this manner. If
B&W chooses to operate continuously, adjustments must
be made to the cost estimates for fuel, labor, and all other
20
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items which are affected by the length of time that the
system is onsite.
The feed rate during the SITE Demonstration Test was
approximately 170 Ib/hr and the furnace consumed
approximately 5 million Btu/hr. The results of this pilot-
scale demonstration were used to estimate the results of
commercial-scale operation. The "six-tenths" rule was used
to estimate the cost of equipment for the commercial-scale
system from available cost data for equipment of a
different capacity [1]. The Marshall & Swift cost index
was used to estimate current costs (fourth quarter of 1991)
from earlier cost data [1]. It is assumed the commercial-
scale unit will have a feed rate of 3.3 tph and will require
approximately 100 million Btu/hr. For this feed rate, the
results of the analysis show a unit cost ranging from $465
per ton to $529 per ton for 80 and 60 percent online
conditions, respectively.
These costs are considered order-of-magnitude estimates
as defined by the American Association of Cost Engineers.
The actual cost is expected to fall between 70 percent and
150 percent of these estimates. Since costs were estimated
from a pilot unit, the range may actually be wider.
Table 10 compares estimated unit treatment costs for sites
containing 10,000, 20,000, and 100,000 tons of contamin-
ated soil, while Table 11 shows the percentage of the
treatment costs contributed by each of the 12 cost
categories. All variables except total amount of
contaminated soil are held constant. In particular, all
three estimates utilize a 3.3 tph cyclone furnace and a 60
percent online factor. If the 3.3 tph cyclone furnace is
used to remediate a site containing less than 20,000 tons
of contaminated soil (all other variables remaining
constant), the startup and fixed costs will become more of
a factor. Unit costs derived from startup and from fixed
expenses will be higher, but unit costs derived from
operating expenses will remain approximately the same.
Variations hi the impacts of the 12 cost categories can be
seen in Tables 10 and 11.
For example, if this system is applied to a site containing
10,000 tons of contaminated soil, the unit treatment costs
(using a 60 percent online factor) are estimated at $601
per ton of soil. If the 3.3 tph cyclone furnace is used at a
site containing over 20,000 tons of contaminated soil (all
other variables remaining constant), the startup and fixed
costs will become less of a factor. Unit costs derived from
startup and from fixed expenses will be lower, but unit
costs derived from operating expenses will remain
approximately the same. For example, if this system is
applied to the remediation of a site containing 100,000
tons of contaminated soil, the unit treatment costs (using
a 60 percent online factor) are estimated at $472 per ton
of soil.
Table 10. Treatment Costs for 3.3 tph Cyclone Furnace
Vitrification System Operating with a 60% Online
Factor
Item
10,000
tons
Cost (S/tonl
20,000
tons
100,000
tons
Site Preparation 31.37
Permitting and
Regulatory Costs —
Equipment Cost Incurred 50.46
Startup and
Fixed Costs 109.90
Labor 219.95
Supplies 2.02
Consumables 157.96
Effluent Treatment
and Disposal —
Residuals Shipping,
Handling and Transport —
Analytical Costs —
Facility Modification, Repair
and Replacement
31.37 31.37
43.83 38.53
58.67 17.69
219.95 219.95
2.02 2.02
157.96 157.96
Site Demobilization
Total Operating Costs
1.24
27.67
600.57
1.24
13.83
528.88
1.24
2.77
471.53
It will take over 8 years to remediate a site containing
100,000 tons of contaminated soil with the 3.3 tph system.
For this volume of soil, a larger unit would be more
appropriate. Although B&W does not currently have any
plans to construct a larger system, a preliminary cost
estimate was prepared for a system capable of treating 20
tph of contaminated soil.
Table 12 compares estimated unit treatment costs for the
use of 3.3 tph and 20 tph systems at a site containing
100,000 tons of contaminated soil, while Table 13 shows
the percentage of the treatment costs contributed by each
of the 12 cost categories. All variables except feed rate
are held constant. In particular, both estimates utilize a 60
percent online factor. This preliminary analysis indicates
that it will cost $505 per ton to remediate a site containing
100,000 tons of contaminated soil using the 20 tph system
(assuming a 60 percent online factor). When the larger
system is used, the treatment tune is approximately
1.3 years and the equipment is onsite for approximately
1.6 years. Transportation and onsite assembly of the
larger unit, however, could present difficulties.
21
-------
Table 11. Treatment Costs as % of Total Costs for 3.3
tph Cyclone Furnace Vitrification System
Operating with a 60% Online factor
Cost (as % of total cost)
Item
Site Preparation
Permitting and
Regulatory Costs
Equipment Cost Incurred
Startup and Fixed Costs
Labor
Supplies
Consumables
Effluent Treatment
and Disposal
Residuals Handling and
Transport
Analytical Costs
Facility Modification,
Repair and Replacement
Site Demobilization
Total Operating Costs
10,000
tons
5.2
—
8.4
18.3
36.6
0.3
26.3
—
—
—
0.2
4.6
100.0
20,000
tons
5.9
—
8.3
11.1
41.6
0.4
29.9
—
—
—
0.2
2.6
100.0
100,000
tons
6.7
—
8.2
3.8
46.6
0.4
335
—
—
—
0.3
0.6
100.0
Table 12. Treatment Costs for the Remediation of 100,000
Tons of Contaminated Soil Using Cyclone Furnace
Vitrification System Operating with a 60% Online
Factor
Cost (S/ton)
Item
3.3 tph
System
20 tph
System
Site Preparation 31.37 31.37
Permitting and
Regulatory Costs — —
Equipment Cost Incurred 38.53 24.62
Startup and Fixed Costs 17.69 46.06
Labor 219.95 90.73
Supplies 2.02 2.02
Consumables 157.96 303.19
Effluent Treatment
and Disposal — —
Residuals Shipping,
Handling and — —
Transport
Analytical Costs — —
Facility Modification,
Repair and Replacement 1-.24 0.68
Site Demobilization 2.77 6.57
Total Operating Costs 471.53 505.24
The costs excluded from this cost analysis are described in
subsections 4.3 and 4.4. This analysis does not include
values for 4 of the 12 cost categories, so the actual cleanup
costs incurred by the site owner or responsible party may
be significantly higher than the costs shown hi this analysis.
4.6 References
1. Peters, M.S. and Timmerhaus, K.D. Plant Design and
Economics for Chemical Engineers; Third Edition;
McGraw-Hill, Inc: New York, 1980.
2. U.S. Environmental Protection Agency Office of Air
Quality Planning and Standards. Cost Control
Manual. PB90-169954. January, 1990.
Table 13. Treatment Costs as Percentages of Total Costs for
Cyclone Furnaces Treating 100,000 Tons of
Contaminated Soil
Cost (as % of total cost)
3.3 tph 20 tph
Item
system
system
Site Preparation 6.7 6.2
Permitting and Regulatory
Costs — —
Equipment Cost Incurred 8.2 4.9
Startup and Fixed Costs 3.8 9.1
Labor 46.6 18.0
Supplies 0.4 0.4
Consumables 33.5 60.0
Effluent Treatment and — —
Disposal
Residuals Handling and — —
Transport
Analytical Costs — —
Facility Modification, Repair 0.3 0.1
and Replacement
Site Demobilization 0.6 1.3
Total Operating Costs 100.0 100.0
22
-------
Appendix A
Process Description
A.1 Introduction
The B&W cyclone furnace technology is a well-
established design for coal combustion. Previous
applications of this technology to municipal solid
waste (MSW) ash containing heavy metals led to its
use on metals-contaminated soils that also contain
organic constituents. B&W's cyclone furnace is an
innovative thermal technology which may offer
advantages in treating soils containing organics, heavy
metals, and/or radionuclide contaminants. The pilot
scale unit used during the SITE demonstration
simulates typical full-scale commercial cyclone boilers
being used for steam generation in power plants.
The demonstration was conducted to evaluate the
ability of the B&W cyclone furnace to vitrify
contaminated soil and waste (liquids and solids). The
process was demonstrated using an SSM provided by
the EPA's Risk Reduction Engineering Laboratory in
Edison, New Jersey. SSMs are well-characterized,
clean soils which are spiked with known
concentrations of specified contaminants.
A.2 The Cyclone Furnace
The pilot unit, shown in Figure A-l, is a scaled-down
version of a B&W commercial coal combustion
cyclone furnace. The furnace is watercooled and
similar to B&W's single cyclone, front-wall fired
cyclone burners. It has a 6-million Btu/hr heat input.
For the demonstration, natural gas was introduced
into the cyclone furnace. Preheated combustion air
(nominal 800°F) entered tangentially into the cyclone.
The feed SSM was introduced via a soil disperser
(atomizer) at the center of the cyclone. The gas
exiting the cyclone barrel had a temperature of
approximately 3000°F while the gas exiting the upper
furnace had a temperature over 2000°F with a 2-
second residence time.
The energy requirements for vitrification of the SSM
were 15,000 Btu/lb. Given the much larger surface
area-to-volume ratio of the pilot unit, one may expect
a full-scale unit to achieve lower energy requirements.
STACK PARTICULATE
SAMPLING LOCATION
SSM FEED
SYSTEM
CONTINUOUS EMISSIONS
MONITOR (CEM)
SAMPLING LOCATION
SSM
SAMPLING
LOCATION
SLAG AND
QUENCH
WATER
SAMPLING
LOCATION
ID FAN
BAGHOUSE
HEAT
EXCHANGER
FURNACE
STACK
NATURAL
GAS
SOIL
INJECTOR
1 \SLAG ^CYCLONE
SPOUT BARREL
-SLAG
QUENCHING
TANK
Figure A-l. Cyclone Test Facility.
23
-------
The cyclone is designed to achieve very high heat
release rates, temperatures, and turbulence.
Participate matter from the soil stream is retained
along the walls of the furnace by the swirling action of
the combustion air and is incorporated into the
molten slag layer. Organic material in the soil is
vaporized or combusted in the molten slag. The slag,
which has a temperature of 2400°F, exits the cyclone
furnace from a tap at the cyclone throat and drops
into a water-filled tank where the material is
quenched. A small portion of the soil exits as flyash
in the flue gas and is collected hi a baghouse. A heat
exchanger cools stack gases to approximately 200°F
before they enter the baghouse. The cyclone facility is
also equipped with a scrubber to control any acid
gases that maybe generated. For this demonstration,
the scrubber was not required since chlorinated
compounds were not spiked into the SSM.
The SSM was delivered onsite in 55-gallon drums and
fed to the system by connecting the SSM transport
drum to the feed cone. A system of dust-free valves
was opened to allow a screw feeder to transfer the soil
to the cyclone feed hopper. A screen above the feed
hopper removed oversized materials and a mixer kept
the SSM from settling in the feed hopper. After
passing the screw feeder, the soil was fed to the
furnace pneumatically, utilizing a small fraction of the
combustion air.
A variety of sampling ports and instrument monitors
were fitted to the pilot unit. A system of stairways
and walkways provided access to all required gas
stream sampling points.
24
-------
Appendix B
Vendor's Claims
B.I Site Demonstration Vendor's Claims
The effectiveness of the B&W Cyclone Furnace
Vitrification Technology at destroying organics and
immobilizing heavy metals and simulated radionuclides in
a non-leachable slag was evaluated during the SITE
Demonstration. To perform this evaluation, the following
critical and non-critical Vendor's Claims were developed
by Babcock & Wilcox, based on discussions with the U.S.
EPA, for evaluation in the Demonstration. These claims
are presented in Table B-l.
B.2 Comparison of Performance Results from
the Two SITE Emerging Technologies
Projects with the Vendors Claims
B.2.1 Synthetic Soil Matrix and Feed Conditions
Two Superfund Innovative Technology Evaluation (SITE)
Emerging Technology projects were conducted prior to the
SITE Demonstration. These two projects, Phase I and
Phase II, were conducted to establish the feasibility of the
cyclone vitrification process for dry soil (Phase I) and wet
soil (Phase II) treatment. In each project, measurements
were made to evaluate TCLP leachabilities, volume
reduction, and materials and heavy metals mass balances.
A synthetic soil matrix formulated by EPA was used for all
cyclone testing. Both clean and spiked SSM were obtained
from the EPA Risk Reduction Engineering Laboratory
(RREL) Releases Control Branch in Edison, NJ. SSM,
used by EPA for treatment technology evaluations, has
been well-characterized in previous studies [1]. Clean soil
was used for furnace conditions optimization. The spiked
SSM used in the Emerging Technologies projects
contained 7,000 ppm (0.7 percent) lead, 1,000 ppm (0.1
percent) cadmium, and 1,500 ppm (0.15 percent)
chromium.
Table B-l. B&W Claims for Cyclone Vitrification Technology
Parameter Claim
Critical
TCLP Produce a vitrified slag that does not
exceed Toxicity Characteristic
Leaching Procedure (TCLP) regula-
tory levels for cadmium (i.e., < 1
mg/L), lead (<5 mg/L), and
chromium (<5 mg/L).
Achieve at least a 10 to 1 ratio (dry
weight basis) of slag to flyash.
Capture at least 60% (by weight) of
the non-volatile metal chromium
from the dry, untreated SSM in the
vitrified slag.
Achieve at least a 25 percent volume
reduction in solids when comparing
product solid to untreated SSM.
Achieve a 99.99% destruction and
removal efficiencies DREs for each
organic contaminant spike
(anthracene and dimethylphthalate).
Comply with emission limits for CO,
total hydrocarbons (THC), and
particulates from the stack as
stipulated by 40 CFR 264 (i.e., CO
of <100 ppm, THC of <20 ppm,
and particulates of <0.08 gr/dscf at
7% oxygen).
Produce a slag that immobilizes
(passes leaching standards)
radionuclides as measured by the
American Nuclear Society test
(ANS) 16.1 (i.e., ANS 16.1 calculated
teachability index (LI) >6).
Capture at least 60% (by weight) of
the non-volatile metals strontium
and zirconium in the vitrified slag.
Slag to Flyash Ratio
Non-Volatile Metals
Capture (Cr) in the
Slag
Volume Reduction
DREs
CO, THC, Particulates
Non-Critical
ANS 16.1 Simulated
Radionuclide
Leachability
Non-Volatile
Radionuclide Capture
in the Slag
In Phase I, dry SSM was processed at feed rates of 50 to
150 Ib/hr. In Phase II, wet SSM was processed at
feed rates of 100 to 300 Ib/hr (dry basis).
25
-------
Approximately 11 tons of spiked and unspiked SSM were
processed during each of the two project Phases.
B.2.2 Performance Results
A comparison of Phase I and II results against the
Vendor's Claims developed for the Demonstration is
presented in Table B-2. Not ah1 of the Demonstration
claims were tested during these projects (e.g., DRE, ANS
16.1 were omitted). All claims tested were met or
exceeded during these Emerging Technology projects (the
Claims were finalized on the basis of these results).
Table B-2. Phase I & Phase II Performance vs. Vendor Claims
Parameter
TCLP-Cadmium
TCLP-Lcad
TCLP-Chromlum
Slag to Flyash
Ratio
Non-Volatile
Metal (Or)
Capture in the
Slag
Volume Reduction
Performance Performance
Criterion in Measured in
Vendor's Claim Phase 1°
< 1.0 mg/L 0.13 mg/L
< 5.0 mg/L 0.20 mg/L
< 5.0 mg/L 0.11 mg/L
> 10:1 14.6:1
> 60% 80-95%
>25% 35%
Performance
Measured in
Phase II"
0.07 mg/L
0.20 mg/L
0.04 mg/L
34:1
78-95%
25%
a Average results where several measurements were made.
B.3 Compar
ison of Performance Rt
ssultsfrom
the SITE Demonstration with the Vendors
Claims
B3.1 Synthetic Soil Matrix and Feed Conditions
On the basis of the Phase I and II Emerging Technology
projects, Babcock & Wilcox was asked to perform a SITE
Demonstration. For the Demonstration, a wet SSM was
used. Demonstration goals included the vendor's claims
given above.
The SSM used in the SITE Demonstration contained 7,000
ppm lead, 1,000 ppm cadmium, and 4,500 ppm chromium;
6,500 ppm anthracene; 8,000 ppm dimethylphthalate; and
the three simulated radionuclides: 4,500 ppm bismuth,
4,500 ppm strontium, and 4,500 ppm zirconium. The
rationale for B&Ws choice of radionuclide surrogates is
as follows: Bismuth was used as a surrogate for volatile
radionuclides important at DOE/DOD sites such as
cesium (cold cesium was originally proposed but found to
be excessively expensive). Cold strontium was used as a
surrogate for radioactive strontium (the cold version of the
radionuclide is the best possible surrogate). Zirconium
was considered an excellent surrogate for radioactive
thorium and uranium from the standpoint of both volatility
and chemical behavior (all are oxophillic and tend to be in
the +4 oxidation state).
A total of 3 tons of SSM were processed during the
Demonstration at a feed rate of 170 Ib/hr.
B3.2 Performance Results
A comparison of the Demonstration results against the
Vendor's Claims developed for the Demonstration is
presented in Table B-3. AH claims tested were exceeded
during the Demonstration.
Table B-3. SITE Demonstration Performance vs. Vendor Claims
Parameter
Performance Performance
Criterion in • Measured
Vendor's Claim in Demonstration"
TCLP-Cadmium
TCLP-Lead
TCLP-Chromium
Slag to Flyash Ratio
Non-Volatile Metal
(Cr) Capture in the
Slag
Non-Volatile Metal
(Sr) Capture in the
Slag?3
Non-Volatile Metal
(Zr) Capture in the
Slag>
Volume Reduction
DRE-Anthracene
DRE-
Dimethylphthalate
CO
THC
Participates
< 1.0 mg/L
< 5.0 mg/L
< 5.0 mg/L
> 10:1
>60%
> 60%
> 60%
>25%
> 99.99%
> 99.99%
<100 ppm
<20 ppm
< 0.08 gr/dscf3
0.12 mg/L
0.29 mg/L
0.30 mg/L
15.6:1
76%
88%
96%
28.1%
> 99.996%
> 99.998%
4.8-54.1 ppm
<5.9-18.2 ppm
0.001 gr/dscf
ANS 16.1 Leachability-
Bismuthb
ANS 16.1 Leachability-
Strontiumb
ANS 16.1 Leachability-
Zirconiumb
LI > 6
LI > 6
LI > 6
LI = 13.4
LI = 13.1
LI = 8.7
a Average results where several measurements were
made.
b Non-critical parameter.
c Corrected to 7 percent oxygen.
26
-------
B.4 Summary
The Babcock & Wilcox 6-million Btu/hr pilot cyclone
furnace met or exceeded all critical and non-critical
Vendor's Claims. Because these performance results were
measured on a pilot cyclone furnace configured as a utility
boiler, and by no means optimized for soil vitrification, a
unit designed for dedicated soil vitrification may improve
process performance and throughput.
B.5 Reference
1. P. Esposito, J. Hessling, B. Locke, M. Taylor, M.
Szabo, R. Thurnau, C. Rogers, R. Traver, and E.
Barth, "Results of Treatment Evaluations of a
Contaminated Synthetic Soil," JAPCA. 39: 294
(1989).
27
-------
Appendix C
SITE Demonstration Results
C.1 Introduction
This appendix summarizes the results of the SITE
Demonstration Test of the B&W Cyclone Furnace
Vitrification Technology. These results are also discussed
in Section 3 of this report. A more detailed account of the
demonstration may be found in the TER.
During the demonstration, the effectiveness of the process
was evaluated by conducting three identical runs using a
B&W pilot-scale unit (Runs 1, 2, and 3). In addition, a
background run was conducted to determine baseline
conditions (Run 0). Sampling of the feed SSM and waste
streams was performed in accordance with the procedures
outlined in the Demonstration Plan.
The emphasis of a SITE demonstration is for the
technology to meet ARARs. The ability of the cyclone
furnace to destroy semivolatile organics and immobilize
heavy metals and simulated radionuclides into a non-
leachable slag was evaluated. Results from this
demonstration include TCLPs of the slag, metals
partitioning, DREs, and emissions from the technology.
The concentration of contaminants hi the quench water
and baghouse solids, as well as the slag-to-flyash ratio,
volume reduction, radionuclide teachability from the slag,
and SSM characteristics are also addressed.
Data regarding simulated radionuclides are suspect
because the method has not been validated for these
metals. Since the method's accuracy and precision are not
well quantified, the data are used for information purposes
only.
C.2 Slag Characteristics
During the demonstration, 94 percent of the non-
combustible portion of the feed was transformed from
loosely packed soil to a brittle, glass-like slag. The
remaining 6 percent of the non-combustible feed was re-
leased hi the flue gas as particulate matter. By comparing
the particulate emission rate from the furnace
outlet with the amount of slag produced per hour by the
cyclone furnace, a relative measure of slag and flyash
production can be calculated. This "slag-to-flyash ratio" is
a comparative measure of solids generation and is calcu-
lated by dividing the mass of the slag (dry weight) by the
mass of the flyash (dry weight). Average slag-to-flyash
ratios of 14.5, 13.7, and 12.9 were obtained for Runs 1, 2,
and 3, respectively. These results are consistent with
Demonstration Test objectives and support B&W's claim
that a greater than 10:1 ratio of slag-to-flyash ratio can be
achieved using the cyclone furnace.
C.2.1 Leachability
TCLPs were performed on both the feed SSM and
vitrified slag. The teachabilities obtained for these
materials are summarized hi Table C-l. Significant
reductions were experienced for all the metals, particularly
cadmium and lead, which were brought into compliance
with regulatory limits as a result of cyclone vitrification
treatment. The data demonstrate the cyclone furnace can
immobilize cadmium, chromium, and lead so that
regulatory compliance is achieved.
To verify that decreases in teachability are due to changes
in the leaching behavior of the soil, and not due to lower
concentrations of metals hi the slag, the percent
teachability of metals in the SSM and slag was determined
by dividing the amount of each heavy metal which leached
during the TCLP test from the SSM and slag by the total
amount of each heavy metal which could be leached.
These percent leachable metals are listed in Table C-2 and
are based on average results for the demonstration. The
results indicate the vitrification process decreases the
leachability hi the slag by changing the physical/chemical
behavior of the soil.
ANS Method 16.1 (American National Standard
Measurement of the Leachability of Solidified Low-Level
Radioactive Wastes by a Short-Term Test Procedure) was
28
-------
Table C-l.
Average TCLF Results from B&W SITE Demonstration
Runs1' (mg/L)
Cadmium Chromium
Lead
SSM
Runl
Run 2
Run3
Slag
Runl
Run 2
RunS
52.0
63.6
34.2
<0.11»
0.19
0.07
2.29
1.77
3.87
0.15
0.37
0.15
90.8
75.6
125
<0.25
<0.39b
<0.29b
a Average values were calculated from nine individual samples
collected over course of each run.
b If result was undetected, the detection limit was used in
calculations for averages. This represents worst case scenario.
Table C-2. Percentage of Leachable Metals from B&W
Cyclone Furnace
Metal Leached
Total from lOOg
Heavy Metals
SSM
Cadmium
Chromium
Lead
Slag
Cadmium
Chromium
Lead
Metal in lOOg
sample
(nig)
126
435
641
10.6
161
176
sample in TCLP
Test
(mg)
99.8
5.28
195
0.24
0.44
0.62
% of Metal
Present That
Leached
79
1.2
30
2.3
0.27
0.35
used to determine the leachability of the simulated
radionuclides strontium, zirconium, and bismuth from the
slag generated during the SITE demonstration. The
method was modified to account for the irregular shape of
the slag.
Although all other equations and data reduction
procedures remain the same, the method accuracy and
precision are not well quantified because the method has
not been verified for the slag and the data are therefore
suspect. Results from the ANS method are reported as a
leachability index and presented in Table C-3.
C22 Volume Reduction
Combustion of any carbonates, sulfates, and organics
present hi the SSM contributed to the volume reduction
experienced during the Demonstration Test. The percent
Table C-3.
Slag
Runl
Range
Mean
Run 2
Range
Mean
Run3
Range
Mean
Leacha
Bismuth
12.9-13.7
13.2
13.5-14.2
13.8
123-14.0
13.3
ibilify Index of Sim
Strontium
12.1-13.6
12.9
12.8-13.7
13.3
11.6-14.0
13.0
ulated Radionuclii
Zirconium
8.2-8.8
8.6
8.2-9.4
8.7
8.3-9.0
8.7
volume reduction of dry SSM after treatment (as deter-
mined by the volume of slag produced) was computed
according to the following equation:
Percent Volume Reduction = Vf - Vs
X100%
Where:
Vf = Volume of the SSM feed on a dry weight
basis
Mass of the feed (dry basis) used for the
run divided by the bulk density of the
feed
Vs = Volume of the slag on a dry weight basis
= Mass of the slag produced for the run
divided by the bulk density of the slag
The bulk density of the slag was initially analyzed using
the American Society for Testing and Materials (ASTM)
method for specific gravity (ASTM D854 Test Method for
Specific Gravity of Soil). This method defines the specific
gravity as the ratio of the mass of a unit volume of soil to
the mass of the same volume of water. The result from
this analysis could not be effectively employed in calcula-
tions using the bulk density values obtained for the feed.
The feed was re-analyzed using a method B&W developed
for determining bulk density. This method determines
bulk density by weighing the soil in a box of known
volume. Bulk density is calculated as follows:
Bulk density in lb/ft3 = Wt - W0
Where:
V
V = Volume of the box in ft3
Wj = Weight of the box with sample in pounds
W0 = Original weight of the box in pounds
29
-------
This method was also used to determine bulk density of
the slag. Although the accuracy of the data obtained using
this non-standardized method is questionable, comparisons
between the SSM and slag data provide reliable results.
Table C-4 lists the percent volume reductions achieved
using the slag bulk density values from the ASTM and
B&W methods. The negative values for volume reduction
calculated using the ASTM generated values for the slag
specific density are inconsistent with both testing
expectations and field observations. The results obtained
using the B&W data, however, agreed with field
observations and Demonstration Test objectives. These
results confirm B&Ws claim that an average of 25 percent
reduction in the volume is experienced during treatment.
Table C-4.
Method of
Bulk Density
ASTM
B&W
Volume Reduction (%)
Run 1
-43.8
31.2
Run 2
-32.7
32.0
Run3
-49.7
23.5
Avg
-42.0
28.9
C.3 Metals Partitioning
The fate of a metal spiked within the SSM was dependent
on the relative volatility of the metal. The majority of the
metals spiked within the SSM were either captured within
the slag or the flyash; however, a small portion did escape
to the ambient air. Metal emission data are presented in
Table C-5.
Table C-5.
Run
No.
Summary of Metals Emissions
Emission rate (Ib/h)
Location
Cd
Cr
Pb
Furnace
Outlet
Stack
Furnace
Outlet
Stack
Furnace
Outlet
Stack
7.4xlO'2 4.3xlO'2 3.6x10-'
3.8xlO-s 5.8xlO'5 1.2X10-4
7.9xlO'2 4.4xlO'2 4.2x10-'
1.9X10"
ZlxlO"4
7.8xlO'2 6.4xlO'2. 4.7x10''
9.4x10-* 2.1xlO'5 4.8xlO'5
Percent retentions in the slag of the metals initially present
within the SSM were evaluated by comparing the total
mass of metals hi the SSM to the total mass of metals in
the slag.
These values were determined using the following
equation:
Percent Metal Retention =
Where:
pP
MSi
MPi + MSi
xlOO%
= Percentage of non-combustible SSM that
becomes furnace outlet participate
= Furnace outlet particulate emission rate
divided by the non-combustible portion
of the feed
pS = Percentage of non-combustible SSM that
becomes slag
= 100% - pP
MPi = Percentage of metal of interest in the
furnace outlet particulate
= pP x concentration of metal of interest in
furnace outlet particulate
MSi = Percentage of metal of interest in the
slag material
= pS x concentration of metal of interest in
slag
MPi + MSi = Percentage of metal of interest in SSM
Table 5 in Section 3 lists the percent metal retention of
the six metals spiked in the SSM. On the average, over 75
percent of the chromium was incorporated in the vitrified
slag. This supports B&W's claim that greater than 60
percent of the chromium (by weight) would be trapped
within the vitrified slag. Approximately 88 and 97 percent
of the strontium and zirconium, respectively, were
captured within the slag. These results are consistent with
the non-volatile nature of these metals. The more volatile
bismuth, cadmium, and lead experienced lower captures.
The bulk of these metals partitioned to the flue gas and
were eventually captured by the baghouse.
Comparisons between the emissions entering the baghouse
from the furnace outlet and exiting the stack yield an
average particulate removal efficiency of 99.89 percent.
The majority of the metals exiting the furnace in the flue
gas are captured within the baghouse, although small
amounts were detected in the stack gas.
30
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C.4 Air Emissions
Where:
C.4.1 Particulate
Participate emissions were measured at the furnace outlet
prior to the air pollution control devices and at the stack
for all runs. Particulate emissions out of the stack
averaged 0.0008 gr/dscf (corrected by 7 percent O2), or
0.01 Ib/hr, which is well under the RCRA regulatory limit
of 0.08 gr/dscf. Average particulate emissions from the
furnace outlet were 0.806 gr/dscf (corrected to 7 percent
O2), or 6.07 Ib/hr. Before furnace outlet emissions
reached the stack, they were controlled by a baghouse,
which had an average removal efficiency of 99.89 percent
efficiency. Table 6 in Section 3 summarizes particulate
testing during the demonstration.
CA2 ORE
In addition to producing a slag capable of retaining a high
percentage of the heavy metals, the cyclone furnace
achieved the organic destruction efficiency required of
RCRA hazardous waste incinerators (99.99 percent). By
comparing the concentrations of the spiked organic
contaminants, anthracene and dimethylphthalate, present
in the SSM to their concentrations in the stack gas, DREs
for these compounds were calculated as follows:
W.
in
W.
out
Mass feed rate of the POHC of interest
in the waste stream feed to the furnace
Mass emission rate of the same POHC
present in exhaust emissions prior to
release to the atmosphere
As listed in Table C-6, the cyclone furnace was capable of
removing greater than 99.99 percent of both anthracene
and dimethylphthalate. Because these organics are
relatively difficult to destroy, it is projected that the
commercial-scale cyclone furnace will be capable of
achieving DREs of at least 99.99 percent for all or nearly
all organics.
Table C-6.
Compound
Anthracene
Dimethyl
phthalate
DREs
Run 1
> 99.996
> 99.998
(%)
Run 2
> 99.997
> 99.998
Run3
> 99.996
> 99.998
Average
> 99.997
> 99.998
DRE(%) =
xlOO%
'in
C.43 PICs
VOC concentrations were measured by the Volatile
Organic Sampling Train (VOST) analysis. Average VOC
concentrations are presented in Table C-7. Run 0 data
Table C-7. Summary of Volatile Organic Concentrations in Stack Gas from B&W SITE Demonstration (pg/m3)8
TriPu Field Blank
Compound
Blankb
RunO
Run 1
(Run 1)
Chloroethane
Methylene chloride
Acetone
Carbon Disulfide
Chloroform
1,1,1-Trichloroethane
Carbon tetrachloride
Trichloroethene
Benzene
Tetrachloroethene
Toluene
Ethylbenzene
Total xylenesh
c
0.40
c
1.45
d
d
d
d
d
d
d
d
0.85
c
<0.25-1.15f
<050-2.50f
d
0.48-0.70
0.48-0.73
d
d
1.06-3.47
1.41-2.23
1.22-8.32
0.67-554 !
3.04-20.4
c
2.95-3.69
<0.50-5.896
<0.25-10.2f
<0.25-0.45e
29.8-31.4
<0.25-3.81e
d
2.02-2.78
1.01-1.12
1.79-4.85
<0.25-0.91f
0.63-1.92
c
2.20
0
2.20
d
d
d
d
d
d
0.25
d
0.70
<0.50-1.51e
< 0.50-0.96°
0.81-5.26
c
<0.25-1.28e
<0.25-0.37f
14.4-18.7
< 0.25-1.60°
0.25-0.27
1.26-2.34
0.84-1.01
1.32-1.76
< 0.25-0.26°
0.64-1.26
<0.50-1.85a>S
c
1.01-20.8
<050-41.1f
<0.25-1.61f
<0.25-0.42e
<0.25-20.2f
<0.25-2.52°
d
1.44-7.29
<0.25-0.94f
0.72-2.71
0.25-051
1.41-2.06
No field blank was taken for Run 0. No compounds were detected in the lab blanks and field blanks for Run 2/3.
Concentrations are based on a sample volume of 20L.
Not detected. Detection limit 050 fig/m3.
Not detected. Detection limit 0.25/tg/m3.
Emissions were detected in 1 out of 3 samples.
Emissions were detected in 2 out of 3 samples.
An estimated 15 mg was detected in the lab blank during this analyses; however, it was less than the specified detection limit
The laboratory indicated that painting activities during the VOST analysis time period may have contributed to xylene contamination
in the samples at levels similar to those detected in the trip and field blank. All other xylene levels may be biased slightly high
31
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represent VOC concentrations when natural gas only was
fired. Although no chlorinated compounds were spiked in
the SSM, several chlorinated VOC compounds were
detected in the stack gas. In order to account for these
chlorinated compounds, the feed SSM was analyzed for
trace levels of chlorine. The chlorine levels ranged from
<0.01 percent to 0.03 percent. These trace amounts may
have resulted in the formation of chlorinated VOCs.
C.4.4 CEMs
CEMs were used to measure NO,, CO, THC, CO* and
O2 emissions during the Demonstration Test. CEM data
are summarized in Tables C-8 and C-9. CEM data for
CO2 and O2 compare favorably with values obtained from
Orsat analysis. These data reflect typical excess air values
for a natural gas-fired furnace.
C.5 Quench Water
The quench water was tested to determine if any of the
metals or semivolatile organics present in the slag or
infusible matter leached into the quench water.
Concentrations of cadmium, chromium, and lead were
detected and are listed in Table C-10. It appears these
concentrations increased after Runs 1 and 2. Since many
of the readings are close to or below analytical detection
limits and method quantitation limits, the significance of
these increases is minimal, however. Concentrations of
semivolatiles, bismuth, and zirconium are considered
insignificant, since they were at or below the analytical
detection limits and method quantitation limits.
Table C-10. Quench Water from B&W SITE
Demonstration
Table C-8. Summary of NOX, CO, and THC CEM Data
Concentration (ppm •
Run No. Value
1 Average
Low
High
2 Average
Low
High
3 Average
Low
High
NOX
357
328
373
338
310
423
383
311
435
- dry basis)
CO THC as CjHg
>6.1
4.8
>54.1
6.9
6.3
7.4
5.0
4.9
5.2
<7.4
<6.9
8.4
11.3
8.9
18.2
<6.4
<5.9
8.1
Cadmium Chromium Lead
Oig/L) Og/L) Og/L)
Before Run 0 <3.0
After Run 0 <3.0
Before Run 1 6
After Run 1 11
Before Run 2 <3.0
After Run 2 (4)
Before Run 3 (4)
After Run 3 (4)
Notes:
1. Values given as less than (<) a
the instrument detection limit;
<7.0 <25
<7.0 <25
18 <25
26 31
<7.0 <25
16 41
16 41
10 <25
certain quantity were below
the quantity given is the
detection limit.
1 x/nl.mp in *-»o*ja«tV\*»cAc r/»T»i-pcpnt MptitifipH jmalvtcs with
estimated values that are above instrument detection limits
but below method quantitation
limits.
Table C-9. Summary of CO2 and O2 CEM Data
Concentration (%)
Run No. Value CO2 O2
1
2
3
Average
Low
High
Average
Low
High
Average
Low
High
9.2
8.8
9.5
8.9
8.2
11.8
9.6
9.6
9.7
4.9
4.6
6.5
4.9
4.4
5.2
4.9
4.8
5.1
32
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Appendix D
Case Studies
D.I Municipal Solid Waste (MSW) Ash
Testing
The cyclone furnace was used in a research and
development project to vitrify MSW ash containing
heavy metals. The cyclone furnace produced a
vitrified MSW ash which was below EPA leachability
limits for all eight of the RCRA metals. The
successful treatment of MSW ash suggested that the
cyclone furnace could treat high-inorganic-content
hazardous wastes and contaminated soils that also
contain organic constituents. These types of
wastes/soils exist at many Superfund sites, as well as
at sites where petrochemical and chemical sludges
have been disposed.
The suitability of the cyclone vitrification technology
relies on the premise that for acceptable performance
in treating hazardous waste mixtures containing
organic and heavy metals constituents, the cyclone
furnace must melt the SSM while producing a non-
leachable slag. It must also achieve the DREs
(currently 99.99%) for organic contaminants normally
required for RCRA hazardous waste incinerators.
The high temperature (over 3000°F), turbulence, and
residence time in the cyclone and main furnace are
expected to achieve high organics DREs.
D.2 Emerging Technologies
Testing
D.2.1 Introduction
The B&W Cyclone Vitrification Furnace was initially
evaluated for the treatment of heavy- metal-contami-
nated soil under the EPA's SITE Emerging Technolo-
gies Program. The sampling and analysis program for
this test was conducted by B&W. The favorable
results of that two-part study led to B&W's
participation in the present Technology Demonstration
Program.
The Emerging Technology tests took place during the
fall of 1990 and summer of 1991. These tests were
designed to evaluate whether the 4 to 6-million Btu/hr
B&W cyclone furnace located at the B&W Alliance
Research Center in Alliance, Ohio was capable of
treating soils contaminated with heavy metals The
same pilot-scale unit was employed during this
Technology Demonstration Test, with minor
modifications to the feed system.
D22 Phase I
The specific objectives of the first phase of Emerging
Technology tests included the establishment of cyclone
operability, determination of slag leachability and
volume reduction, and determination of preliminary
mass balance for the cyclone treatment process.
Testing utilized SSMs spiked with high levels of lead,
cadmium, and chromium. These soils were fed at
nominal rates of 50 and 150 Ib/hr tangentially into the
cyclone furnace. The soil was melted and the result-
ing slag was released into a water-filled slag tank
where it was solidified.
In order to determine whether a vitrified material was
produced, samples of the feed SSM and slag were
taken and analyzed for total metals content and
metals leachability using the Toxicity Characteristic
Leachability Procedure (TCLP). The properties of
the SSMs, the volume reductions experienced, and
preliminary metals mass balances to determine the
fate of the heavy metals during soil treatment were
also determined.
The results of this study are summarized in the
following:
Metals Leachabilitv after Cyclone Treatment: The
results indicate the vitrification process changed the
physical and chemical composition of the soil in such
a manner as to render the heavy metals less teachable.
The percent leachability for lead, cadmium, and
chromium in the untreated SSM were 29, 84, and 3.8
33
-------
percent, respectively. Percent leachability of the slag
for lead, cadmium, and chromium was 0.18, 2, and
0.07 percent, respectively. All slag samples were well
below TCLP limits for the three heavy metals.
Total Metals in Soil and Slag: The total metals
results on the soil and slag samples, averaged and
reported on a dry basis, are given in Table D-l. As
compared to the level of total metals in the SSM, the
slag was relatively enriched hi chromium and depleted
in lead and cadmium.
Volume Reduction; The vitrification process achieved
a volume reduction of approximately 35 percent over
the dry SSM.
Table D-l.
Sample
Composite Soil
(DiySSM)
11/15
11/16
Reagent Blank
Composite Slag
11/15
11/16
Reagent Blank
Multiple Metals
Train Particulatcs
11/15
11/16
Filter Blank
Total Metals in Soil, Slag, and Multiple
Metals Train Particulates (mg/kg)
Cadmium Chromium Lead
1316.+40
1223+34
<0.05
101
134.+3.2
<0.05
15146
14816
15
1391+86
1339+.93
<0.05
1907
2169_+_147
<0.05
12493
9893
108
8007.+248
7390jf214
<0.05
1624
2432.+.221
<0.05
80414
99880
149
Fate of Heavy Metals: Heavy metals could be
trapped within the vitrified slag or be volatilized and
leave the furnace with the flue gas. Metal volatility
controls the distribution of heavy metals between the
fiyash and the slag. To determine the mass balance,
a total heavy metals analysis was performed on the
SSM, vitrified slag, and captured fiyash. Chromium
was determined to be the least volatile with between
80 and 95 percent retention in the slag. Cadmium
was the most volatile metal, with a range of 7
to 8 percent retention in the slag. Lead fell between
chromium and cadmium, in terms of slag retention, at
24 to 35 percent.
DJ53 Phase II
The second phase of the Emerging Technology tests
was designed to build upon the knowledge gained in
the first phase of tests. Phase I established the
suitability of the cyclone furnace for the vitrification of
contaminated soils. Phase II provided additional
operating data and allowed further optimization of
process parameters.
Like Phase I, Phase II utilized SSMs spiked with lead,
cadmium, and chromium. Feed rates in Phase II
ranged from 100 to 300 pounds of SSM per hour.
When the feed rate was increased to 400 pounds per
hour, the furnace temperature dropped and slag
tapping stopped or was blocked. The effects of feed
rate on various parameters were studied. Results
indicated that NOX levels and heavy metals
concentrations in the slag were proportional to feed
rate, while slag temperatures were inversely
proportional to feed rate.
Phase II testing included an evaluation of Borax as a
fluxing agent. Fluxing agents are intended to cause
the soil to melt and tap at lower temperatures,
thereby decreasing metals volatilization and increasing
metals capture in the slag. In a fluxing test, a mixture
containing 10 percent Borax and 90 percent SSM was
fed to the cyclone furnace at a nominal rate of 200
pounds per hour. The results of this Borax addition
are as follows:
• Natural gas load was reduced from 5 million
Btu per hour to 4.1 million Btu per hour.
• The slag temperature was reduced from
2430°F to 2320°F.
• NOX levels in the stack decreased from
between 318 and 337 ppm to 260 ppm.
• Fiyash production increased.
• Metals emissions rates decreased slightly.
• TCLP results indicate that the leachability of
lead from the SSM decreased slightly; further
testing would be required to determine
whether this change was statistically
significant.
• Volume reduction, though not directly
measured, appeared to decrease.
• Cadmium retention in the slag increased
sh'ghtly, but further testing would be required
to confirm the significance of this change.
34
-------
After these results were evaluated, the developer
determined that the addition of Borax did not
significantly improve the operation of the cyclone
furnace.
The remainder of the Phase II testing primarily
reinforced the results of the Phase I testing, although
Phase II testing used wet feed and Phase I testing
used dry feed. Additional data from Phase II testing
are summarized hi the following:
• All slag samples were below TCLP limits for
the three metals.
• The percent teachabilities for lead, cadmium,
and chromium in the untreated SSM were 20,
57, and 0.55 percent, respectively. The
percent teachabilities for lead, cadmium, and
chromium in the slag were 0.09, 0.70, and
0.02 percent, respectively.
As compared to the feed SSM, the slag was
relatively enriched in chromium and depleted
in lead and cadmium.
The vitrification process achieved a volume
reduction of approximately 25 percent
between the SSM and the slag. This is
somewhat lower than the 35 percent volume
reduction achieved in Phase I, but the
difference may simply reflect the difficulty of
obtaining representative samples of the slag.
As in Phase I, heavy metals were retained in
the slag or were volatilized into the flue gas.
In Phase II testing, the following percentages
of heavy metals were retained in the slag:
Chromium: 78 to 95 percent
Lead: 38 to 54 percent
Cadmium: 12 to 23 percent
35
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