EPA-450/3-89-004
HOSPITAL INCINERATOR OPERATOR
TRAINING COURSE:
VOLUME II
PRESENTATION SLIDES
CONTROL TECHNOLOGY CENTER
SPONSORED BY:
Emission Standards Division
Office of Air Quality Planning and Standards
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
Air and Energy Engineering Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
Center for Environmental Research Information
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, OH 46268
March 1989
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EPA-450/3-89-004
March 1989
HOSPITAL INCINERATOR OPERATOR TRAINING COURSE:
VOLUME II
PRESENTATION SLIDES
EPA Contract No. 68-02-4395
Work Assignment 16
Prepared by:
Midwest Research Institute
Suite 350
401 Harrison Oaks Boulevard
Gary, North Carolina 27513
Prepared for:
James A. Eddlnger
Office of Air Quality Planning and Standards
U. S. Environmental Protection Agency
Research Triangle Park, North Carolina 27711
Control Technology Center
U. S. Environmental Protection Agency
Research Triangle Park, North Carolina 27711
-------
NOTICE
This training course is intended to provide the operator with a basic
understanding of the principles of incineration and air pollution
control. This training course is not a substitute for site-specific
hands-on training of the operator with the specific equipment to be
operated.
11
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DISCLAIMER
This document generally describes the proper operation of a hospital
waste incinerator. It is based on EPA's review and assessment of various
scientific and technical sources. The EPA does not represent that this
document comprehensively sets forth procedures for incinerator operation,
or that it describes applicable legal requirements, which vary according'
to an incinerator's location. Proper operation of an incinerator is the
responsibility of the owner and operator.
Mention of trade names or commercial products does not constitute
endorsement or recommendation for use.
111
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ACKNOWLEDGEMENT
This document was prepared by Midwest Research Institute located In
Gary, North Carolina. Principal authors were Roy Neulicht and Linda
Chaput; Dennis Wallace, Mark Turner, and Stacy Smith were contributing
authors. Participating on the project team for the EPA were Ken Durkee
and James Eddinger of the Office of Air Quality Planning and Standards,
Charles Masser of Air and Energy Engineering Research Laboratory, James
Topsale of Region III, Charles Pratt of the Air Pollution Training
Institute, and Justice Manning of the Center for Environmental Research
Information. Also participating on the project team were Carl York and
William Paul of the Maryland Air Management Administration.
Numerous persons were very helpful throughout this project and
provided information and comments for these course materials. Listed
below are some who deserve special acknowledgement for their assistance.
Mr. Larry Doucet, Doucet and Mainka, who provided a thorough
review of the student handbook.
The following persons and facilities who provided our staff access
to their facilities:
Messrs. Steve Shuler and Greg Swan, Joy Energy Systems;
William Tice, Rex Hospital; Dean Clark, Bio-Medical Services,
Inc.; Gary Kamp, PresbyterianUniversity Medical Center; Don
Rust, Duke University Medical Center; Chip Priester, Southland
Exchange Joint Venture; and Gregory Price, The Johns Hopkins
Hospital.
The following manufacturers who provided us with detailed
operating and maintenance information:
Joy Energy Systems, John Zink Company, Cleaver Brooks, and
Industronics.
Mr. Charles BoHack and his staff, Mercy Medical Center, who
hosted the first trial run of this course and Mr. Robert J.
Winterbottom, R. J. Winterbottom, Inc., who assisted during the
course at Mercy Medical Center.
iv
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PREFACE
The program for development of a training course for operators of
hospital medical waste incinerators was funded as a proiect of EPA1 5
Control Technology Center (CTC).
MRn^n/Jff^ ef!-11nhed^y n?A'S Office of Research and Development
(ORD) and Office of Air Quality Planning and Standards (OAQPS) to provide
technical assistance to State and local air pollution control agencies
in?f?M]6uelStof ass1stance can be accessed through the CTC. First, a CTC
HOTLINE has been established to provide telephone assistance on matters
relating to air pollution control technology. Second, more in-depth
engineering assistance can be provided when appropriate. Third the CTC
can provide technical guidance through publication of technical guidance
documents, development of personal computer software, and presentation of
workshops on control technology matters. The technical guidance projects
such as this one to develop training materials for hospital waste
incinerator operators, focus on topics of national or regional interest
that are identified through contact with State and local agencies.
OOPrJnr*CIฃ hnc^ Jnterjst?d !n developing a basic training course for
operators of hospital waste incinerators with the idea that properly
trained operators can improve operating and maintenance procedures and
consequently minimize air emissions. This training course was prepared
inr?nฑS? the Sperator1?1?! a basic understanding of the principles of
incineration and. air pollution control and to identify, in a general
sense, good operating practices. The course is not intended as a
substitute for site-specific hands-on training of~The operator with the
specific equipment to be operated. M^rauor wnn tne
The course consists of three volumes:
Volume I Student Handbook
Volume II Course Presentation Slides
Volume III Instructor Handbook
This volume contains the classroom materials including a copy of the
presentation s ides and student worksheets. A copy of the presentation
til "??" PT1ded 1n Part l Sฐ that *ou can easi1> fo11ow alฐng during
the class. You may want to make notes on the slides to remind yourself
later of important points brought up by the instructor or other
students. Several worksheets also are included in Part II. Your
instructor will allow time for you to complete these worksheets during
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-------
CONTENTS
PART I: COURSE SLIDES
COURSE INTRODUCTION
SESSION 1. PROTECTING THE ENVIRONMENT - YOUR RESPONSIBILITY
SESSION 2. BASIC COMBUSTION PRINCIPLES
SESSION 3. BASIC INCINERATOR DESIGN
SESSION 4. AIR POLLUTION CONTROL EQUIPMENT DESIGN AND FUNCTIONS
SESSION 5. MONITORING AND AUTOMATIC CONTROL SYSTEMS
SESSION 6. INCINERATOR OPERATION
SESSION 7. AIR POLLUTION CONTROL SYSTEMS OPERATION
SESSION 8. MAINTENANCE INSPECTION-A NECESSARY PART OF YOUR JOB
SESSION 9. TYPICAL PROBLEMS
SESSION 10. STATE REGULATIONS
SESSION 11. SAFETY: AN IMPORTANT PART OF YOUR JOB
LIST OF SOURCES FOR DRAWINGS
PART II: CLASSROOM WORKSHEETS
1. INCINERATOR SYSTEM INFORMATION
2. INCINERATOR SYSTEM INFORMATION
3. INCINERATOR SYSTEM INFORMATION
4. OPERATING REVIEW
5. OPERATING PROBLEMS REVIEW
6. INCINERATOR SYSTEM INFORMATION
7. SAFETY REVIEW
vi
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PART I. SLIDE PRESENTATION
This section presents the slides and worksheets which will be used
10 the claซrnnm nny+,nrt of the course< The slides are
n T ' ze
nhn?nn h ? tl ^ Presented here will be supplemented with actual
photographs (which are not presented in this hand-out) during the
presentation. Some drawings have been taken from other documents* the
sources for these drawings are listed at the end of this part?
vii
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COURSE GOALS
TO PROVIDE YOU WITH AN UNDERSTANDING OF:
BASIC PRINCIPLES OF INCINERATION
PROPER OPERATION AND MAINTENANCE PRACTICES
REGULATORY REQUIREMENTS AND SAFETY CONCERNS
-------
UPON COMPLETING THIS COURSE YOU SHOULD:
UNDERSTAND AIR POLLUTION PROBLEMS AND HOW TO MINIMIZE THEM
UNDERSTAND THE CAUSE OF COMMON OPERATING PROBLEMS AND
SAFETY HAZARDS AND HOW TO MINIMIZE THEM
KNOW HOW TO MONITOR OPERATION TO AID IN COMPLYING WITH
REGULATORY REQUIREMENTS
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SESSION 1.
PROTECTING THE ENVIRONMENT - YOUR RESPONSIBILITY
-------
SLIDE 1-1
WHY INCINERATE?
REDUCES WEIGHT AND VOLUME OF WASTE
STERILIZES THE WASTE
DESTROYS ORGANIC MATERIALS THAT MAY DEGRADE AND
PRODUCE HARMFUL BY-PRODUCTS IN LANDFILLS
AESTHETIC REASONSDESTROYS WASTES SUCH AS BODY PARTS
THAT PUBLIC FINDS OBJECTIONABLE
-------
SLIDE 1-2
ENVIRONMENTAL CONCERNS
PATHOGEN DESTRUCTION
AIR EMISSIONS
ASH QUALITY
-------
SLIDE 1-3
Organic
Compounds
Pathogens
Paniculate Carbon
Monoxide
Toxic
Metals
'Hydrochloric Acid
Gas
Waste Feed
(May contain pathogens)
Fugitive
Paniculate
(windblown ash)
Ash
(May contain pathogens)
ENVIRONMENTAL CONCERNS
-------
SLIDE 1-4
THE OPERATOR-YQUR ROLE
IT IS YOUR ROLE AND RESPONSIBILITY TO PROTECT THE
ENVIRONMENT BY:
MINIMIZING POLLUTANT EMISSIONS THROUGH PROPER
OPERATION
MAINTAINING ACCEPTABLE ASH QUALITY THROUGH
PROPER OPERATION
PREVENTING PARTICULATE EMISSIONS FROM ASH
HANDLING AND STORAGE.
IDENTIFYING MAINTENANCE PROBLEMS BY PERFORMING
REGULAR INSPECTIONS
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-------
SESSION 2.
BASIC COMBUSTION PRINCIPLES
-------
SLIDE 2-1
Air
Organics in
Hospital -
Waste
Organics in
Auxilary
Fuel
Combustion
Gases
Energy'
Ash
THE COMBUSTION PROCESS
-------
SLIDE 2-2
Combustion
Air -
N2 Passes
Through
02(21%)
React
Carbon
and
Hydrogen
Organic Feed and Fuel
FATE OF COMBUSTION AIR
-------
SLIDE 2-3
\/
Fixed Carbon
and
Ash
\/
Oo
OXYGEN REACTION
-------
SLIDE 2-4
OPERATING FACTORS RELATED TO COMBUSTION
COMBUSTION AIR
FLOW RATE
DISTRIBUTION
OPERATING TEMPERATURES
WASTE FEED CHARACTERISTICS
-------
SLIDE 2-5
Combustion
Air
Waste /
Organics
Combustion
Chamber
Ash
STOICHIOMETRIC AIR LEVEL
-------
SLIDE 2-6
Combustion
Air
Waste/
Fuel
Ash
AIR LEVEL BELOW STOICHIOMETRIC
"STARVED-AIR"
-------
SLIDE 2-7
Combustion
Air
Waste/ ^^^^
Fuel Organics
Combustion Gas:
02 Remains
1
Ash
AIR LEVEL ABOVE STOICHIOMETRIC
"EXCESS AIR"
-------
SLIDE 2-8
TEMPERATURE
MAXIMUM
TEMPERATURE
DEFICIENT AIR
EXCESS AIR
PERCENT EXCESS AIR
CONTROL OF TEMPERATURE AS A FUNCTION OF EXCESS AIR1
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SLIDE 2-9
HOSPITAL WASTE CHARACTERISTICS
WASTE TYPE
HIGH HEAT
VALUE,
BTU/LB
MOISTURE,
I
HEAT VALUE
AS-FIRED,
BTU/LB
GAUZE, PADS, SWABS,
GARMENTS, PAPER
PLASTICS
8,000-12,000
9,700-20,000
0-30 5,600-12,000
0-1 9,600-20,000
HUMAN ANATOMICAL
8,000-12,000
70-90
800-3,600
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SLIDE 2-10
KEY OPERATING PARAMETERS
COMBUSTION AIR
MIXING
TEMPERATURE
RESIDENCE TIME/RETENTION TIME
WASTE CHARACTERISTICS
HEATING VALUE
~ MOISTURE CONTENT
CHLORINE CONTENT
-------
SLIDE 2-11
COMPLETE COMBUSTION
-------
SLIDE 2-12
Oioxin
-lnorganics\ /'Pathogens
INCOMPLETE COMBUSTION
-------
SLIDE 2-13
OPACITY
Poor Mixing
Starved-Air Conditions
Low Temperatures
Acid Gases
-------
SLIDE 2-14
STACK GAS 0, AND CO
Low 02
INSUFFICIENT AIR
HIGH 02
TOO MUCH EXCESS AIR COOLS GAS
HIGH CO MEANS POOR COMBUSTION
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SLIDE 2-15
ASH QUALITY
VISUAL APPEARANCE
NO RECOGNIZABLE MEDICAL WASTES
BURNOUTCARBON REMAINING
WHITISH GRAY VS BLACK
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SESSION 3.
BASIC INCINERATOR DESIGN
-------
SLIDE 3-1
To
Atmosphere
To
Atmosphere
t
Stack
Air
j Pollution '
' i Control [~
i System i
Ash
MAJOR COMPONENTS OF AN INCINERATION SYSTEM
-------
SLIDE 3-2
INCINERATOR TYPES
MULTIPLE'CHAMBEREXCESS AIR
CONTROLLED (STARVED) AIR
ROTARY KILN
-------
SLIDE 3-3
MULTIPLE-CHAMBER INCINERATORS
COMBUSTION OCCURS IN TWO OR MORE CHAMBERS
PRIMARY AND SECONDARY CHAMBER OPERATE WITH AIR LEVELS
ABOVE STOICHIOMETRIC
PRIMARILY USE OVERFIRE COMBUSTION AIR
IN-LINE AND RETORT DESIGNS
-------
SLIDE 3-4
Ignition
Chamber
Charging Door
with Overfire
Air Port
Curtain Wall
i-Secondary
Combustion
Chamber
: - - .iv.v J .*-
/.:::> .:%> v.fvx-
rf -11 VMV- - /<-
Grates
Cleanout Doors with-
Undergrate Air Port
Location ot
Secondary
Burner
Mixing Chamber
CleanoutJ
Doors
Curtain
Wall Port
IN-LINE MULTIPLE-CHAMBER, EXCESS-AIR INCINERATOR'
-------
SLIDE 3-5
Charging
Door
Stack
Ignition Chamber
Hearth
Secondary
Air Ports
Secondary
Burner Port
Mixing
Chamber
First
Underhearth
Port
Secondary
Combustion
Chamber
Mixing Chamber
Cleanout
Doors
Rama Port
Charging
Door
Hearth
Primary
Burner Port
Second
Underhearth
Port
RETORT MULTIPLE-CHAMBER, EXCESS-AIR INCINERATOR
-------
SLIDE 3-6
CONTROLLED-AIR INCINERATION
COMBUSTION OCCURS IN TWO OR MORE CHAMBERS
AMOUNTS AND DISTRIBUTION OF COMBUSTION AIR
TO EACH CHAMBER ARE CONTROLLED
PRIMARY CHAMBER BELOW STOICHIOMETRIC
SECONDARY CHAMBER ABOVE STOICHIOMETRIC
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SLIDE 3-7
WASTE FEED
-*
AUXILARY1
IGNITION
BURNER
/
V.
ซ*:
^
k COMBUSTION GASES
_ '
^s
SECONDARY CHAMBER
Volatile Content is Burned
Under Excess Air Conditions
-c
/ PRIMARY CHAMBER
/ (Starved Air Condition)
Volatiles and Moisture
*
n
?
T
?
\ .
i ,
\ i
k
i
k
_j
L
A
^
f ^
n
i/
r
MAIN BURNER
FOR MAINTAINING
MINIMUM COMBUSTION
TEMPERATURE
/
If
MAIN FUMEPORT AIR
ASH AND
NON-COMBUSTIBLES
CONTROLLED UNDERFIRE
AIR FOR BURNING
"FIXED CARBON"
PRINCIPLE OF CONTROLLED-AIR INCINERATION
-------
SLIDE 3-8
TEMPERATURE
PRIMARY *-
CHAMBER OPERATING
RANGE
* SECONDARY
CHAMBER OPERATING
RANGE
DEFICIENT AIR
EXCESS AIR
PERCENT EXCESS AIR
CONTROL OF TEMPERATURE AS A FUNCTION OF EXCESS AIR
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SLIDE 3-9
Stack
Secondary Chamber
Mechanical
Charge System
Secondary Combustion
Air Blower
Primary
Burner
Primary Combustion
Air Burner Blower
Viewport
Secondary Burner
Viewport
Ash Removal
Door
Primary Chamber
MAJOR COMPONENTS OF A CONTROLLED-AIR INCINERATOR
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SLIDE 3-10
ROTARY KILNS
COMBUSTION OCCURS IN MULTIPLE CHAMBERS
PRIMARY CHAMBER is ROTATING CYLINDER
PRODUCES TURBULENCE IN WASTE BED
-------
SLIDE 3-11
Augar-Faadar
, Rotating
Kiln
Bag House
To
Atmosphara
Y
, l Secondary
Chambar
Stack
Exhaust Fan
Scrubber
ROTARY KILN WITH AUGER FEED1
-------
SLIDE 3-12
OPERATING HOPE
SINGLE BATCH
INTERMITTENT DUTY
CONTINUOUS DUTY
-------
SLIDE 3-13
WASTE FEED LOADING/CHARGING SYSTEMS
CONSISTENT WITH INCINERATOR CAPACITY
CONSISTENT WITH OPERATING MODE
MANUAL vs MECHANICAL vs AUTOMATED
-------
SLIDE 3-14
Hydraulic Fire
Door Actuator
Hopper Cover
Hydraulic
Ram
Actuator
Waste
Charging
Hopper
Primary
Combustion
Chamber
Fire Door
Enclosure
Furnace
Opening
HOPPER RAM ASSEMBLY1
-------
SLIDE 3-15
START
WASTE LOADED INTO HOPPER
STEP1
FIRE DOOR OPENS
STEP 2
RAM COMES FORWARD
STEP 3
RAM REVERSES TO CLEAR FIRE DOOR
STEP 4
FIRE DOOR CLOSES
STEPS
RAM RETURNS TO START
HOPPER RAM CHARGING SEQUENCE
-------
SLIDE 3-16
ASH DISCHARGE AND REMOVAL SYSTEMS
CONSISTENT WITH OPERATING MODE
CONSISTENT WITH CAPACITY
MANUAL vs MECHANICAL
-------
SLIDE 3-17
MECHANICAL ASH REMOVAL
TRANSFER OF ASH TO END OF HEARTH
COLLECTION CONTAINER
TRANSFER FROM COLLECTION POINT
-------
SLIDE 3-18
To Boiler
Feed Ram
Ash Transfer Rams
Ash Discharge Ram
Secondary Burner
/- Primary Burner
Ash Sump
Ash Chute
Ash Quench-
INCINERATOR WITH STAGED HEARTH AND
AUTOMATIC ASH REMOVAL7
-------
SLIDE 3-19
COMBUSTION GAS HANDLING SYSTEMS
NATURAL DRAFT
INDUCED DRAFT
BALANCED DRAFT
-------
SLIDE 3-20
MAJOR COMPONENTS OF BURNER SYSTEM
FORCED AIR BLOWER(S)
FUEL TRAIN
PILOT AND MAIN BURNER
FLAME SAFE GUARD SYSTEM
-------
SLIDE 3-21
n
Ihutoff X
i/alve ^^
Bypass
Stack
Incinerator
Gas Flow
S
J J
Stack
Waste Heat
Boiler
Damper
Fan
INCINERATOR WITH WASTE HEAT BOILER AND BYPASS STACK'
-------
SESSION 4.
AIR POLLUTION CONTROL EQUIPMENT
DESIGN AND FUNCTIONS
-------
SLIDE 4-
CONTROL STRATEGIES FOR AIR POLLUTANTS
CONTROL
strategy
Controlling
feed
material
Combustion
control
Add-on pollution
control
equipment:
Spray tower
Venturi
Packed-bed
Fabric filter
Dry injection13
Dry scrubberb
ESP
Part icu late
matter
X
X
a
X
a
X
X
X
X
POLLUTANT
Hydrochloric Toxic Toxic Carbon
acid organics metals monoxide
X X
X X
X a a
a ax
X a a
X
X a X
X a X
^Achieves limited control; not designed for high efficiency.
'"J by high-efficiency particulate control
-------
SLIDE 4-2
AIR POLLUTION CONTROL SYSTEMS FOR
HOSPITAL WASTE INCINERATORS
WET SCRUBBERS
SPRAY TOWERS
VENTURI SCRUBBERS
PACKED-BED SCRUBBERS
FABRIC FILTERS
DRY SCRUBBERS
~ DRY INJECTION
SPRAY DRYERS
ELECTROSTATIC PRECIPITATORS
-------
SLIDE 4-3
SPRAY TOWER
LOW ENERGY
LIMITED PARTICULATE CONTROL
LIMITED HCL ACID GAS CONTROL
-------
SLIDE M
Clean Exhaust Gas
Liquid
Sprays
Dirty Flue Gas
Water
Drain
COUNTERCURRENT-FLOW SPRAY TOWER
-------
SLIDE 4-5
Stack
Water
Inlet
Combustion
Gases from
Secondary
Chamber
Waste Water
to
Drain
Spray Tower System
-------
SLIDE 4-6
VENTURI SCRUBBER
HIGH ENERGY
HIGH EFFICIENCY PARTICULATE CONTROL
LIMITED HCL ACID GAS CONTROL
-------
SLIDE 4-7
DIRTY FLUE GAS
SPRAY NOZZLES
LIQUID INLET
VENTURI THROAT-
CYCLONIC MIST ELIMINATOR
SPRAY VENTURI WITH RECTANGULAR THROAT
-------
SLIDE 4-8
Clean exhaust gas
Clean
exhaust gas
containing droplets
CYCLONIC MIST ELIMINATOR1
-------
SLIDE 4-9
Stack
Combustion
Gases from ^
Secondary W
Chamber
Waste
Heat
Boiler
_
y
r~*
1
X
( J
Make up ,4s
Water
C*rHlVtfa
waudUw
Ventun 1
1
MM^
i
^ Cyclonic
1 Jie,4
MlSt
Eliminator
\/
Y
1
1
1
!*- J
1
1 ' T
Scrubber
Liquor
Recycle
Tank
1
1
1 Discharge
(Slowdown)
Pump
L.
VENTURI SCRUBBER SYSTEM WITH
RECIRCULATED SCRUBBER LIQUOR
-------
SLIDE 4-10
PACKED TOWER
LOW ENERGY
HIGH EFFICIENCY ACID GAS CONTROL
-------
SLIDE 4-
CLEAN EXHAUST
DIRTY EXHAUST
SHELL
MIST ELIMINATOR
LIQUID SPRAYS
PACKING
COUNTERCURRENT-FLOW
PACKED-BED SCRUBBER1
-------
SLIDE 4-12
Stack
1 -
Combustion Waste
Gases from . H , ..
Secondary w . i
Chamber boller 1
T
1 -fr
X
r J
i
L_
Make up /TN
Water 1 "
Caustic ^ " i
Feed *
Scrubber
Liquor
Recycle
Tank
1 I
1 I
Pump
I
1 t
Water 1
| / V Mist
1 .j i Eliminator
* 'ffl'WF ^~~~~^^m^m
'S/'.t/z/'S ii i i-l
L.,^, Packed
1
1
Discharge
(Slowdown)
1
1
1
1
. J
VENTURI SCRUBBER WITH PACKED BED
-------
SLIDE 4-13
FABRIC FILTER
- OFTEN CALLED "BAGHOUSE"
PARTICIPATE CONTROL
~ ESPECIALLY EFFECTIVE FOR FINE PARTICIPATE
ACID GAS CONTROL
~ IF USED IN CONJUNCTION WITH DRY SCRUBBER
-------
SLIDE H-
Clean Air Plenum
Blow Pipe
Bag Retainer
Dirty Air Inlet and Diffuser'
To Clean Air Outlet
and Exhauster
Tubular Filter Bags
Dirty Air Plenum
PULSE JET BAGHOUSE'
-------
SLIDE 4-15
DRY SCRUBBERS
ACID GAS CONTROL
IN CONJUNCTION WITH PARTICIPATE CONTROL
~ FABRIC FILTER
~ ELECTROSTATIC PRECIPITATOR
-------
SLIDE 4-16A
Sorbent
Storage
Blower
Feeder
Combustion
Gases from'
Incinerator
Pneumatic
Line
Stack
Waste
Heat
Boiler
Mm
Combustion^
Air Diirt
Expansion/
Reaction
Chamber
Solid
Residue
DRY INJECTION ABSORPTION SYSTEM
-------
SLIDE 4-16a
Combustion
Gases from
Incinerator
Injector
Stack
Solid
Residue
DRY INJECTION ABSORPTION SYSTEM
-------
SLIDE 4-17
Flue Gas
Sorbent Slurry
X.
Spray Nozzle
To Particulate
Control Device
SPRAY DRYER ABSORBER VESSEL
-------
SLIDE 4-18
Lime
Storage
Slurry
Mixing
Tank
Slurry
Feed
Tank
i
Stack
Combustion
Gases
COMPONENTS OF A SPRAY DRYER ABSORBER SYSTEM
-------
SLIDE 4-19
ELECTROSTATIC PRECIPITATES
PARTICULATE CONTROL
LARGER REGIONAL FACILITY MOST LIKELY APPLICATION
SOMETIMES USED WITH DRY SCRUBBERS
-------
SLIDE 4-20
Rappers
Discharge
electrodes
% I . , Flue gas
in
Collection
electrodes
Hoppers
COMPONENTS OF AN ESP
-------
SLIDE 4-21
Gas Corona
cฃ
X
ซ"ป
/
/
'
*f
1
ป .
I
I
I
1
t
ป
i
t
i
i
/I
'
1-
f,
y
fl
i
-
>
t
ions
1 \'
> * *- "0
1
- -.--.:
! --'0
*-,-'
Lr **
f
' " *" ป-":
. y ,^
/ -M y
^^ discharge
"v^^
^
/// ^
x^- . ."^f
--.,-
';.:
(;. ^j.
J
J
7*
V' /
t^ft LJ /
^P7 ^ Charged
'V;' / particles
4 ซ /
' ' ' Discharge
electrode
^
^
ซ/
/
,
/
0
Collection
elet:trode
GAS FLOW THROUGH A PLATE PRECIPITATOR3
-------
SESSION 5,
MONITORING AND AUTOMATIC CONTROL SYSTEMS
-------
SLIDE 5-1
MONITORED VS CONTROLLED PROCESS PARAMETERS
MONITORED PARAMETER
~ MEASURE AND DISPLAY VALUE
CONTROLLED PARAMETER
MEASURE AND DISPLAY VALUE
AUTOMATICALLY ADJUSTS PROCESS OPERATION
TO MAINTAIN CONTROL PARAMETER WITHIN LIMITS
-------
SLIDE 5-2
CONTROL ROOM
Recorder
t
L.
Burner [~
Combustion
Chamber
TEMPERATURE MONITORING SYSTEM
-------
SLIDE 5-3
Temperature
Meter
90-
80-
70-
60-
50-
Ace Heating and Cooling
Set Point
THERMOSTAT WITH TEMPERATURE "SET POINT"
-------
SLIDE 5-4
CONTROL ROOM
Warning
Limit
Alarm
r
Signal
Processor
f
Burner
Combustion
Chamber
t
Combustion
Air
Blower
Recorder
SCHEMATIC OF TEMPERATURE CONTROL LOOP
-------
SLIDE 5-5
ROTATE OUTER DIAL TO
SELECT TEMPERATURE
SETPOIHT OR PROPORTIONAL
SETPOINT
ROTATE INNER DIAL TO
SELECT TEMPERATURE
SETPOINT
TEMPERATURE
INDICATOR
LOCKING SCREW
(.OCXS DIAL
POSITION
TEMPERATURE CONTROLLER/METER
WITH LOW/HIGH SETPOINTS:
-------
SLIDE 5-6
HIGH SETPOINT
ADJUSTMENT
SCREW-
HIGH SETPOINT
DISPLAY BUTTON
a
,0
i in
i -i
i i i i
II LJ
NEWPORT
ฉ-
oy
ฐF
LOW SETPOINT
ADJUSTMENT
SCREW
LOW SETPOINT
DISPLAY BUTTON
TEMPERATURE CONTROLLER
WITH DIGITAL DISPLAY1
-------
SLIDE 5-7
BASIC TYPES OF INCINERATOR PROCESS CONTROL SYSTEMS
MANUAL
AUTOMATIC TIMER SEQUENCE
AUTOMATIC MODULATED CONTROL
-------
SLIDE 5-8
AUTOMATIC TIMER SEQUENCE
PRESET TIMER SEQUENCE
~ ACTIVATES ON/OFF OR HIGH/LOW SETTINGS
- BURNERS
- COMBUSTION AIR
- CHARGE FEEDER
SETPOINT LIMITS OVERRIDE TIMER SEQUENCE
-------
SLIDE 5-9
AUTOMATIC MODULATED CONTROL
SETPOINT FOR CONTROLLED PARAMETER is CHOSEN
OPERATING PARAMETERS ARE CONTINUOUSLY ADJUSTED TO
MAINTAIN SETPOINT
COMBUSTION AIR
-------
SLIDE 5-10
MONITORED AND CONTROLLED PROCESS PARAMETERS
FOR INCINERATORS
MONITORED/CONTROLLED INCINERATOR FUNCTIONS
PARAMETER ____ CONTROLLED
TEMPERATURE COMBUSTION AIR
(PRIMARY AND AUXILIARY BURNERS
SECONDARY CHAMBERS)
DRAFT BAROMETRIC DAMPER
ID FAN DAMPER
OXYGEN COMBUSTION AIR
CARBON MONOXIDE
OPACITY
CHARGE RATE AUTOMATIC FEED INTERLOCK
-------
SLIDE 5-11
MONITORED AND CONTROLLED PROCESS PARAMETERS
FOR SCRUBBERS
MONITORED PARAMETER
SCRUBBER FUNCTIONS
CONTROLLED
PRESSURE AND PRESSURE DROP
SCRUBBER LIQUID FLOW RATE OR
PRESSURE
SCRUBBER LIQUID pH
INLET TEMPERATURE
VENTURI THROAT
ID FAN
LIQUID FLOW CONTROL VALVE
CAUSTIC FLOW CONTROL
VALVE
PREQUENCH
EMERGENCY QUENCH
BYPASS STACK
DILUTION AIR
-------
SLIDE 5-12
MONITORED AND CONTROLLED PROCESS PARAMETERS
FOR FABRIC FILTERS
FABRIC FILTER OPERATING
MONITORED PARAMETER FUNCTIONS CONTROLLED
PRESSURE DROP CLEANING CYCLE
INLET GAS TEMPERATURE EMERGENCY BYPASS STACK
EMERGENCY QUENCH
DILUTION AIR
-------
SLIDE 5-13
MONITORED AND CONTROLLED PROCESS PARAMETERS
FQRESP's
ESP OPERATING
MONITORED PARAMETER FUNCTIONS CONTROLLED
POWER INPUT PowER SUPPLY
" PRIMARY VOLTAGE T/R SETTINGS
PRIMARY CURRENT
SECONDARY VOLTAGE
SECONDARY CURRENT
SPARK RATE QAS TEMPERATURE
RAPPER OPERATION
CONDITIONING AGENTS
(RESISTIVITY)
INLET GAS TEMPERATURE INCREASE/DECREASE
INCINERATOR OR BOILER
OUTLET TEMPERATURE
CONDITION GAS
-------
SLIDE 5-14
TEMPERATURE
THERMOCOUPLE(S)
DEGREES FAHRENHEIT
EXIT OF SECONDARY COMBUSTION CHAMBER
MIDDLE OF PRIMARY CHAMBER
BEFORE/AFTER APC
-------
SLIDE 5-15
DRAFT PORT
THERMOCOUPLE X CONNECTION
\ f
(W r 3
> V 1 %' ^ ' , V- ' s
C'v-V1''-"''''
-^ *
?.
x\ซ\*
fv v
lVvr
^
i
. / v v ป v 71 VrvT ^ " 'r"'7l
ป '^/' "/ "^ 'V 0^- "J^9 '
x ' u "> -C1"'* '"' ซ V '^ / >* f
\ ง
\ CHAMBER ^
THERMOCOUPLE UNINQ
PENETRATION
THERMOCOUPLE AND
DRAFT GAUGE CONNECTIONS l
-------
SLIDE 5-16
INCINERATOR DRAFT AND APCS PRESSURE DROP
DIFFERENTIAL PRESSURE GAUGE, AP
INCHES OF WATER COLUMN, IN, w,c,
DIFFERENCE OF PRESSURE AT TWO POINTS
DRAFT:
&P OF INCINERATOR CHAMBER AND ATMOSPHERIC PRESSURE
APCS PRESSURE DROP:
A? BEFORE AND AFTER APC
-------
SLIDE 5-17
LOW DRAFT
SETPOINT
INDICATOR
LOW DRAFT
SETPOINT
ADJUSTMENT KNOB
HIGH DRAFT
SETPOINT
INDICATOR
HIGH DRAFT
SETPOINT
ADJUSTMENT KNOB
METER FOR DIFFERENTIAL
PRESSURE GAUGE1
-------
SLIDE 5-18
Air
To
Atmosphere
I
Stack
"Draft-
Incinerator
BAROMETRIC/AUTOMATIC DAMPER
-------
SLIDE 5-19
Damper Fully Open
X"
(O
* -
Fan
Damper Partially Closed
Fan
Stack
-Stack
ID FAN DAMPER CONTROL
-------
SLIDE 5-20
POSITION MOTOR
CONTROL LINKAGE
COMBUSTION BLOWER
WITH AUTOMATIC CONTROLLER'
-------
SLIDE 5-21
OXYGEN AND CO MONITORS
CONTINUOUS EMISSION MONITORING SYSTEMS, CEMS
PERCENT OXYGEN, I 02
PARTS PER MILLION CARBON MONOXIDE, PPM CO
MONITOR LOCATION
COMBUSTION CHAMBER OUTLET
" STACK
SOMEWHERE IN BETWEEN
-------
SLIDE 5-22
In-Situ
Stack
Source
n
Detector
n
Detector Cell
r
Electronics
Extractive
Stack
ProbeL
/Sample
S Transport
jAnalyzer
IN SITU VS EXTRACTIVE CEMS
-------
SLIDE 5-23
r r
J
f
J
SECONDARY
COMBUSTION
CHAMBER
n
i
r
SAMPLE
*\
r PROBE r - \
h FILTER -H
BACK FLUSH
PURGE AIR
ZERO
SPAN
VENT
DRAIN
SAMPLE
PUMP
LOW MID
LEVEL LEVEL
CAL. CAL.
EXTRACTIVE MONITORING SYSTEM
-------
SLIDE 5-24
Transceiver
assembly
Preseparator air inlet
Ambient
air
Retroreflector
assembly
Blower
Blower
OPACITY MONITORING SYSTEM
(Transmissometer)
-------
SLIDE 5-25
CHARGE RATE
LB/LOAD
LB/H
WEIGH SCALE/LOG BOOK
AUTOMATIC WEIGH SCALE OR WEIGH HOPPER
-------
SLIDE 5-26
ARC MONITORS
SCRUBBER LIQUID FLOW
~ GALLONS PER MINUTE, GPM
FLOW METER
PUMP PRESSURE
' PH OF SCRUBBER LIQUID
PH METER
TEMPERATURE
~ THERMOCOUPLE
PRESSURE DROP, A?
DIFFERENTIAL PRESSURE GAUGE
-------
SESSION 6.
INCINERATOR OPERATION
-------
-------
SLIDE 6-1
TOPICS
WASTE HANDLING
OPERATION OF CONTROLLED-AIR INCINERATORS
OPERATION OF EXCESS-AIR INCINERATORS
-------
SLIDE 6-2
WASTE HANDLING
STURDY CONTAINERS
MINIMIZE HANDLING
PROPERLY OPERATE/MAINTAIN WASTE CHARGING DEVICES
SAFE STORAGEEVEN FOR SHORT TIMES
-------
SLIDE 6-3
INCINERATOR OPERATION
KEY OPERATING PARAMETERS
OPERATING RANGES
MONITORING OPERATION
CONTROLLING OPERATION
WASTE CHARGING PROCEDURES
'. ASH HANDLING PROCEDURES
1 STARTUP/SHUTDOWN PROCEDURES
-------
SLIDE 6-4
KEY OPERATING PARAMETERS FOR
CONTROLLED-AIR INCINERATORS
CHARGING RATE
PRIMARY CHAMBER TEMPERATURE
SECONDARY CHAMBER TEMPERATURE
COMBUSTION CHAMBER DRAFT
PRIMARY CHAMBER COMBUSTION AIR LEVEL
TOTAL COMBUSTION AIR LEVEL
COMBUSTION GAS OXYGEN CONCENTRATION
-------
SLIDE 6-5
KEY OPERATING PARAMETER-WASTE CHARGING RATE
OPERATING RANGE:
HEAT INPUT CONSISTENT WITH DESIGN
SINGLE BATCH OPERATION
FILL CHAMBER; DO NOT OVERFILL
INTERMITTENT AND CONTINUOUS DUTY
~ SMALL BATCHES AT FREQUENT INTERVALS
10 TO 25 PERCENT RATED CAPACITY AT 5 TO 15 MINUTES
FACTORS;
WASTE PROPERTIES
OPERATING MODE OF INCINERATOR
-------
SLIDE 6-6
KEY OPERATING PARAMETER-WASTE CHARGING RATE
OPERATOR MONITORS;
CHARGE RATE, LB/H
~ AMOUNT AND FREQUENCY OF CHARGE
ASH BED
BUILDUP
ASH QUALITY
"GOOD" BURNOUT
TEMPERATURE TRENDS
LOW TEMPERATURECHARGE NEEDED?
~ HIGH SECONDARY TEMPERATUREWAIT?
CONTROL BY;
SMALLER OR LARGER BATCHES
LESS OR MORE FREQUENT CHARGES
-------
SLIDE 6-7
Secondary Chamber
Temperature
Charges
Last
Charge
Primary
Chamber
Temperature
Burndown
TEMPERATURE TREND1
-------
SLIDE 6-8
PRIMARY CHAMBER TEMPERATURE
LOWER LIMIT: MINIMUM OPERATING TEMPERATURE
ACHIEVE ADEQUATE BURNOUT
STERILIZE ASH
UPPER LIMIT; MAXIMUM OPERATING TEMPERATURE
LIMIT SLAGGING OF ASH
THERE MAY BE A REGULATORY REQUIREMENT ON LOWER LIMIT
-------
SLIDE 6-9
KEY OPERATING PARAMETFR--PRIHARY CHAMBER TEMPERATURE
RECOMMENDED OPERATING RANGE;
BATCH - 1000ฐ TO 1800ฐF
INTERMITTENT - 1000ฐ TO 1800ฐF
CONTINUOUS - 1400ฐ TO 1800ฐF
OPERATOR MONITORS
TEMPERATURE READING
TEMPERATURE TREND
CONTROL BY;
ADJUSTING CHARGING RATE
ADJUSTING PRIMARY COMBUSTION AIR LEVEL
AUXILIARY BURNER OPERATION
-------
SLIDE 6-10
SECONDARY CHAMBER TEHPFRATIIRF
LOWER LIMIT; MINIMUM OPERATING TEMPERATURE
HIGH ENOUGH TEMPERATURE TO COMBUST ALL ORGANIC
COMPOUNDS
UPPER LIMIT; MAXIMUM TEMPERATURE
PREVENT DAMAGE TO REFRACTORY
THERE MAY BE A REGULATORY REQUIREMENT ON LOWER LIMIT
-------
SLIDE 6-11
KEY OPERATING PARAHFTFR-SECONDARY CHAMBER TEMPERATURE
RECOMMENDED OPERATING RANGE:
1800ฐ TO 2200ฐ
OPERATOR MONITORS;
TEMPERATURE READING
TEMPERATURE TREND
CONTROL BY;
ADJUSTING SECONDARY COMBUSTION AIR LEVEL
SECONDARY BURNER OPERATION
ADJUSTING PRIMARY CHAMBER PARAMETERS
ADJUSTING CHARGING RATE
-------
SLIDE 6-12
PRIMARY CHAMBER COMBUSTION AIR LEVEL
CONTROLS COMBUSTION RATE AND TEMPERATURE IN
PRIMARY CHAMBER
CONTROLS RELEASE RATE OF COMBUSTIBLE GASES TO
SECONDARY CHAMBER
MAINTAINED BELOW STOICHIOMETRIC
-------
SLIDE 6-13
KEY OPERATING PARAMETFR-PRIHARY CHAMBER COMBUSTION AIR
RECOMMENDED OPERATING RANGE;
30 TO 80 PERCENT OF STOICHIOMETRIC
MONITOR;
VISUAL OBSERVATION
DARK RED SMOKEY COMBUSTION ZONE
PRIMARY CHAMBER TEMPERATURE
CONTROL BY;
INCREASE/DECREASE COMBUSTION AIRFLOW
-------
SLIDE 6-14
SECONDARY CHAMBER AMD TOTAL COMBUSTION AIR LEVEL
CONTROLS TEMPERATURE OF SECONDARY CHAMBER
EXCESS AIR ASSURES SUFFICIENT OXYGEN FOR COMPLETE
COMBUSTION
-------
SLIDE 6-15
KEY OPERATING PARAMFTER-TOTAL COMBUSTION AIR LEVEL
RECOMMENDED OPERATING RANGE:
140 TO 200 PERCENT EXCESS AIR
MONITORING;
SECONDARY COMBUSTION CHAMBER TEMPERATURE
STACK GAS OPACITY
BLACK SMOKE - DEFICIENT AIR
COMBUSTION GAS OXYGEN LEVEL
CONTROL BY;
ADJUSTING SECONDARY AIRFLOW
-------
SLIDE 6-16
COMBUSTION CHAMBER DRAFT
PREVENT EXCESSIVE PARTICULATE MATTER ENTRAINMENT
PREVENT AIR OUT-LEAKAGE
-------
SLIDE 6-17
KEY OPERATING PARAMFTER-CQMBUSTIQN CHAMBER DRAFT
RECOMMENDED RANGE:
NEGATIVE 0,05 TO 0,1 INCHES WATER
MONITOR;
DRAFT GAUGE
CONTROL BY;
NATURAL DRAFT DAMPER SETTING
-- BAROMETRIC, AUTOMATIC, MANUAL
FAN DAMPER SETTING
-------
SLIDE 6-18
OTHER PARAMETERS TO MONITOR
STACK GAS OPACITY
EASY TO DO
INDICATOR OF PARTICIPATE EMISSION/POOR COMBUSTION
ADJUST SECONDARY AIR OR CHARGE RATE
CHECK SECONDARY BURNER
-------
SLIDE 6-19
OTHER PARAMETERS TO MONITOR
ASH QUALITY
EASY TO DO
PIECES OF UNBURNED WASTE NOT GOOD
GRAY COLOR BETTER THAN BLACK
INCREASE PRIMARY TEMPERATURE
DECREASE CHARGE RATE
INCREASE BURNOUT TIME
-------
SLIDE 6-20
OTHER PARAMETERS TO MONITOR
STACK GAS CARBON MONOXIDE
INDICATOR OF COMBUSTION EFFICIENCY
NEED INSTRUMENT
SHOULD BE <100 PPM
-------
SLIDE 6-21
OTHER PARAMETERS TO MONITOR
SECONDARY BURNER FLAME PATTERN
BRIGHT YELLOW/ORANGE
No SMOKE
NO IMPINGEMENT
-------
SLIDE 6-22
CONTROL AND MONITORING SUMMARY
WASTE COMPOSITION, CHARGE RATE, TEMPERATURES, AIR LEVELS
ARE ALL INTERRELATED
WITHIN LIMITS OF DESIGNAUTOMATIC CONTROL SYSTEM ADJUSTS
AIR LEVEL TO CONTROL HEAT RELEASE AND TEMPERATURE
OPERATOR CAN CONTROL CHARGE RATE
-------
SLIDE 6-23
CONTROL AND MONITORING SUMMARY (CONTINUED)
TO OPERATE INCINERATOR WITHIN DESIGN LIMITS, THE OPERATOR
MONITORS:
- TEMPERATURES
- CHARGE RATE
- WASTE BED APPEARANCE
- ASH QUALITY
- OPACITY
ADJUSTS:
- CHARGE RATE
- COMBUSTION AIR LEVELS
- BURNERS
-------
SLIDE 6-24
CAPACITY
Ib/hr
1000-t-
900--
800 --
700 --
600 --
500--
400- -
300 --
200--
100--
o
Requires
Auxilary
Fuel
Heat Release Rate = 4,800,000 BTU/hr
1000 2000
4000
6000
8000
10000
HEAT CONTENT OF WASTE
STU/lb
INCINERATOR CAPACITY VERSUS HEAT CONTENT OF WASTE
-------
SLIDE 6-25
PROPER WASTE CHARGING PROCEDURES
SINGLE BATCH OPERATION
CHARGE INCINERATOR COLD
Do NOT "STUFF" INCINERATOR
CLOSE AND SEAL DOOR BEFORE IGNITION
PREHEAT SECONDARY CHAMBER BEFORE IGNITION
DECREASE SIZE OF LOAD, AS NECESSARY, TO PREVENT
EMISSIONS AT STARTUP
-------
SLIDE 6-26
PROPER WASTE CHARGING PROCEDURES
INTERMITTENT DUTY AND CONTINUOUS DUTY
MORE FREQUENT SMALLER CHARGES ARE BETTER THAN ONE LARGE
CHARGE
ADJUST CHARGE VOLUME AND FREQUENCY TO ACCOUNT FOR WASTE
VARIATIONS
-------
SLIDE 6-27
PATHOLOGICAL WASTES
LIMIT AMOUNT OF PATHOLOGICAL WASTE IF INCINERATOR
IS NOT A PATHOLOGICAL DESIGN
OPERATE PRIMARY BURNERS DURING INCINERATI
CHARGE WASTE TO HEARTH IN SHALLOW LAYER
~ DO NOT PILE
EXPOSE TO FLAME
ON
-------
SLIDE 6-28
PROPER ASH HANDLING PROCEDURES
SINGLE BATCH/INTERMITTENT OPERATION
ALLOW INCINERATOR TO COOL
DO NOT SPRAY WATER INTO COMBUSTION CHAMBER
USE FLAT/BLUNT TOOL FOR ASH REMOVAL
AVOID PUSHING ASH INTO UNDERFIRE PORTS
PLACE ASH IN METAL CONTAINER
DAMPEN ASH TO PREVENT FUGITIVE DUST
PROPERLY DISPOSE OF ASH
MAKE SURE ASH DOOR is PROPERLY SEALED
INSPECT ASH QUALITY;
MAKE CORRECTIONS TO OPERATION, IF NECESSARY
-------
SLIDE 6-29
PROPER ASH HANDLING PRQCEDURFS
CONTINUOUS DUTY
WATCH FOR JAMS IN CONVEYOR SYSTEMS
ASSURE QUENCH WATER FLOW IS ADEQUATE
REPLACE FULL ASH CONTAINER WITH EMPTY CONTAINER
KEEP ASH WET OR COVER TO PREVENT FUGITIVE DUST
INSPECT ASH QUALITY
ADJUST INCINERATOR OPERATION, IF NECESSARY
-------
SLIDE 6-30
STARTUP AND SHUTDOWN
SINGLE BATCH UNIT
STARTUP;
CHARGE INCINERATOR COLD
PREHEAT THE SECONDARY CHAMBER BEFORE IGNITING WASTE
SHUTDOWN:
INCREASE PRIMARY COMBUSTION CHAMBER AIR TO PROMOTE
COMBUSTION OF FIXED CARBON
AFTER PRIMARY TEMPERATURE DECREASES TO PRESET LEVEL,,
SHUT DOWN SECONDARY BURNER
KEEP COMBUSTION BLOWERS OPERATING TO COOL INCINERATOR
REMOVE ASH AFTER INCINERATOR COOLS
-------
SLIDE 6-31
STARTUP AND SHUTDOWN
INTERMITTENT AND CONTINUOUS DUTY
STARTUP:
PREHEAT SECONDARY CHAMBER BEFORE INITIATING CHARGING
CHARGE WASTE
IGNITE WASTE
SHUTDOWN;
INTERMITTENT DUTYSAME AS BATCH
CONTINUOUS DUTY
' STOP CHARGING SYSTEM
MAINTAIN OPERATION OF INCINERATOR AND ASH SYSTEM
UNTIL ALL WASTE IS DISCHARGED FROM INCINERATOR
SHUTDOWN INCINERATOR
-------
SLIDE 6-32
OPERATORS LOG
WRITTEN LOG BOOK
RECORD SIGNIFICANT EVENTS
STARTUP/SHUTDOWN
ADJUSTMENTS
CHANGES IN CHARGE RATE
' RECORD UNUSUAL PROBLEMS AND CORRECTIVE ACTIONS
-------
SLIDE 6-33
DO
PAY CAREFUL ATTENTION TO CHARGING RATE
~ ADJUST CHARGING RATE, IF NECESSARY
MONITOR COMBUSTION TEMPERATURES
LEARN TO RECOGNIZE TRENDS
MONITOR STACK OPACITY
INSPECT THE CHAMBERS THROUGH VIEWPORTS
INSPECT ASH QUALITY
ADJUST OPERATION, IF NECESSARY
PROPERLY HANDLE AND DISPOSE OF ASH
PREHEAT THE SECONDARY CHAMBER BEFORE STARTUP
KEEP AN OPERATING LOG
-------
SLIDE 6-34
DON'T
IGNORE PROBLEMS INDICATED BY MONITORS
OVERCHARGE THE INCINERATOR
-------
SLIDE 6-35
KEY OPERATING PARAMETFRS-
MULTIPLE-CHAMBER, EXCESS-AIR INCINERATORS
RECOMMENDED
PARAMETER OPERATING RANGE
WASTE CHARGE RATE
BAG 10-25% OF RATED CAPACITY
AT 10-15 MINUTE INTERVALS
-PATHOLOGICAL SINGLE LAYER ON HEARTH
-------
SLIDE 6-36
KEY OPERATING PAMHETFRS.
MULTIPLE-CHAMBER, EXCESS-AIR INCINERATORS
RECOMMENDED
PARAMETER OPERATING RANGE
PRIMARY CHAMBER TEMPERATURE
-GENERAL REFUSE 1000ฐ-1400ฐF
PATHOLOGICAL 1600ฐ-1800ฐF
SECONDARY CHAMBER TEMPERATURE 1800ฐ-2200ฐF
-------
SLIDE 6-37
KEY OPERATING PARAMETERS:
MULTIPLE-CHAMBER, EXCESS-AIR INCINERATORS
RECOMMENDED
PARAMETER OPERATING RANGE
PRIMARY CHAMBER COMBUSTION AIR 80-150% EXCESS AIR
TOTAL COMBUSTION AIR 120 TO 300% EXCESS AIR
COMBUSTION GAS OXYGEN CON, 10-16%
COMBUSTION CHAMBER DRAFT NEGATIVE 0,05 TO
0,1 IN, w,c,
-------
SLIDE 6-38
SUMMARY OF OPERATION
UNITS ARE BATCH OR INTERMITTENT DUTY
PRIMARY CHAMBER is EXCESS AIR ATMOSPHERE
HEAT RELEASE RATE is CONTROLLED BY CHARGE RATE AND
BURNERS
-- FOR PATHOLOGICAL WASTE HEAT RELEASE RATE IS CONTROLLED
BY PRIMARY BURNERS
-------
SLIDE 6-39
SUMMARY OF MONITORING AND CflNTRni
OPERATOR MONITORS:
CHARGING RATE
TEMPERATURES OF BOTH CHAMBERS
TEMPERATURE TRENDS
DRAFT
ASH BED APPEARANCE
ASH QUALITY
OPACITY
-------
SLIDE 6-40
SUMMARY OF MONITORING AND CONTROI
OPERATOR CONTROLS;
CHARGE RATE
AlR DAMPER SETTINGS
AUXILIARY BURNER OPERATION
-------
SLIDE 6-41
WASTE CHARGING PROCEDIIRFS
ADJUST CHARGE VOLUME AND FREQUENCY TO ACCOUNT FOR WASTE
VARIATIONS
MORE FREQUENT SMALLER CHARGES ARE BETTER THAN ONE LARGE
CHARGE
Do NOT "STUFF" INCINERATOR
ASSURE PRIMARY BURNER IS OFF PRIOR TO CHARGING
GENTLY PUSH OLD WASTE TO BACK OF HEARTH; CHARGE NEW
WASTE AT FRONT OF HEARTH
-------
SLIDE 6-42
Frequent Small Charges
PROPER CHARGE PROCEDURES
-------
SLIDE 6-43
"Stuff and Burn"
IMPROPER CHARGE PROCEDURES
-------
SLIDE 6-44
Ash Bed Stoked To Rear;
Load To Front
PROPER LOADING ON HEARTH
-------
SLIDE 6-45
Partially Burned
Ash Smothered
IMPROPER LOADING ON HEARTH
-------
SLIDE 6-46
PATHOLOGICAL WASTES
CHARGE WASTE TO HEARTH IN A SHALLOW LAYER
Do NOT PILE
EXPOSE TO FLAME
TURN OFF PRIMARY BURNER BEFORE CHARGING
-------
SLIDE 6-47
PROPER ASH HANDLING PROCEDURE
ALLOW INCINERATOR TO COOL
DO NOT SPRAY WATER INTO COMBUSTION CHAMBER
USE FLAT/BLUNT TOOL FOR ASH REMOVAL
PLACE ASH IN METAL CONTAINER
DAMPEN ASH TO PREVENT FUGITIVE DUST
PROPERLY DISPOSE OF ASH
INSPECT ASH QUALITY; MAKE CORRECTIONS IN OPERATION, IF
NECESSARY
-------
SLIDE 6-48
STARTUP AND SHUTDOWN
STARTUP;
PREHEAT SECONDARY CHAMBER BEFORE INITIATING CHARGING
CHARGE WASTE
IGNITE WASTE
SHUTDOWN;
SHUT DOWN BURNERS
ALLOW INCINERATOR TO COOL
REMOVE ASH
-------
SLIDE 6-49
DO
PREHEAT THE SECONDARY CHAMBER
PAY CAREFUL ATTENTION TO CHARGING PROCEDURES AND RATES
SHUT OFF PRIMARY BURNER WHEN CHARGING
MONITOR COMBUSTION CHAMBER TEMPERATURES
MONITOR COMBUSTION CHAMBER DRAFT
MONITOR STACK GAS OPACITY-ESPECIALLY AFTER CHARGING
INSPECT ASH QUALITY
FOR PATHOLOGICAL WASTES, OPERATE PRIMARY BURNER AT ALL
TIMES
-------
SLIDE 6-50
DON'T
OVERCHARGE THE INCINERATOR
DEEPLY PILE PATHOLOGICAL WASTE ON THE HEARTH
-------
SESSION 7.
AIR POLLUTION CONTROL SYSTEMS OPERATION
-------
SLIDE 7-1
AIR POLLUTION CONTROI SYSTEMS FOR HOSPITAL INCINERATOR!
WET SCRUBBERS
~ SPRAY TOWERS
VENTURI SCRUBBERS
~ PACKED-BED SCRUBBERS
FABRIC FILTERS
DRY SCRUBBERS
~ DRY INJECTION
-- SPRAY DRYERS
ELECTROSTATIC PRECIPITATORS
-------
SLIDE 7-2
RECOMMENDED OPERATING RANGES FOR KEY PARAMETERS
VENTURI SCRUBBER
PARAMETER RANGE
PRESSURE DROP 20-30 IN, w,c,
LIQUID SUPPLY 7-10 GAL/1,000 ACF
PH 5,5-7,0
SUSPENDED SOLIDS 0-3 PERCENT
-------
SLIDE 7-3
VENTURI SCRUBBER PARAMETERS USUALLY
MONITORED BY OPERATOR
PRESSURE DROP
LIQUID FLOW RATE
pH
FAN
~ STATIC PRESSURE
-- RPM
AMPERAGE
-------
SLIDE 7-4
VENTURI SCRUBBER QPERATinN
KEY PARAMETER ADJUSTMENT
PRESSURE DROP VARIABLE THROAT
FAN DAMPER
FAN SPEED
LIQUID SUPPLY LIQUID FLOW RATE
SUSPENDED SOLIDS MAKEUP WATER
SLOWDOWN
pH MAKEUP CAUSTIC
-------
SLIDE 7-5
VENTURI SCRUBBER STARTUP SEQUENCE
1. TURN ON LIQUID SUPPLY AND RECIRCULATION
2, SET LIQUID FLOW TO MANUFACTURER SPECIFICATIONS
3, CLOSE FAN DAMPER
4, START FAN
5, GRADUALLY OPEN DAMPER
6, ADJUST LIQUID FLOW TO OBTAIN DESIRED LIQUID SUPPLY
7, ADJUST VENTURI THROAT, FAN AMPERAGE, OR DAMPER TO OBTAIN
DESIRED PRESSURE DROP
8, ADJUST SLOWDOWN
-------
SLIDE 7-6
VENTURI SCRUBBER SHUTDOWN SEQUENCE
1. SHUT OFF SCRUBBER FAN
2, SHUT OFF RECIRCULATION
3. SHUT OFF MAKEUP WATER
-------
SLIDE 7-7
RECOMHENDED OPERATING RANGES FOR KEY PARAMETERS
PACKED-BED SCRUBBER
PARAMETER
LIQUID SUPPLY
RANGE
15-25 GAL/1,000 ACF
SUSPENDED SOLIDS
INLET GAS TEMPERATURE
PRESSURE DROP
5,5-7,0
0-3 PERCENT
SPECIFIED BY MANUFACTURER
1-5 IN, w,c,
-------
SLIDE 7-8
PACKED-BED SCRUBBER PARAMETERS USUALLY
MONITORED BY OPERATOR
LIQUID FLOW RATE
PRESSURE DROP
INLET GAS TEMPERATURE
pH
FAN
-- STATIC PRESSURE
RPM
AMPERAGE
-------
SLIDE 7-9
PACKED-BED SCRUBBER OPERATION
KEY PARAMETER ADJUSTMENT
LIQUID SUPPLY LIQUID FLOW RATE
pH CAUSTIC FEED RATE
SUSPENDED SOLIDS MAKEUP WATER
SLOWDOWN
INLET GAS TEMPERATURE INCINERATOR EXHAUST TEMPERATURE
PREQUENCH
-------
SLIDE 7-10
RECOMMENDED OPERATING RANGES FOR KEY PARAMETERS
SPRAY TOWER
LIQUID SUPPLY 5 TO 20 GAL/1,000 ACF
PRESSURE DROP i To 3 IN, w,c,
-------
SLIDE 7-11
RECOMMENDED OPERATING RANGES FOR KEY PARAMETERS
PULSE-JET FABRIC FIITFR
PARAMETER RANGE
FLUE GAS TEMPERATURE:
UPPER LIMIT SPECIFIED BY MANUFACTURER
LOWER LIMIT ABOVE
PRESSURE DROP 5_g IN< WiCi
CLEANING AIR PRESSURE 60-100 PSIG
-------
SLIDE 7-12
FABRIC FILTER PARAMETERS USUALLY
MONITORED BY OPERATOR
OPACITY
PRESSURE DROP
INLET GAS TEMPERATURE
OUTLET GAS TEMPERATURE
-------
SLIDE 7-13
FABRIC FILTER OPERATION
KEY PARAMETER ADJUSTMENT
FLUE GAS TEMPERATURE:
UPPER LIMIT BYPASS FABRIC FILTER
LOWER INCINERATOR (BOILER)
EXHAUST TEMPERATURE
INTRODUCE COOL AMBIENT AIR
LOWER LIMIT INCREASE AUXILIARY FUEL
PRESSURE DROP BAG CLEANING FREQUENCY
CLEANING AIR PRESSURE COMPRESSED AIR SYSTEM
-------
SLIDE 7-14
FABRIC FILTER STARTUP
PRECOAT BAGS
USE AUXILIARY FUEL-FIRING TO BRING SYSTEM TO OPERATING
TEMPERATURE
GRADUALLY BUILDUP DUST CAKE
-------
SLIDE 7-15
FABRIC FILTER SHUTDOWN
STOP WASTE CHARGING
MAINTAIN SECONDARY CHAMBER BURNER FIRING UNTIL WASTE is
COMBUSTED
SHUT OFF INCINERATOR
PURGE REMAINING COMBUSTION PRODUCTS
CLEAN BAGS
-------
SLIDE 7-16
RECOMMENDED OPERATING RANGES FOR KEY PARAMFTFRS
DRY INJECTION
PARAMETER RANGE
SORBENT INJECTION RATE SPECIFIED BY MANUFACTURER
SORBENT PARTICLE SIZE 90 PERCENT BY WEIGHT THROUGH
325 MESH SCREEN
-------
SLIDE 7-17
RECOHHENDED OPERATING RANGES FOR KEY PARAMETERS
SPRAY DRYERS
PARAMETER RANGE
SLURRY SORBENT CONTENT 5-20 PERCENT
WET BULB/DRY BULB TEMPERATURE 90ฐ TO 180ฐF
DIFFERENCE
-------
SLIDE 7-18
SPRAY DRYER OPERATION
KEY PARAMETER ADJUSTMENT
SLURRY SORBENT CONTENT DRY SORBENT/WATER RATIO
WET BULB/DRY BULB TEMPERATURE SLURRY FLOW RATE
DIFFERENCE
-------
SLIDE 7-19
SPRAY DRYER STARTUP/SHUTDOWN
STARTUP ALTERNATIVES:
1. USE AUXILIARY FUEL-FIRING TO BRING SYSTEM UP TO OPERATING
TEMPERATURE BEFORE INJECTING SLURRY
2, GRADUALLY INCREASE SLURRY FEED AS EXHAUST TEMPERATURE
INCREASES TO MAINTAIN 90ฐ TO 180ฐF WET BULB/DRY BULB
DIFFERENCE
SHUTDOWN;
1. USE AUXILIARY FUEL-FIRING TO MAINTAIN TEMPERATURE ABOVE
SATURATION UNTIL ALL WASTE IS COMBUSTED
2, SHUT OFF SPRAY DRYER
-------
SLIDE 7-20
RECOHHENDED OPERATING RANGES FDR KEY PARAMETERS
ELECTROSTATIC PRECIPITATES
PARAMETER RANGE
INLET GAS TEMPERATURE
-- HOT SIDE ESP 570ฐ T0 800oF
COLD SIDE ESP <400ฐF
PARTICIPATE RESISTIVITY io7 TO 1010 OHM-CM
POWER RATIO 0,5 TO 0,9
-------
SLIDE 7-21
ESP OPERATION
KEY PARAMETER ADJUSTMENT
PRIMARY VOLTAGE/CURRENT POWER SUPPLY
CLEAN/ADJUST ELECTRODES
SECONDARY VOLTAGE/CURRENT T/R
RESISTIVITY
RESISTIVITY GAS TEMPERATURE
CONDITIONING AGENT ADDITION
COMBUSTION/CARBON CONTENT
GAS TEMPERATURE CONDITION GAS STREAM
INCINERATOR/BOILER OPERATION
-------
SLIDE 7-22
ESP STARTUP/SHUTDOWN
STARTUP
CHECK HOPPER/ASH HANDLING OPERATION
PREHEAT HOPPERS
SET RAPPER CYCLE
CHECK RAPPER OPERATION
CHECK T/R SETTING
SEQUENTIALLY ENERGIZE T/R BY FIELD
SHUTDOWN
SHUTDOWN INCINERATOR
DEENERGIZE T/R BY FIELD
AFTER 4 HOURS DEENERGIZE HEATERS
AFTER 8 HOURS SHUTDOWN RAPPERS
-------
SESSION 8.
MAINTENANCE INSPECTION-A NECESSARY PART OF YOUR JOB
-------
SLIDE 8-1
PREVENTIVE MAINTENANCE
PROGRAM TO CONDUCT MAINTENANCE ON REGULAR SCHEDULED BASIS
RESPONSIBILITY OF MAINTENANCE DEPARTMENT?
You CAN HELP
~ INSPECT UNIT
~ IDENTIFY MINOR PROBLEMS
REPORT TO MAINTENANCE DEPARTMENT
-------
SLIDE 8-2
TYPICAL MAINTENANCE INSPECTInN srHFnm f
ACTIVITY
FREQUENCY
HOURLY
DAILY
WEEKLY
MONTHLY
90 DAY
INCINERATOR COMPONENT
ASH REMOVAL CONVEYOR
WATER QUENCH PIT
RAM COOLING SYSTEM
STACK
THERMOCOUPLES
LIMIT SWITCHES
UNDERFIRE AIR PORTS
OPACITY MONITOR
OXYGEN MONITOR
BLOWER INTAKES
INDUCED-DRAFT FANS
CONTROL PANELS
REFRACTORY
EXTERNAL SURFACE OF INCINERATOR AND STACK
SHUT DOWN AND DO COMPLETE WALKTHROUGH
(FIRST YEAR)
-------
SLIDE 8-3
TYPICAL MAINTENANCE INSPECTION SCHEDULE FHR
A WET SCRUBBER
INSPECTION
FREQUENCY
DAILY
MONTHLY
COMPONENT
SCRUBBER LIQUID PUMP
VARIABLE THROAT ACTIVATOR
SCRUBBER LIQUID LINES
REAGENT FEED SYSTEM
FAN
pH METER
AP METER
DUCT WORK
-------
SLIDE 8-4
TYPICAL MAINTENANCE INSPECTION SCHEDULE FOR
A FABRIC FILTER SYSTEM
INSPECTION
FREQUENCY COMPONENT
DAILY STACK
MANOMETER
COMPRESSED AIR SYSTEM
COLLECTOR/CLEAN CYCLE
HOPPERS/DUST REMOVAL SYSTEM
FAN
-------
SLIDE 8-5
RECORDKEEPING
RECORDS ALLOW TRENDS TO BE TRACKED
ASSISTS WITH EVALUATING PM PROGRAM
' ASSISTS INVENTORY DECISIONS
-------
SLIDE 8-6
DAILY MAINTENANCE INSPECTION LOG
Facility name:
Operator's name:
Date:
^^^^i^^H^^MMHM
Time Equipment inspected
Notes
Ash removal conveyor
Mater quench pit
Opacity monitor
Oxygen monitor
Underfire air ports
Ash pit/dropout sump
Stack
Scrubber liquid pump
Variable throat activator
Scrubber liquid lines
Mist eliminator pressure lines
Reagent feed system
Fan
Fan belt
-------
SESSION 9.
TYPICAL PROBLEMS
-------
-------
SLIDE 9-1
PROBLEMS
IT'S BETTER TO PREVENT PROBLEMS
THAN TO CORRECT PROBLEMS
-------
SLIDE 9-2
INCINERATOR PROBLEMS
BLACK SMOKE
WHITE/BLUE-WHITE SMOKE
WHITE SMOKE/HAZE
PUFFING SMOKE FROM CHAMBER
EXCESSIVE AUXILIARY FUEL USAGE
POOR ASH QUALITY
BURNER PROBLEMS
-------
SLIDE 9-3
Too Much _
Highly Volatile
Waste
BLACK
SMOKE
X 1
\ Too Much
Underfire Air
ซ Not Enough
\~\ Secondary Air
BLACK SMOKE FROM INCINERATOR STACK
-------
SLIDE 9-4
r
WHITE/
BLUE-WHITE
SMOKE
Secondary Chamber
Temperature Too Low
Too Much
Secondary Air
WHITE/BLUE-WHITE SMOKE FROM INCINERATOR STACK
-------
SLIDE 9-5
n
Hydrochloric
Acid Gas
Condensing
WHITE
SMOKE/HAZE
APPEARING
SHORT DISTANCE
FROM STACK
U
n
WHITE SMOKE/HAZE A SHORT DISTANCE FROM INCINERATOR STACK
-------
SLIDE 9-6
SMOKE LEAKING
FROM PRIMARY
CHAMBER
Too Much
Highly Volatile
Waste
Malfunction In Stack
Damper or Fan
Too Much
Primary Air
SMOKE LEAVING PRIMARY CHAMBER OF INCINERATOR
-------
SLIDE 9-7
TOO MUCH
AUXILIARY
FUEL USAGE
^
-c=^
L , , 1 j
v \J
Leaky / ' \
Door Seal ^^^ r '
Inconsistent _ \ ,
Waste unarrjmn \j I I i/
/ ' \
Fuel Leak , Mnt Fnniinh
Improper , , L !] g.
Underfire Air Underfire A
Distribution
i
^^
T l> i-
1 00 MUCn
Secondary Air
i
ir
TOO MUCH AUXILARY FUEL USAGE
-------
SLIDE 9-8
Too Much
Waste/Wet Waste
Improper
Underfire Air
Distribution
/ \
CZK
Insufficient
Burnout Period/
Temperature
Not Enough
Underfire Air
INCOMPLETE
BURNOUT/POOR
ASH QUALITY
INCOMPLETE BURNOUT/POOR ASH QUALITY
-------
SLIDE 9-9
Proper Flame
Pattern
BURNER FLAME PATTERNS
-------
SLIDE 9-10
Detached Flame; Too
Much Burner Air
Smoking Flame;
Not Enough Air
BURNER FLAME PATTERNS
-------
SLIDE 9-11
Flame Impingement
On Refractory
BURNER FLAME PATTERNS
-------
SLIDE 9-12
PREVENT INCINERATOR PROBLEMS
PROPERLY CHARGE INCINERATOR
NOTE SMALL OPERATING AND MAINTENANCE PROBLEMS
AND GET FIXED BEFORE THEY BECOME BIG PROBLEMS
-------
SLIDE 9-13
WET SCRUBBER PROBLEMS
CORROSION
PLUGGED SPRAY NOZZLES
FAN VIBRATION
-------
SLIDE 9-1/1
PREVENT SCRUBBER PRflRI FMS
MAINTAIN CORRECT pH FOR SCRUBBER LIQUID
MAINTAIN LOW LEVEL OF SOLIDS IN RECIRCULATED
SCRUBBING LIQUID
USE PREVENTIVE MAINTENANCE PROGRAM FOR
INSPECTING/CLEANING NOZZLES, FANS, DAMPERS
-------
SLIDE 9-15
HIGH OPACITY
STACK EMISSIONS
Improperly
Installed Bags
Broken Bags
BAGHOUSE
HIGH OPACITY FROM FABRIC FILTER
-------
SLIDE 9-16
Moisture
Coixteflsalion
Cleaning System
Failure or
Infrequent
Cleaning
HIGH
PRESSURE
DROP
BAGHOUSE
~z
HIGH PRESSURE DROP IN FABRIC FILTER
-------
SLIDE 9-17
PREVENT FABRIC FILTER PROBLEMS
MAINTAIN PROPER TEMPERATURE RANGE WITHIN BAGHOUSE
MONITOR A?
MAINTAIN PROPER CLEANING CYCLE
MONITOR OPACITY
-------
SLIDE 9-18
OTHER PROBLEMS
WATER COOLING SYSTEMS FOR RAMS
"MAINTAIN WATER FLOW
MAINTAIN COOLER OPERATION
MlCROSWITCHES
CHECK MOVEMENT BY HAND
LUBRICATE
-------
SLIDE 9-19
WHAT PROBLEMS
DO
YOU HAVE?
-------
SESSION 10.
STATE REGULATIONS
-------
-------
SLIDE 10-1
TYPES OF REQUIREMENTS IN STATE REGULATIONS
EMISSION LIMITS
OPERATING PRACTICES/LIMITS
CONTINUOUS EMISSION MONITORING
RECORDKEEPING AND REPORTING
OPERATOR TRAINING
-------
SLIDE 10-2
1 Grain
1 Foot
1 Foot
1 Foot
1 Grain Per Dry Standard
Cubic Foot
7000 Grains=1 pound
-------
SLIDE 10-3
100 Cubic
Meters
Contains 1 Million
Cubic Meters
100 Parts Per million
-------
SLIDE 10-4
.., 1 gr/dscf
i 7% oxygen
-J 12% carbon dioxide
Barometric
Damper ,
Closed 1
INCINERATOR
Combustion Air
21% oxygen
79% nitrogen
0% carbon dioxide
1 gr/dscf
' 7% oxygen
12% carbon dioxide
f--~1 0.5 gr/dscf
i j 14% oxygen
6% carbon dioxide
Barometric f
Damper ,
Open ' ' '
JJ
1 scf air
21% oxygen
0% carbon dioxide
1 gr/dscf
' 7% oxygen
12% carbon dioxide
INCINERATOR
Combustion Air
21% oxygen
79% nitrogen
0% carbon dioxide
1 gr/dscf @ 7% Oa = 0.5 gr/dscf @ 14% 02
1 gr/dscf @ 12% C02=0.5 gr/dscf @ 6% CO2
CORRECTION FOR DILUTION
-------
SLIDE 10-5
Equ.val.nt to 20% BUK* Equivalent to 40% Black Equivatem to 60% Black Equivalent to 80% Black
Ringtemann's Scale for Grading the Density at Smoke
20%
40%
60%
80%
OPACITY AND THE RINGLEMANN CHART
-------
SESSION 11.
SAFETY: AN IMPORTANT PART OF YOUR JOB
-------
-------
SLIDE 11-1
TORN "RED" BAG
-------
SLIDE 11-2
WASTE HANDLING SAFFTY
HAZARDS
SHARP OBJECTS IN WASTE BAGS
INFECTIOUS WASTE SPILLAGE
MICRO-ORGANISMS IN AIR
PRECAUTIONS
MINIMIZE BAG HANDLING
DO NOT OPEN OR CRUSH BAGS
WEAR PROTECTIVE CLOTHING AND SAFETY GEAR
DO NOT EAT OR DRINK IN THE AREA
WASH HANDS BEFORE EATING OR DRINKING
-------
SLIDE 11-3
Thick rubber gloves
Ear protectors
Hard-soled rubber shoes
Dust mask
Long-sleeved shirt/coveralls
Safety glasses
PROPER SAFETY GEAR
-------
SLIDE
INCINERATOR OPERATION-
INJURIES AND SAFETY HA7ARIK
BURNS
HOT SURFACES
~ CARELESS CHARGING
CARELESS ASH REMOVAL
OPENING INSPECTION PORTS
INJURY
MOVING BELTS AND HYDRAULIC CYLINDERS
ELEVATED WALKWAYS
EXPOSURE TO AIR CONTAMINANTS/LACK OF OXYGEN
~ LEAK IN EQUIPMENT OR DUCTWORK
POOR VENTILATION OF AREA
-------
SLIDE 11-5
BURNER FLAME SAFEGUARD SYSTEM
CONTROLS BURNER IGNITION
PURGES SYSTEM
PILOT IGNITION
~ DETECTOR
~ 15 SECONDS
~ FUEL RELAY
MAIN BURNER IGNITION
SHUTDOWN
FLAME OUT
~ AIR SUPPLY FAILURE
-------
SLIDE 11-6
INCINERATOR OPERATION SAFETY PRECAUTIONS
Do's
WEAR PROTECTIVE CLOTHING AND SAFETY GEAR
BE CAREFUL AROUND MOVING BELTS, HYDRAULIC CYLINDERS, AND
DOORS
AVOID CONTACT WITH HOT SURFACES
WATCH FOR FUEL LEAKS
BE CAREFUL ON ELEVATED WALKWAYS
VENTILATE ROOM IF THERE is LACK OF OXYGEN OR UNUSUAL ODORS
LEAVE AREA IF YOU DEVELOP
~ HEADACHE, DROWSINESS, SHORTNESS OF BREATH, NAUSEA
-------
SLIDE 11-7
INCINERATOR OPERATION SAFETY PRECAUTIONS
DON'TS
DO NOT OPEN INSPECTION PORTS DURING OPERAT
ION
DO NOT PLACE HANDS OR FEET INTO FEED RAM ASSEMBLY OR ASH
REMOVAL SYSTEM
DO NOT LEAN ON GUARDRAILS OF WALKWAYS
DO NOT BYPASS BURNER FLAME SAFEGUARD SYSTEM
-------
SLIDE 11-8
INCINERATOR OPERATION SAFETY PRECAUTIONS: MANUAL CHARGING
Do's
WAIT FOR PREVIOUS CHARGE TO BURN DOWN
TURN OFF PRIMARY CHAMBER BURNER
STAND BEHIND AND AWAY FROM DOOR
DON'TS
DO NOT LOOK INTO OPEN CHARGE DOOR
DO NOT CHARGE BOTTLES OF FLAMMABLE LIQUIDS
-------
SLIDE 11-9
INCINERATOR QPEMTinM SflFฃTY PRECAUTIONS; ASH REMflVAi
Do's
USE PROPER EQUIPMENT TO REMOVE ASH
WATCH OUT FOR HOT SPOTS AND SHARP OBJECTS
PUT ASH INTO NONCOMBUSTIBLE CONTAINER
SPRAY WATER ON ASH IN CONTAINER TO COOL
-------
SLIDE 11-10
INCINERATOR OPERATION SAFETY PRECAUTIONS; ASH REMOVAL
DON'TS
DO NOT ENTER INCINERATOR CHAMBER
DO NOT DAMAGE INCINERATOR REFRACTORY
DO NOT SPRAY WATER INTO CHAMBER
DO NOT HANDLE ASH DIRECTLY
-------
SLIDE 11-11
WET SCRUBB RS; HAZARDS
CHEMICAL BURNS
FALLS
FAN/FAN BELTS
HEARING LOSS
-------
SLIDE 11-12
WET SCRUBBERS; SAFETY PRECAUTIONS
Do's
KEEP SCRUBBER LIQUOR OFF SKIN AND EYES
LEARN LOCATION OF AND HOW TO USE EYEWASH
GET SCRUBBER LEAKS REPAIRED
STAY AWAY FROM FANS, DRIVE SHAFTS, AND FAN BELT
ASSEMBLIES
WEAR EARPLUGS OR EARMUFFS AROUND NOISY EQUIPMENT
-------
SLIDE 11-13
WET SCRUBBERS; SAFETY PRECAUTIONS
DON'TS
DO NOT PLACE HAND IN FAN BELT/PULLEY ASSEMBLY
DO NOT CONTINUE TO OPERATE IF FAN IS VIBRATING SEVERELY
-------
SLIDE 11-14-
FABRIC FILTERS: HAZARDS
TOXIC CHEMICALS IN FINE DUSTS
EXCESSIVE HEAT
FAN/FAN BELTS
HEARING LOSS
INSIDE FABRIC FILTER
~ TOXIC GASES AND DUST
-- HOT, FREE FLOWING SOLIDS
~ OXYGEN DEFICIENCY
ROTATING EQUIPMENT
-- MOVING MECHANICAL PARTS
-------
SLIDE 11-15
FABRIC FILTERS; SAFETY PRECAUTIONS
Do's
PREVENT INHALATION OF DUST BY WEARING DUST MASK
WEAR EARPLUGS OR EARMUFFS AROUND NOISY EQUIPMENT
STAY AWAY FROM FANS, DRIVE SHAFTS, AND FAN BELT ASSEMBLIES
BEFORE ENTERING A FABRIC FILTER
CLEAN DUST FROM BAGS AND HOPPER
PURGE WITH AIR
&E SURE FAN IS "LOCKED OUT"
HAVE A SECOND TRAINED PERSON STANDING BY
PLAN TO STAY INSIDE AS SHORT A TIME AS POSSIBLE
-------
SLIDE 11-16
FABRIC FILTERS; SAFETY PRECAUTIONS
DON'TS
DO NOT PLACE HAND IN FAN BELT/PULLEY ASSEMBLY
DO NOT CONTINUE TO OPERATE IF FAN IS VIBRATING SEVERELY
NEVER ENTER FABRIC FILTER WITHOUT PROPER TRAINING AND
EQUIPMENT
-------
SLIDE 11-17
EMERGENCY PROCEDURES
POST TELEPHONE NUMBERS FOR EMERGENCY SERVICES
SECURITY SHOULD INCLUDE INCINERATOR ON ROUNDS
POST SPILL CONTROL/DECONTAMINATION PROCEDURES
POST PROCEDURES FOR ADDRESSING PUNCTURE WOUNDS
-------
-------
REFERENCES FOR SLIDES
-------
References for Slides
Session 2
1. McRee, R. Operation and Maintenance of Controlled Air Incinerators
Ecolaire Environmental Control Products. Undated.
Session 3
1. Air Pollution Control District of Los Angeles County. Air Pollution
Engineering Manual, 2nd Edition AP-40. (NTIS PB 225132) U S
Environmental Protection Agency. May 1973.
2. Ecolaire Combustion Products, Inc. Technical Article: Principles of
Controlled Air Incineration. Undated.
3. McRee, R. Operation and Maintenance of Controlled Air Incinerators
Ecolaire Environmental Control Products. Undated.
4. Consertherm Systemsฎ. Technical Data Form for Rotary Kiln.
Industronics, Inc. Undated.
5. Doucet, L. Waste Handling Systems and Equipment. Fire Protection
Handbook, 16th edition. National Fire Protection Association.
6. Consumat Systems Inc. Technical Data Form for Waste Feed System.
Undated.
7. U. S. Environmental Protection Agency. Source Category Survey
- Industrial Incinerators. EPA 450/3-80-013. (NTIS PB 80-193303) May
1980.
Session 4
1. Joseph, J. and D. Beachler. APTI Course SI:412C, Wet Scrubber Plan
Review Self-Instructional Guidebook. EPA 450/2-82-020. U. S
Environmental Protection Agency. March 1984.
2. U. S. Environmental Protection Agency. Control Techniques for
Particulate Emissions from Stationary Sources, Volume 1.
EPA 450/3-81-005a. (NTIS PB 83-127498) September 1982.
3. U. S. Environmental Protection Agency. APTI Course SI:412B,
Electrostatic Precipitator Plan Review, Self-Instructional
Guidebook. EPA 450/2-82-019. July 1983.
Session 5
1. Cleaver Brooksฎ. Operation, Maintenance, and Parts Manual for the
Pyrolytic Incinerator. Publication No. CBK 6826. September 1988.
-------
PART II.
STUDENT WORKSHEETS
-------
WORKSHEET NO. 1
INCINERATOR SYSTEM INFORMATION
Can you describe the type incinerator you operate? Fill out this
table. Circle the answer that best fits your system.
Operator's name
Incinerator manufacturer
A. Incinerator type (Circle)
1. Controlled ("starved") air
2. Multiple chamber "excess" air
In-line
Retort
3. Rotary kiln
4. Other
5. Don't know
8. My incinerator is designed especially for pathological waste:
Yes No Don't know
C. Operating mode
1. Single batch
2. Intermittent duty
3. Continuous duty
4. Don't know
D. Waste feed charge system
1. Manual - I do alj the work
2. Mechanical hopper/ram
a. Manually operated
b. Automatic timer sequence
3. Mechanical hopper/ram with cart dumper
4. Other
5. Don't know
E. Ash removal system
1. Manual - rake and hoe
2. Continuous mechanical
3. Don't know
-------
INCINERATOR SYSTEM INFORMATION (CONTINUED)
F. Combustion Gas Flow
1. Natural draft
2. Induced draft
3. Balanced draft
Forced combustion air/natural draft stack
Forced combustion air/induced draft fan
G. Waste heat boiler
1. Yes
2. No
-------
WORKSHEET NO. 2
INCINERATOR SYSTEM INFORMATION
Monitoring and Control Systems
Operator's name
Incinerator manufacturer
A- How would you describe the operating made of your incinerator?
1. Single batch
2. Intermittent duty
3. Continuous duty
B' How would you describe the control system used on your incinerator?
1. Manual
2. Automatic timer sequence
3. Automatic modulated control
c- What operating parameters are monitored or used as control parameters
on your incinerator?
Function
Monitored Controlled Controlled
1. . Primary Chamber
Temperature
2. Secondary Chamber
Temperature
3. Draft
4. Charge rate
5. Oxygen
6. Carbon Monoxide
7. Opacity
8. Other:
-------
INCINERATOR SYSTEM INFORMATION
WORKSHEET NO. 3
Operating Parameters
Operator's name
Incinerator manufacturer
What are the
key operating parameters for your incinerator. What are the setpoints or
operating ranges used?
Key Parameter Setpoints/Operating Range No setpoint
lower
1. Primary chamber
temperatuce
2. Secondary chamber
temperature
3. Draft
4. Charge rate
5. Oxygen concentration
6. Carbon monoxide
concentration
-------
WORKSHEET NO. 4
OPERATING REVIEW
A. List the things to do when operating your incinerator that you
think are the most important:
1.
2.
3.
4.
5.
B. Name the things to watch (monitor) when operating your
incinerator that you think are the most important.
1.
. 2.
3.
4.
5.
C. Name the things not to do when operating your incinerator that
your think are the most important:
1.
2.
3.
4.
5.
-------
WORKSHEET NO. 5
OPERATING PROBLEMS REVIEW
What are the most frequent problems you usually have?
A. Problem;
Possible causes:
Possible solutions:
B. Problem;
Possible causes:
Possible solutions:
C. Problem;
Possible causes:
Possible solutions:
-------
WORKSHEET NO. 6
INCINERATOR SYSTEM INFORMATION
Regulatory Limits
Operator's name
Incinerator manufacturer
What regulatory limits are you required to meet during operation of
your incinerator?
Limit
A. Emission Limits:
1. Opacity
2. Particulate
3. Other
B. Operating Limits
1. Charge rate
2. Primary chamber temp
3. Secondary chamber temp
4. Oxygen concentration
5. Ash quality
6. Other
C. Record Keeping
1. Charge rate
2. Primary chamber temp
3. Secondary chamber temp
4. Other
-------
WORKSHEET NO. 7
SAFETY REVIEW
A. What personal safety gear do you use?
1. Coveralls
2. Hard soled shoes
3. Eye protection
4. Gloves
5. Oust mask
6. Ear protection
B. List the most serious safety hazards to which you are exposed,
How do you minimize your chances of injury??
1.
2.
3.
4.
5.
-------
-------
PART C.
REFERENCES FOR SLIDES
-------
References for Slides
Session 2
1. McRee, R. Operation and Maintenance of Controlled Air Incinerators.
Ecolaire Environmental Control Products. Undated.
Session 3
1. Air Pollution Control District of Los Angeles County. Air Pollution
Engineering Manual, 2nd Edition AP-40. (NTIS PB 225132). U. S.
Environmental Protection Agency. May 1973.
2. Ecolaire Combustion Products, Inc. Technical Article: Principles of
Controlled Air Incineration. Undated.
3. McRee, R. Operation and Maintenance of Controlled Air Incinerators.
Ecolaire Environmental Control Products. Undated.
4. Consertherm Systemsฎ. Technical Data Form for Rotary Kiln.
Industronics, Inc. Undated.
5. Ooucet, L. Waste Handling Systems and Equipment. Fire Protection
Handbook, 16th edition. National Fire Protection Association.
6. Consertherm Systemsฎ. Technical Data Form for Rotary Kiln.
Industronics, Inc. Undated.
7. U. S. Environmental Protection Agency. Source Category Survey:
Industrial Incinerators. EPA 450/3-80-013. (NTIS PB 80-193303) May
1980.
Session 4
1. Joseph, J. and D. Beachler. APTI Course SI:412C, Wet Scrubber Plan
Review Self-Instructional Guidebook. EPA 450/2-82-020. U. S.
Environmental Protection Agency. March 1984.
2. U. S. Environmental Protection Agency. Control Techniques for
Particulate Emissions from Stationary Sources, Volume 1.
EPA 450/3-81-005a. (NTIS PB 83-127498) September 1982.
3. Beachler, D. and M. Peterson. APTI Course SI:412A, Baghouse Plan
Review Student Guidebook. EPA 450/2-82-005. U. S. Environmental
Protection Agency . April 1982.
Session 5
1. Cleaver Brooksฎ. Operation, Maintenance, and Parts Manual for the
Pyrolytic Incinerator. Publication No. CBK 6826. September 1988.
-------
2. Jahnke, J. APTI Course SI:476A, Transmissometer Systems Operation and
Maintenance, an Advanced Course. EPA 450/2-84-004. U. S.
Environmental Protection Agency, Research Triangle Park, N.C
September 1984.
Session 6
1. McRee,, R. Operation and Maintenance of Controlled Incinerators
Ecolaire Environmental Control Products. Undated.
Session 9
1. U. S. Environmental Protection Agency. Workbook for Operators of
Small Boilers and Incinerators. EPA 450/9-76-001. March 1976.
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TECHNICAL REPORT DATA
Please reaa instructions on me reverse oerore comvienngi
\ REPORT NO. 12. 3. RECIPI ENT'S ACCESSION NO.
EPA 450/3-89-004 |
4. TITLE AND SUBTITLE
Hospital Incinerator Operator Training Course:
Volume II Presentation Slides
7. AUTHOH(S)
Neulicht, R. M.;. Chaput, L. S.; Wallace, 0. D.;
Turner, M. B.; Smith, S. G.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Midwest Research Institute
401 Harrison Oaks Boulevard, Suite 350
Gary, North Carolina 27513
12. SPONSORING AGENCY NAME ANO ADDRESS
U. S. Environmental Protection Agency
Control Technology Center
Research Triangle Park, N. C. 27711
|5. REPORT DATE
1 March 1 Q8Q
ID. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT MO.
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-02-4395
68-08-0011
13. TYPE OF REPORT AND PERIOD COVERED
Fi na 1
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
James Eddinger, Office of Air Quality Planning and Standards
Justice Manning, Center for Environmental Research
16. ABSTRACT
H
and
onw
document Is Volume II of a three-volume training course for operators of
ar T? ^^J"6^^5* ^^ l 1s the student Handbook (EPA 450/3-89-003),
III is the Instructor Handbook (EPA 450/3-89-010). This traininq course
pdred by ^ .Contro1 Technology Center for the State of Saryฃnd.
SuSe 1s.to.Pi;ov1di hospital waste incinerator operators with a
1?f the P/Tnciples of incineration and air pollution control and
Je!5Xl3yt "ฐd ฐPer?tion and maintenance (O&M) practices. Proper O&M,
hands-ฐn t?a'ing ฐf operatฐ- ^ ""
Volume II contains classroom materials including a copy of the presentation
US SSLflS6"1? Can follow ^* dur1n9 the c]^ * workfhee?I?htt ?an be
eted during the classroom sessions. The course includes 11 separate classroom
!f?I2T?,,?!2rJI&.to?1cs ?Uch !sba?ic combustion principles and InclnerStSr dlilS-
onoi;^S0ntrฐ- ^uipnient desiqn, function, operation, and monitoring; incin-
operation; maintenance inspections; typical problems; and State regulations
17.
KEY WORDS ANO DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
COSATI Held/Group
Medical Waste Incineration
Hospital Waste Incineration
Air Pollution Control Technology
Incinerator Operator Training
Incineration
Medical Waste
Hospital Waste
Air Pollution Control
Training
118. DISTRIBUTION STATEMENT
' Release unlimited
19. SECURITY CLASS
:i. NO. OF PAGES
20. SECuRlTv CLASS tThupasei
= PA Form 2220-1
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