X-/EPA
United States
Environmental Protection
Agency
Industrial Environmental
Research Laboratory
Cincinnati OH 45268
Research and Development
EPA-600/S2-84-1 29 Nov 1984
Evaluation of Hazardous Waste
Incineration in Cement Kilns at
San Juan Cement Company
J.A. Peters, T.W. Hughes, J.R. McKendree, LA. Cox, and B.M. Hughes
Cement kiln incineration of chlorinated
liquid organic wastes was investigated
in a 5-month demonstration program at
San Juan Cement Company in Puerto
Rico. Chlorinated monocarbon com-
pounds (POHC's) were monitored in the
waste and emissions, and the fate of
added chlorine in cement production
was determined. Seven levels of percent
chlorine in the waste were burned at
ten different waste feed rates. Extensive
sampling and analysis was conducted
to look for the potential presence of
polychlorinated dibenzodioxins (PCDD's)
and polychlorinated dibenzofurans
(PCDF's).
The destruction and removal efficien-
cies (ORE) of the POHC's ranged from
91.043 percent to 99.997 percent,
with only 6 percent of the DRE's
greater than 99.99 percent. Poor DRE
results were attributed to the absence
of waste atomization and the difficult
incinerability of chlorinated monocarbon
compounds. It was found that about 82
percent of the input chlorine appeared
in the cement clinker. The amount of
chlorine appearing in the baghouse dust
varied from 5 percent to 26 percent of
total chlorine input. The total absorption
of the HCI formed averaged 99.7
percent in seven tests. PCDD's and
PCDF's were not produced at detectable
levels when the cement plant was
operating normally.
This Project Summary was developed
by EPA's Industrial Environmental
Research Laboratory. Cincinnati. OH,
to announce key findings of the research
project that is fully documented in a
separate report of the same title (see
Project Report ordering information at
back).
Introduction
A number of cement plants have been
used to test cofiring of hazardous wastes,
and the data from these tests appeared to
indicate that properly operated cement kilns
could destroy many organic chemical
wastes. However, the data were not
sufficiently extensive to allow a deter-
mination of minimally acceptable operat-
ing conditions and maximum waste firing
rates for attaining the requirements of
incinerators and were insufficient to
permit a determination of the fate of
heavy metals in such systems. The tests
at the Marquette Cement facility, spon-
sored by the U.S. Environmental Protection
Agency (USEPA) helped to resolve some
of the issues associated with the fate of
heavy metals and provided data on
conventional pollutant emissions, but
questions about the degree of destruction
and removal efficiency remained un-
answered.
To obtain additional data, the USEPA's
Industrial Environmental Research Lab-
oratory-Cincinnati, in cooperation with
USEPA's Region II and the Puerto Rican
Environmental Quality Board, conducted
a comprehensive experimental program
at San Juan Cement, in Dorado, Puerto
Rico, from October 1981 to February
1982 to evaluate the ability of the cement
kiln to destroy hazardous waste containing
chlorinated compounds such as methy-
lene chloride (CH2CI2), chloroform (CHCI3),
and carbon tetrachloride (CCU); to
determine the effects of firing wastes on
the emissions of conventional pollutants
such as particulate, CO, NO* and SO*; and
to evaluate the ability of the process to
consume the HCI generated by incinera-
tion of chlorinated compounds and
measure emissions of HCI in the stack
gas.
Other objectives of the tests were to
determine if chlorinated dibenzofurans
and dibenzodioxins are produced while
burning chlorinated compounds, deter-
mine the fate of heavy metals, and
identify products of incomplete combus-
-------
tion and other residual organic com-
pounds.
Facility and Process
Description
San Juan Cement Company has oper-
ated a cement plant in Barrio Espmosa in
Dorado, Puerto Rico, since 1970. The
plant is located about 27 km west of San
Juan and is dedicated tothe manufacture
of Portland cement. Its annual production
averages 4.082 x 108 kg (450,000 tons)
per year, it employs 350 workers, and it is
the second largest cement plant in Puerto
Rico.
At San Juan Cement, kiln #2 is 137 m
(450 feet) long with an outer shell
diameter of 3.05 m (10 ft) and 0.305 m (12
inch) thick walls The kiln rotates 75 times
per hour and has a gentle slope to allow
material to pass through by gravity. In
cement kilns, solid materials travel in one
direction and hot gases plus dust emis-
sions travel in the opposite direction. A
slurry of 30-40% water (typically 35-39%)
and finely crushed rock is fed into the kiln
at the upper end. At the opposite end of
the kiln is an intense oil fire; at San Juan
Cement kiln #2, No. 6 fuel oil is burned at
about 1.51 x 10~3 mVs (24 gpm), a heat
input of approximately 62 x 106 watts
(212 million Btu/hr). As the raw material
passes slowly through the kiln, it first
dries, then, at a temperature of 550°C
(1,020°F), calcination starts (CO2 is
liberated from the calcium carbonate in
the slurry feed), and finally it approaches
the hot burning zone of the kiln. In the
burning zone, 1,500°C (2,700°F) temper-
atures calcine and fuse the raw materials
creating a complex calcium silicate
alummo-fernte mineral substance called
"clinker," which is discharged from the
lower end of the kiln and cooled by large
fans in the clinker cooler [1]. The clinker
production rate at San Juan Cement
ranged from 28-33 metric tons/hr(31-36
ton/hr). The addition of about 6% gypsum
to milled clinker completes the process m
the production of Portland cement.
Exhaust gases from kiln #2 pass through
a baghouse where entrained particulate
matter is removed. The cleaned exhaust
gases are then released to the atmosphere
through a single stack.
Experimental Design
The sampling and analytical program
was designed to identify all major
pollutants from the burning of the
hazardous wastes available for this
program and to quantify their respective
emission rates, investigate the chlorine
material balance of the cement process.
determine burning rate limits as related
to product acceptability and refractory
lining integrity, and determine the
destruction and removal efficiencies
(DRE) of the principal organic hazardous
constituents (POHC's) in the waste fuels.
The POHC's chosen for this program
were the three chlorinated compounds
known to be present in the waste fuel
mixture:
(1) Methylene chloride (dichlorome-
thane), CH2Cl2 higher heating value
(HHV) - 3058 Btu/lb
(2) Chloroform (trichloromethane),
CHCI3 HHV= 1349 Btu/lb
(3) Carbon tetrachloride (tetrachloro-
methane), CCU HHV = 432 Btu/lb
Emission measurements included pani-
culate matter, carbon monoxide (CO),
carbon dioxide (C02), sulfur dioxide (S02),
nitrogen oxides (NOX), hydrogen chloride
(HCI), total gaseous hydrocarbons (THC),
total chlorinated hydrocarbons, methylene
chloride (CH2CI2), chloroform (CHCI3),
carbon tetrachloride (CCU), trace metals
in particulate matter, organics, with
special attention given to dioxins, and
furans in the baghouse fly ash Chlorine
content of the baghouse fly ash and
cement clinker was also monitored. The
waste fuels and fuel oil used to fire the
cement kiln were analyzed for principal
organics, trace metals, ash, chlorine,
nitrogen, and sulfur content.
Table 1 summarizes the test matrix of
the demonstration program wherein the
waste feed rate to the kiln and the
chlorine content of the waste were
varied. Table 2 summarizes the overall
test program and shows each collection
method and analytical method. A Quality
Assurance Project Plan was prepared and
reviewed prior to the program. A full
description of the QA/QC results involving
replicates, splits, blanks, spikes, and
reference standards is provided in the
final report
Results and Discussion
A detailed summary of the waste fuel
composition of each of the six waste
shipments used in the tests is given in
Table 3. A seventh waste batch composed
of a mixture of shipments 4 and 6 was
burned and tested.
Five baseline tests (no waste fuel
burned) were carried out to determine
stack emissions when waste fuel was not
being burned. Four of the baseline testing
days involved EPA Method 5 testing,
whereas the fifth test was a SASS run.
The SASS was used to identify PICS and
quantify dioxins and dibenzofurans.
NOX, SO2, TSP, total hydrocarbons, and
HCI were measured repeatedly during the
program to determine the difference m
emissions between baseline operation
(no hazardous waste fed to the kiln) and
waste fuel burns.
When waste fuel was burned, ten
comprehensive tests on the seven waste
fuel batches were completed. These
included SASS runs on waste batches 3,
4, and 6; and EPA Method 5 runs on
seven waste fuel burn tests. An additional
fourteen tests were conducted with only
POHC and CO monitoring
Table 4 presents the comparisons for
particulate NOX, SO2, total hydrocarbon,
and HCI emissions using the t-test to
determine statistically significant dif-
ference.
Carbon Monoxide Emissions
High carbon monoxide emissions can
be an indicator of inefficient combustion
m the cement kiln. During stable kiln
combustion, CO emission levels stayed
below 10 ppm. However, any process
fluctuation or change in kiln variables
caused a momentary excursion in CO
emissions to levels often greater than
1,000 ppm (0.1%), even during baseline
testing.
During start-up of the waste fuel burn,
stack CO concentration often changes in
the transient period after the waste is
turned on. From 0800 hours to 0905
hours, the kiln was not burning waste
fuel and CO emission levels hovered at 0-
40 ppm, indicative of stable kiln operation.
As the waste fuel was introduced, the CO
levels rose rapidly beyond 1,000 ppm for
approximately 20 min and then returned
to levels below 100 ppm as the kiln
operation stabilized.
POHC Destruction and
Removal Efficiency
Destruction and removal efficiency
(DRE) for an incineration/air pollution
control system is defined by the following
equation:
DRE =
-W,n-Wout
W,n
(100%)
whereDRE= destruction and removal
efficiency, %
W,n - mass feed rate of the pri nci-
pal organic hazardous con-
stituent(s) to the incinerator
Wout=mass emission rate of the
principal organic hazardous
constituent(s) to the atmos-
phere (as measured in the
stack prior to discharge).
Concentrations of the POHC's were
measured during baseline testing (days
-------
Table 1.
Test Matrix of Waste Feed Rate and Chlorine Content
Approximate waste
feed rate to
kiln, m3/s (gpm)
x = Conditions tested.
Percent chlorine in waste, wt %
6.5
10.1
18.7
21.4
22.9
32.0 35.1
8.39 x 10~5 (1.33)
9.46 x 10's (1 SO)
1.10 x 10~* (1.75)
1.26 x 10'' (2.001
1.89 x 10~4 (3.00)
2.21 x 10'" (3.50)
2.71 x 10"* (430)
3.15 x 10'' (5.00)
3.47 x 10~4 (5.50)
3.79 x 10'A (6.00)
x
X X
X
X X
X X
X
X
X
X
X
X
X
X
when no waste fuel was burned) in order
to give background or normal concentra-
tions of the POHC's in the exhaust gas.
The average background level was then
subtracted from the results obtained
during a waste fuel burn to arrive at the
contribution attributable to the waste
burn.
The average ORE for each test run for
the POHC's is presented in Table 5.
Methylene chloride was destroyed to at
least 99.0% efficiency, with the only
exceptions being the two tests with waste
batch #5, which contained only 1.4%
methylene chloride. In general, the lower
the mass feed rate of a POHC, the lower
the ORE.
Table2. San Juan Cement Company Waste Fuel Demonstration Burn Sampling and Analytical Program
Parameter measured
Sampling
method
Analytical method
Stack Samples
Paniculate matter
Metals on particulate
Organics on particulate
Opacity
Sulfur dioxide
Nitrogen oxides
Carbon monoxide
COzand O2
Hydrogen chloride
Total gaseous hydrocarbons
Total chlorinated hydrocarbons
Three chlorinated species (POHCs)
Organic compound speciation
Ambient Air
Particulate matter
Process Water
Organics (3 species)
No. 6 fuel Oil
Btu content
Chlorinated methanes
Sulfur content
Trace metals
Principal organics
Waste fuel
Btu content
Moisture content
Total chlorine
Total nitrogen
Total sulfur
Trace metals
Principal organics
PCBs and pesticides
Ash content
Solid Waste (kiln dust)
Principal organics
Furans and dioxms
Chlorine content
E.P. toxicity
Furans and dioxins
Trace metals
EPA Method 5
EPA Method 5
EPA Method 5
EPA Method 9
EPA Method 6
EPA Method 7
EPA Method 10
Integrated bag sample
Impinger tram
Direct to analyzer
Integrated bag samples
Integrated bag samples
SASS train
High volume gas sampler
Integrated sample
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
EPA Method 5
ICAP
Extractions and GC/MS
for principal organics,
dioxins, and furans
EPA Method 9 (on site)
EPA Method 6
EPA Method 7
NDIR continuous analyzer
EPA Method 3 (on site)
Specific ion electrode
Continuous FID
GC/EC (on s/te)
GC/EC (on site)
GC/MS
EPA-Appendix BFR 121'0105
EPA priority pollutant
methodology. GC/MS
ASTM D240-64
GC/EC
ASTM D-3177
ICAP
GC/MS
ASTM D240-64
GC/MS
ASTMD8081
Kjeldahl
ASTM D129
ICAP
GC/MS
GC/MS and GC/EC
ASTM D-482-IP4
Extraction and GC/MS
ASTM D-808
Extraction and GC/MS
ICAP
-------
Table3. Summary of Waste Fuel Analyses for Cemento San Juan Demonstration Burn (volume basis)
Batch 1, Batch 2. Batch 3, Batch 4, Batch 5, Batch 6,
Compound vo/% vol % vol % vol % vol % vol %
Water
Methanol
Ethanol
Acetone
2-Propanol
Methylene chloride (POHC)
Hexane isomers
3-Methylpentane
Hexane
Chloroform (POHC)
Ethyl acetate
Methyl acetate
Carbon tetrachloride (POHC)
Benzene
Hexamethyl disiloxane
Toluene
Acrylonitnle
Methyl ethyl ketone
Cs-benzene isomer
Ce-benzene isomer
Sec-butyl ethylbenzene
Xylene isomers
Dimethylphenol isomer
1, 1 '-(1,2-ethanediol)bis-
4-methoxybenzene
Unknowns
PCBs, ppm
Pesticides9, ppm
Properties
Btu content, Btu/lb
Specific gravity
Chlorine content, wt %
Ash content, wt %
<1 0
TO 4
08
14.2
4.7
24.4
3.9
54
198
10
4.0
NO
0.8
0.4
0 1
02
ND
NA
NA
NA
NA
NA
NA
NA
8.9
<50
<100
11.188
NA
320
0.30
4.1
7.1
32
12.2
5.2
16.9
3.2
4.6
17.3
0.8
14.0
NAb
06
04
ND
0.1
1.0
NA
NA
NA
NA
NA
NA
NA
93
<100
<100
11,198
NA
229
020
4.3
139
86
11.2
5.3
120
1.8
27
72
34
90
0.4
1 4
0.2
ND
0.02
1 1
0.08
1 33
ND
1 23
024
004
023
14.3
<100
<100
1 1,022
09948
21 4
0.38
89
6.2
4.7
10.5
4.5
12 1
1.5
3.2
85
5.4
6.6
<1.0
10.2
0.3
MA
<0.5
<0.7
1.1
0.5
NA
1.7
NA
NA
NA
11 9
<100
<100
10,099
0.9885
35.1
0.23
230
10.9
16.8
4.6
3.1
1 4
ND
ND
5.9
40
3.5
ND
78
0.1
NA
ND
1.0
NA
09
ND
NA
NA
ND
NA
17.9
<100
<100
4,546
1.0092
18.7
0.31
20
NDa
5.6
22
1.6
5.0
1.5
3.6
15.7
0.1
22.7
ND
001
005
NA
ND
ND
NA
2.2
23.8
NA
ND
ND
NA
12.9
<100
<100
13,098
0.9163
6.5
0.046
Batch 4/6,
vo/%
NA
NA
NA
NA
NA
5.1
NA
NA
NA
0.9
NA
NA
1.5
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
<100
<100
NA
09410
10 1
NA
Density,
9/mL
1.000
0.7914
0.7983
0.7899
0.7855
1.3266
0.6532
0.6645
0 6603.
1 4832
0.9003
0.9330
1 5940
08787
0.8923
0.8669
0.8060
0.8054
030e
0.90"
0.90e
0.87s
0.90°
0.90"
TLV.C
mg/m3
d
260
1,900
2,400
500
360
-
d
1,800
50'
1,400
610
35'
35'
d
375
5'
590
-d
-d
d
435
-
-d
a/VD = not detected, generally <0.1% by volume. Components were quantified in volume % because external standards were prepared on a volume
basis.
"NA = not analyzed
"Threshold limit value for workplace air
"No TL V assigned to this compound or isomer
"Estimated values
'Suspected or known carcinogen.
gAs per priority pollutant list.
Table 4. Comparison of Pollutant Levels Between Normal Operation and Waste Fuel Firing in
Cement Kiln No 2, San Juan Cement Company
Mean loading
Statistical significance
Pollutant
Paniculate matter
NOx
SO2
Total hydrocarbons
HCI
uasenne
93 + 65 mg/m3a
(n=4)
136 + 83 ppm
(n=4)
279 + 243 ppm
(n=4)
8.3 + 2.1 ppm
0 82 mg/m3
Waste tiring
99 + 65 mg/m3
(n=7)
68 + 23 ppm
(n=9)
450 ± 245 ppm
127 + 2.1 ppm
(n=7)
3.3 ± 1.7 mg/m3
(n=9)
at 95% degree of certainty
No significant difference
Significant difference
Significant difference
Significant difference
Significant difference
a95% confidence level
Chloroform and carbon tetrachloride
were more difficult to destroy than
methylene chloride. Also, in most waste
batches, methylene chloride was the
POHC of highest concentration in the
waste. Waste batches #4 and #5 contained
the most chloroform and carbon tetra-
chloride, and the best ORE results for
carbon tetrachloride were observed for
the test runs on these two batches.
In one instance, run number W6-1 for
CCU, the Wout exceeded the W,n. The mass
feed rate to the kiln was less than 0.11
kg/hr. The higher mass emission rate
observed suggests that CCU could be
formed as a product of incomplete
combustion from the combustion of
methylene chloride and chloroform.
The probable reasons for the low ORE
results are: (1) lack of air atomization of
the waste fuel, and (2) difficulty of
incinerabihty of highly chlorinated mono-
carbons and poor combustion of the
primary fuel. According to company
practice, the waste fuel injection had to
match the fuel oil injection pattern in
order to prevent flame impingement on
inner wall of the kiln and pre-ignition, or
back-puffing, of the fuel oil stream.
Therefore, methods to air-atomize the _
waste fuel were not attempted. U
-------
Tabled. Destruction and Removal Efficiencies of POHC's for Demonstration Burn Tests at San
Juan Cement Company Kiln #2
Run
number
W1-2*
W2-1a
W3-a
W3-2
W3-3
W4-1
W4-2
W4-3
W4-4
W4-5C
W5-1C
W5-2C
W6-1
W4/6-Jc
W4/6-2c
W4/6-3c
W4/6-4c
W4/6-5c
Methylene
chloride
>99 997
99.995
>99.991
99.960
99659
98.237
99.418
99.461
99.984
99.335
93.292
96.663
99.223
99.760
99.668
99564
99. 133
99.474
Chloroform
>99.842
>99.859
99.887
99932
>99.960
98.592
99.470
99.283
98975
99950
98388
96099
b
55.6/7
92. 1 71
98.703
>99 737
97515
Carbon
tetrachloride
99.309
>99.996
91.043
96864
98.977
97732
98 122
99. 142
99.684
99.069
99.553
99460
b
94 129
99325
94.512
92.253
95.873
"Waste feed rate was estimated.
bNot present in waste fuel
"Stack gas volumetric flow rate of 1619 dscmpm used.
Other compounds eluted from the
GC column at retention times of 0.51 mm
(CH2 CI2), 0.80 min (CHCI3), and 1.01 min
(CCU). The most commonly seen com-
pound had a retention time (R.T.) of 0.57
to 0.61 min, and a post-test laboratory
experiment with duplicate GC conditions
tentatively identified it as a trichlorotri-
fluoroethane. Another compound which
was seen in several instances eluted at
about 1.1. min and was tentatively
identified as trichloroethylene, a likely
PIC from chloromethane combustion;
1,1,1-trichloroethane (1.54 min R.T.),
tetrachloroethylene (1 68 min R T.),
acetone (2.11 mmR T.), acetonitrite(2 15
min R.T.), and acrylomtrile (2.16 min R.T.)
were never detected by the in-field
GC/EC analyses.
The SASS samples collected for
chlorinated dioxins and chlorinated
dibenzofurans were also analyzed for
products of incomplete combustion. Four
samples (one baseline and 3 waste
burning) were analyzed for PIC's The
baseline sample was analyzed, since the
cement plant burns fuel oil as its primary
energy source. During the program, fuel
oil accounted for 87 to 100% of kiln's
energy requirement. Products of incom-
plete fuel oil combustion need to be
distinguishable from products of incom-
plete hazardous waste combustion,
hence the baseline sample. Three SASS
samples were collected during hazardous
waste burning representing different
feed compositions, feed rates, and
operating conditions.
The PIC's which were not detected
during the baseline test and may be
attributable to hazardous waste burning
are Trichloroethylene (100-100,000
mg/hr), Phenol (2.4-11.0 mg/hr), C2-
naphthalene isomers(10-50 mg/hr), and
Ca-naphthalene isomers (14-46 mg/hr)
HCI Emissions
Based on the amount of chlorine
charged to the kiln in the waste and
analyses of HCI in the stack gas, results
showed an average removal of 99.7% of
the HCI generated by the combustion. In
any event, the emissions of HCI were
considerably less than 4 Ib/hr, the
regulatory threshold emission rate for
requiring control equipment on inciner-
ators. However, statistical analysis indi-
cates a discernable difference in HCI
emissions between baseline and waste
burning tests.
One of the objectives of the program
was to determine whether polychlorinated
dibenzodioxins (PCDD) and polychlori-
nated dibenzofurans (PCDF) might be
found as products of incomplete com-
bustion while hazardous wastes are
being fired to the kiln Because chlorinated
dioxins and dibenzofurans are believed to
be among the most toxic substances to
humans, EPA officials required that
during the demonstration program,
extensive sampling and analysis be
conducted for these compounds Thus, a
total of 28 different samples were
collected for analyses, as shown below.
• 4 SASS tram samples (particulates
and vapors in stack gas);
• 5 EPA Method 5 samples (particu-
lates in stack gas);
• 11 baghouse dust samples (plant
solid waste);
• 8 RCRA extracts of baghouse dust
samples (plant solid waste).
Eight samples were taken during
baseline conditions and 20 samples were
taken during hazardous waste burning
operations. The SASS train samples
resulted in three sections for analysis: 1)
methylene chloride rinses of the sampling
probe, teflon line, filter holder, and
organic module, 2) combined filter and
XAD-2 absorbent resin, and 3) the
condensate water removed from the
organic module during sampling.
The baseline SASS run (BW-SASS)
showed some positive, detectable values
of hexachloro-and heptachlorodibenzo-
furan in the absorbent resm extract,
although none could be detected in the
other portions of the train. This caused
the reported values to be less than the
average detection limit for the entire
train, which was 3.4 ng/m3. It is
noteworthy that no dioxins or furans
were detected in any waste burning
SASS samples at a detection limit
ranging from 1.6 ng/m3 for tetrachloro-
isomers to 4 9 ng/m3 for octachloro-
isomers.
In the analyses of the paniculate catch
from EPA Method 5 runs, no detectable
quantities of PCDD's were found in any of
the paniculate samples. In only one
sample, run W3-3, 11.0 ng/m3 of
pentachloro dibenzofuran, 26 ng/m3 of
hexachloro-, and 8 ng/m3 of dibenzofuran
heptachloro-PCDF isomer»were found.
These detectable emissions occurred
when the kiln was fed 2.75 x 10~4 m3/s
(4.35 gpm) of waste which contained
21.4% chlorine. This corresponds to'a
chlorine input of 3.5% by weight of total
fuel input (fuel oil plus hazardous waste)
which resulted in the production of off-
spec cement clinker and a potentially
kiln-damaging condition. Excessive chlo-
rine in the clinker will lengthen cement
set time and reduce strength. The
Chlorine Material Balance (CMB) section
of the full report describes how this is an
intolerable operating conditions for the
cement plant. Thus, the generation of
detectable quantities of PCDF's occurred
only when operating an "upset" or "out-
er-control" kiln. Under other conditions,
the cement process did not emit PCDF's
or PCDD's under any waste burning
conditions.
Major Conclusions
Some of the results observed in this
demonstration program contradicted
results from other cement kiln incineration
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tests: for example, lower DRE's, no
change in participate emissions, and
significant changes in 862 and NOx
emissions. The following conclusions
apply only to this particular kiln and the
results of this demonstration program.
1. The inability of this kiln to consistently
achieve 99.99% ORE (a level which
hazardous waste incinerators must
demonstrate) of the POHC's is attri-
buted to unatomized waste introduc-
tion to the kiln flame and the difficult
mcinerabihty of the POHC's. In the
past, these compounds (CH2CL2,
CHCIa, and CCU) were employed as fire
retardants because they were able to
remove hydrogen atoms from the
free-radical branching combustion
reactions to form HCI. Combustion of
chlorinated species containing less
chlorine may have resulted in higher
DRE's.
2 Chlorinated dioxms and chlorinated
dibenzofurans were not produced at
detectable levels (1 6 ng/m3) when
the cement kiln was operating norm-
ally
3 Less than 0 3% of the chlorine
introduced into the cement kiln with
the waste is emitted in the stack gas
as HCI The majority (99.7%) of the
chlorine reacts with the alkaline
material in the kiln and is incorporated
into the clinker and the baghouse
dust.
At San Juan Cement, approximately
82% of the chlorine fed to the cement
kiln appears in the clinker. This may
vary at different cement plants, since
process feedstock alkalinity (ability to
absorb chlorine) varies at each
cement plant
4. Achievable fuel savings are a function
of the chlorine content of the waste
and each plant's ability to absorb
chlorine At San Juan Cement, a
hazardous waste containing less than
5% will result in at least a 20%
savings in fuel costs. Higher fuel
savings may be possible for higher
chlorine contents at other plants.
5. At this facility, there was no signifi-
cant increase in particulate emissions
due to the burning of chlorinated
hazardous wastes.
6 Emissions of sulfur dioxide, total
hydrocarbons, and hydrogen chloride
increased significantly when waste
was burned.
7 HCI emissions rates were below the 4
Ib/hr, which is the limitation imposed
on incinerators by RCRA, above
which additional HCI removal treat-
ment is required.
8 Emissions of nitrogen oxides de-
creased significantly when waste
was burned.
References
1. Lauber, J D., "Burning Chemical
Wastes as Fuels in Cement Kilns."
Journal of the Air Pollution Control
Association, 32(7): 771-777, July
1982.
J. A. Peters, T. W. Hughes, J. ft. McKendree, L A. Cox, andB. M. Hughes are with
Monsanto Research Corporation, Dayton. OH45407; the EPA author, Robert E.
Mournighan (also the EPA Project Officer, see below) is with Industrial
Environmental Research Laboratory, Cincinnati, OH 45268.
The complete report, entitled "Evaluation of Hazardous Waste Incineration in
Cement Kilns atSanJuan Cement Company, "(Order No. PB 84-226 935; Cost:
$20.50, subject to change) will be available only from:
National Technical Information Service
5285 Port Royal Road
Springfield, VA 22161
Telephone: 703-487-4650
The EPA Project Officer can be contacted at:
Industrial Environmental Research Laboratory
U.S. Environmental Protection Agency
Cincinnati, OH 45268
I
SUSGPO: 1984 — 559-111/10728
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United States
Environmental Protection
Agency
Center for Environmental Research
Information
Cincinnati OH 45268
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