United States
                    Environmental Protection
                    Agency
 Industrial Environmental
 Research Laboratory
 Cincinnati OH 45268
                                                                                     .Si."/
                    Research and Development
 EP A-600/S2-84-132  Nov. 1984
&ERA         Project  Summary
                    Evaluation  of  Hazardous Waste
                    Incineration  in  a  Lime  Kiln:
                    Rockwell  Lime  Company
                    D. R. Day, L. A. Cox, and R. E. Mournighan
                     During a one-week test burn, hazard-
                    ous waste was used as supplemental
                    fuel and co-fired with petroleum coke in
                    a  lime  kiln in  eastern Wisconsin.
                    Detailed sampling and analysis was
                    conducted on the stack gas for principal
                    organic hazardous constituents (POHCs).
                    particulates, paniculate metals, HCI,
                    SO2, NOx, CO, and THC and on process
                    streams for metals and chlorine. POHCs
                    were also  analyzed in the waste fuel.
                    Sampling was conducted during three
                    baseline and five waste fuel test burn
                    days. Results show average destruction
                    and removal efficiencies (DREs) greater
                    than 99.99% for each POHC and little
                    change  in pollutant emissions from
                    baseline to waste fuel test conditions.
                    In addition, material balance results
                    show that 95% of chlorine enters the
                    process from the limestone feed and the
                    chlorine exits the kiln in the baghouse
                    dust and lime product at 61 % and 38%,
                    respectively.
                     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
                     Cofiring  hazardous wastes in  high-
                    temperature industrial processes is  an
                    attractive alternative to incineration,
                    because it makes use of the heat content
                    of the waste.  Many cofiring devices,
                    which include cement and dolomite kilns,
                    glass furnaces, steel furnaces, and some
                    industrial boilers, provide temperatures
and residence times similar to those
required for incinerators dedicated to
hazardous wastes. In addition to the
savings derived from the heat value,
using existent equipment saves the
capital required  to build a  separate
incinerator and may thus provide an
environmentally acceptable alternative to
conventional hazardous waste disposal.
  Because of their high energy use, lime
kilns are  an excellent example of this
concept. Such kilns typically  operate at
temperatures over 1093°C (2000°F), have
gas residence times exceeding 1.5
seconds, and have a  highly  turbulent
combustion zone. However, the  need
exists  for  data that show the effect of
cofiring hazardous waste on the emissions
from the lime process.
  The  State of Wisconsin Department of
Natural Resources (DNR) and the U.S.
Environmental Protection Agency (EPA),
Region V,  issued a temporary permit to
Rockwell  Lime Company to  conduct a
hazardous waste test burn. This test
would allow the burning of  hazardous
liquid waste as supplemental  fuel along
with petroleum  coke. The waste fuel
would replace natural gas  as a fuel
component.
  Through a contract with the Industrial
Environmental Research Laboratory,
Cincinnati, OH (lERL-Ci),  Monsanto Re-
search Corporation (MRC) performed the
sampling and analysis of stack gases and
process samples during  the  test  burn
conducted at the Rockwell Lime Company
in Rockwood, Wisconsin.
  The primary objectives of the sampling
and analysis were to (1)  determine the
effects of  cofiring petroleum  coke and
hazardous waste OP the emissions from

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 the kiln, (2) determine the fate  of the
 principal organic hazardous constituents
 (POHCs) and determine destruction and
 removal efficiencies (DREs), (3) determine
 the fate  of chlorine and trace metals in
 the  kiln  process, (4) determine the
 concentration of SOa, NOX, particulates,
 HCI,  metals, total hydrocarbons, and
 carbon  monoxide  in  the  stack  gas  at
 baseline and  waste fuel  test burn
 conditions, and (5) evaluate kiln operation
 during  hazardous waste  fuel burning
 conditions. This testing  provides the
 Wisconsin DNR and EPA Region  V with
 the data  necessary to determine whether
 a permit can be issued to Rockwell Lime
 Company to burn hazardous waste. The
 testing  also will provide the  EPA-ORD
 with additional data in their research on
 the incineration of hazardous waste and
 the environmental problems associated
 with incineration.
  Facility and Process
  Description
    The Rockwell Lime Company's lime kiln
  in Rockwood, Wisconsin, approximately
  10 miles north of Manitowoc, produces
  lime at approximately 1.3x106kg(1,430
  tons) per week, which varies based upon
  product  demand. The  process involves
  heating  limestone to approximately
  1,100°C (2,000°F) in a horizontal rotary
  kiln. Calcining is achieved by interfacing
  the hot gases with the limestone, which
  drives off the C02  from the limestone,
  leaving the lime product (CaO).
    The kiln, with refractory linings, is 2.4
  m (8 ft)  in diameter and 67.1 m  (220 ft)
  long. The kiln rotates  at  approximately
   Natural Gas m
     Supply
Petroleum Coke—^*..
    Supply     |

           Primary
             Air
                    Screw Conveyor
one  revolution  per  minute and  has a
gentle  slope to allow material to pass
through by gravity. It also has a counter-
current flow pattern, that is, solids travel
in one  direction and hot gases and dust
emissions travel in the opposite direction,
as shown in Figure 1. Limestone is fed
into the upper end of the kiln at approxi-
mately 15,440 kg/hr (34,000 Ib/hr). At
the opposite end of the kiln, a mixture of
coal and natural  gas is burned at
approximately 1,450 kg/hr (3,200 Ib/hr)
and 142 mVhr (5,000 ftVhr) to provide a
heat input of approximately 14,700  kw
(50 million Btu/hr) or approximately 6.5
million Btu/ton of lime  product. As the
limestone feed travels down the inclined
rotating kiln, it passes through  various
temperature zones, and the  hot gases
calcine the limestone into the lime
product. The  product   is  produced at
approximately 7,720  kg/hr (17,000
Ib/hr). After transformation in the kiln,
the lime product is air cooled and either
directly stored in silos or hydrated prior to
storage.
  Primary air mixed with the gas, coke,
and secondary (heated) air from the lime
product cooler is fed to the kiln to provide
oxygen for the combustion of the coke
and natural gas (or waste fuel). The kiln
exhaust gases pass through a series of
large radiator coolers that cool the gases
before they enter the baghouse; this
removes particulates and SOa from the
gas stream. The gases then pass through
the induced draft fans and out the stack at
approximately  200°C (392°F) and  5.5
m/s (18 ft/s). The collected dust is stored
in a silo and  mixed  with  water to
granulate. Some of the dust is sold and
                                                       Limestone
                                                          Fe.ed   \Exhaust
                                                                 Stack
                                           Klln ^°'
                                                                     Dust
                                        Air
                                                                                the  remainder is disposed of  in the
                                                                                quarry. No dust is reinjected into the kiln.
                                                                                  During baseline conditions, a blended
                                                                                combination  of petroleum coke and
                                                                                natural  gas was  used to fire  the kiln.
                                                                                During the waste fuel runs, a temporary
                                                                                1-inch diameter stainless steel  pipe was
                                                                                placed on the burner pipe with its nozzle
                                                                                pointed into the flame, and the waste fuel
                                                                                and  petroleum coke were fed unblended
                                                                                to fire the kiln.
                                                                                  The hazardous waste fuel was trucked
                                                                                to the site and stored in a 5,000-gallon
                                                                                tanker between kilns 1 and 2  near the
                                                                                burner end. The  diaphram-type  waste
                                                                                fuel  pump, located next  to the tanker,
                                                                                pumped fuel through the stainless steel
                                                                                pipe to the flame. Air was added to the
                                                                                pipe to supply oxygen for combustion and
                                                                                to cool the pipe.
                                                                                  The waste fuel  consisted primarily of
                                                                                lacquer  thinner solvents, alcohols, still
                                                                                bottoms, paint wastes, and  a  small
                                                                                fraction  of chlorinated  hydrocarbons
                                                                                (0.4%).  Tetrachloroethylene  and tri-
                                                                                chloroethylene were spiked to the waste
                                                                                fuel  before the test to bring  the total
                                                                                chlorine content to approximately 3.0%,
                                                                                which would allow easier evaluation of
                                                                                the destruction of the chlorinated species.
                                                                                During test conditions, the  waste fuel
                                                                                ranged from 8% to 36% of the Btu input to
                                                                                the kiln, and petroleum coke ranged from
                                                                                64% to  90%. Comparatively,  under
                                                                                baseline  conditions, the petroleum coke
                                                                                averaged  90% and the natural gas
                                                                                averaged 10% of the Btu input to the kiln.

                                                                                Experimental Program
                                                                                  Table  1  summarizes the test  program.
                                                                                Measured  pollutants in  the stack gas
                                                                              Radiators
                                                                                                     Exhaust
                                                                                                      Gases

                                                                                                        I.D. Fans
\ ~\

•*•






Baghouse
(8 Modules)
                                                                                              NXXXXXX/
                                                                                                    Dust
                                                                                                 to Storage
                                                                                                    Silo
              Lime
             Product
Figure 1.    Schematic diagram of lime kiln process.

                                     2

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include  POHCs (tetrachloroethylene
(PERC), trichloroethylene (TCE), methylene
chloride (MeCI2), 1,1,1-trichloroethane
(CH3CCI3), methyl ethyl ketone (MEK), and
toluene),  paniculate  matter, particulate
trace metals, hydrogen chloride, sulfur
dioxide, nitrogen oxides, carbon monoxide,
total  hydrocarbons, and  oxygen.  In
addition,  the distribution  of  metals and
chlorine  was measured in all of the
process input and output streams. Waste
fuel,  coke,  baghouse dust, and lime
product  samples were  submitted  for
sulfur analyses.  Coke  samples  were
analyzed  for ash and Btu content. Waste
fuel  samples also  were analyzed  for
POHCs and Btu content.
  Sampling was conducted under baseline
conditions (i.e., no waste fuel burned) on
April  15,  29, and 30. Sampling at waste
fuel  conditions (i.e., waste fuel burned)
was  conducted from  May 2 to May 6. A
                                        Quality Assurance (QA/QC) Project Plan
                                        was reviewed and approved prior to the
                                        test program. A full  description  of the
                                        QA/QC results involving replicates,
                                        blanks, spikes, and standards is provided
                                        in the full report.

                                        Results and Discussion

                                        Waste Fuel
                                         A detailed summary of the waste fuel
                                        composition for two waste fuel samples
                                        collected is shown in Table 2.  Tables 3
                                        and 4 show the concentration of each
                                        POHC and  other properties for the five
                                        waste fuel samples (one sample per day,
                                        Runs 4-8).

                                        POHC Destruction and
                                        Removal Efficiencies
                                          The complex combustion chemistry for
                                        organic materials is  perplexing when a
Table 1.    Summary

    Parameter
                  of Rockwell Lime Kiln Sampling and Analytical Program

                             Sampling method               Analytical method
Stack Gas
  POHCs*

  Particulate matter
  Metals on
   particulate
  Hydrogen chloride
  Carbon dioxide
    and oxygen
  Nitrogen oxides

  Sulfur dioxide


  Carbon monoxide
                         Volatile organic sampling
                           train (VOST)
                         EPA Method 5
                         EPA Method 5

                         Impinger absorption in
                           0.5 M NaoAc (back half
                           of EPA Method 5)

                         EPA Method 3


                         Continuous

                         Continuous

                         Continuous
CC/MS, thermal desorption
  and SIM
EPA Methods
ICP

Specific ion electrode
Fyrite

Chemiluminescence photo-
  metric analyzer
Pulsed fluorescence
  TECO analyzer
Infrared-EPA Method 10
Total hydrocarbons
Oxygen
Waste fuel
POHCs
Metals
Chlorine, sulfur
Btu content
Baghouse dust
Metals
Chlorine, sulfur
Lime product
Metals
Chlorine, sulfur
Dry limestone feed
Metals
Chlorine
Primary fuel coke
Metals
Chlorine, sulfur
Btu content
Continuous
Continuous
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
— composite
— composite
— composite
-~ composite
-~ composite
— composite
— composite
— composite
— composite
— • composite
— composite
— composite
— composite
Flame ionization detector
Teledyne's micro-fuel cell
GC/MS
ICP
ASTM D240-64
ASTM D482-IP4
ICP
XRF
ICP
XRF
ICP
XRF
ICP
XRF
ASTM D240-64
                         broad range of organic compounds in a
                         liquid waste  are  burned.  On a weight
                         basis, most of the organic carbon in the
                         waste is oxidized to COa in the combustion
                         process,  but  trace amounts of organic
                         chemicals survive oxidation and are only
                         partially  reacted.  Accordingly, the test
                         burn investigated the amount of destruc-
                         tion of  the organic  compounds in  the
                         hazardous waste.
                           The ORE for an incineration/air pollu-
                         tion control  system  is  defined by  the
                         following equation:
                                  DRF= Win'w°u'(inn)
                                          W,n
                                  (1)
where DRE=destruction and removal
            efficiency, %
       W,n = mass feed rate of principal
            organic hazardous constit-
            uent(s) (POHCs) fed  to the
            incinerator
      Wout = mass emission rate of prin-
            cipal  organic hazardous
            constituent(s)  (POHCs) to
            the  atmosphere (as mea-
            sured  in stack prior  to dis-
            charge).

ORE calculations are based on combined
efficiencies of the destruction  of  the
POHC in the incinerator or the lime  kiln
and the removal of the POHC from the gas
stream in the air pollution control system.
The presence of POHCs in solid discharges
from  the air pollution control devices is
not accounted for in the ORE calculation
as currently defined by EPA. RCRA, Part
264, Subpart 0 regulations for hazardous
waste incinerators require  a  ORE of
99.99% for all principal organic hazardous
constituents of a waste during trial burns
unless it can be  demonstrated  that a
higher or lower ORE is more appropriate
based on human health criteria. Specifi-
cation of the POHCs in a waste is  subject
to best engineering judgment, considering
the toxicity, thermal stability, and quantity
of each organic  waste constituent. ORE
requirements in the Subpart 0 regulations
do not apply to metals or other noncom-
bustible materials.
  Toluene,  MEK.  Pare, and TCE were
present in high concentration for organic
compounds (see  Table 2). Spikes  of Perc
and TCE were added  to the waste fuel
prior to the test burn to obtain the higher
concentrations.  Perc, TCE, methylene
chloride, and 1,1,1-trichloroethane were
selected  because the chlorinated hydro-
carbons are,  in general, difficult to
destroy thermally. All  six of the com-
*Tetrachloroethylene. trichloroethylene, methylene chloride,
 ketone, and toluene.
                                                  1,1,1-triehloroethane. methyl ethyl

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  30

   10-
     Methylene Chloride
                                          30
                                        8 20<
                                        3
                                          10-
                                                Trichloroethylene
  30-
  20

   10
       1234
       Number of Nines ORE



     Methylethyl Ketone
                                          30-
                                          10-
                                                12345
                                                  Number of Nines ORE
                                               Tetrachloroethylene
      /    2    3   4     5
      Number of Nines ORE



30 4  1.1,1 Trichloroethane
                                                12345

                                                  Number of Nines ORE

   10
I
        12345
         Number of Nines ORE
Figure 2.    Destruction and removal efficiencies.
30-
| 20-
"5
"6
tj 10-
Toluene












                                              1    2    3.   4    5
                                               Number of Nines ORE
pounds except methylene chloride were
found in  the top twenty constituents of
the waste fuel. All  six compounds are
listed as  hazardous  in  RCRA Part 261,
Appendix VIII.
  Approximately six VOST sampling runs
were made each day (Runs 1 -8). Destruc-
tion and removal efficiencies, calculated
for waste fuel runs 4-8, are summarized
in Figure  2.
  In general, DREs ranged from 99.60%
to >99.999%  for all  compounds and
averaged 99.9989%. Only four runs had
DREs less than 99.99%; three of these
were for  methylene  chloride, the fourth
for 1,1,1-trichloroethane.
                                       DREs for methylene chloride (MeCI2)
                                     ranged from 99.60% to <99.999% and
                                     averaged 99.983% ± 0.15% (95% con-
                                     fidence limits).

                                       Methyl  ethyl ketone (MEK) had  an
                                     average ORE of 99.999% ± 0.0002% (95%
                                     confidence limit) and ranged from 99.998%
                                     to greater  than  99.999%.  These high
                                     destruction efficiencies were consistent
                                     throughout the test runs.

                                       DREs for 1,1,1-trichloroethane (CH3
                                     CCI3) ranged from 99.989%  to 99.999%
                                     and averaged 99.997% ± 0.004% (95%
                                     confidence limits). Only Run No. 4E had a
                                     ORE less than 99.99%.
  DREs for trichloroethylene (TCE) were
greater than 99.999% for all runs. TCE
was spiked to the waste fuel prior to
testing to increase its concentration and
allow easier detection of TCE in the stack
gas. Spiking of TCE to  concentrations
greater than approximately 1.3%  by
volume was not possible due to permit
requirements which specified a maximum
of 3.0% by volume for chlorine.
  DREs for tetrachloroethylene  (Perc)
also were greater than  99.99% for  all
runs. Like TCE, Perc was spiked to the
waste  fuel to  the  maximum  allowable
concentration described in the test burn
permit prior to the test.
  Toluene  was the POHC of highest
concentration in the waste fuel (average
11.6% by weight). DREs for toluene were
above  99.999% for all  runs. Data  for
toluene was very consistent during  all
waste fuel test runs.

Stack Samples
  Results  for stack  conditions and
paniculate, hydrogen chloride, sulfur
dioxide, nitrogen oxides, carbon monoxide,
and total hydrocarbon  emissions  for
baseline and waste fuel runs are sum-
marized in Table 5. The overall stack rate
averaged 917 mVmin (32,420 ftVmin)
and the  dry stack  rate averaged 487
dscm/min  (17,210  dscf/min). As evi-
denced by the high  standard deviations
the CO and, to a lesser degree, the S02
fluctuated.  Minor kiln  upsets (i.e., coke
feed chute cleaning, clumps of coke
falling to kiln, change  in process condi-
tions) created  high  CO  excursions.  An
increase in SOz by —200 ppm, followed by
a  reduction in NOX  by ~50 ppm and a
subsequent increase in CO by ~500 ppm
occurred quite often over a  15 minute
period. These trends are expected when a
lower  intensity flame occurs (or kiln
upset). However, as revealed by Figure 2,
the kiln upsets had little or no effect on
the ORE results.

Chlorine, Sulfur and Metals
Balance

   Chlorine and sulfur  material balances
are summarized for baseline and waste
fuel conditions in Table 6. The majority of
chlorine (for either baseline or waste fuel
conditions) enters the kiln in the limestone
feed and exits the kiln  in the lime
product and baghouse dust. Sulfur  (for
either baseline or waste fuel conditions)
enters the kiln in the petroleum coke and
exits the kiln distributed in the lime
product (—9%), baghouse dust (—27%),
and stack gas (—64%).

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  Typical  metals material balance  is
shown in Table 7. There was no difference
for baseline and waste fuel conditions for
distribution of metals in the kiln process.
As shown in Table 7, the majority of mass
entering the kiln  is  contributed by the
limestone feed, except for zinc. The mass
exiting the kiln is distributed between the
lime product and baghouse dust.

Baseline vs.  Waste Fuel and
Kiln  Operation
  Emissions were evaluated under
baseline and waste fuel conditions. For
 Table 2.   Results of Capillary GC/MS Analysis of Major Components of Waste Fuels
Concentration,
wt%
Waste fuel component
Acetone
Methyl ethyl ketone (MEK) (POHC)
1, 1 ,1 -Trichloroethane CH3 CCI3 (POHCi
1 -Butanol
Trichloroethylene TCE (POHC)
2-Ethoxyethanol
Methyl isobutyl ketone
Toluene (POHC)
Tetrachloroethylene (PercJ (POHC)
Butyl acetone
Ethylbenzene
Xylene (isomer No. 1)
Xylene (isomer No. 2)
2-Butoxyethyanol
2-Ethoxyethyl acetate
Ca-Benzene (isomer No. 1)
Cs-Benzene (isomer No. 2)
C 10- Alkane
Alkane >Ca
Alkane
Cn- Alkane
2-Cyclohexen-1 -one or 3,5,5-Trimethyl (isomer)
Alkane >C6
Number
4'
0.23
2.48
0.24
0.32
1.73
0.85
1.06
11.0
2.17
0.27
1.42
4.92
1.43
1.99
5.91
0.28
0.46
0.80
0.24
0.14
1.26
0.15
0.27
Number
7"
0.22
3.17
0.22
0.37
2.16
0.92
1.16
12.5
2.49
0.32
1.58
5.58
1.60
2.07
6.37
0.32
0.57
0.94
0.28
0.18
1.48
0.18
0.24
aAver age of split sample.
Table 3.    Concentration of POHCs
Run
No.
4
5
6
7b
7°
8
POHCs concentration, wt %*
MeClz
0.101
0.097
0.106
0.120
0.120
0.116
MEK
2.48
2.75
2.48
3.17
3.17
2.59
CH3 CC/3
0.238
0.239
0.228
0.216
0.216
0.282
TCE
1.73
1.64
1.78
2.16
2.16
1.89
Perc
2.17
2.02
2.05
2.49
2.49
2.56
Toluene
10.97
10.55
10.95
12.50
12.50
12.90
*No waste fuel burned on baseline runs 1 -3.
"Runs 7A-7C.
cRuns 7D-7F.
the pollutants listed in Table 5, HCI, NO*
and THC showed a significant difference
in stack emissions under baseline and
waste  fuel conditions. For the POHCs,
only methylene chloride and toluene
showed an increase  from baseline  to
waste  fuel conditions. All remaining
POHCs showed no significant difference
in baseline vs. waste fuel emissions.
  As  described  previously,  the  kiln
operation fluctuated as indicated by CO
and SO2 emission variations during
waste  fuel burning.  Kiln fluctuations
were caused by several factors, including
non-constant fuel rates, product rushes,
clumps of coke fed to kiln accidentally,
and operator inexperience with burning
waste  fuel. The fluctuation resulted  in
occasional  kiln 02 increases and stack
gas SOa decreases that caused a poorer
quality lime product most likely  due  to
excess sulfur. The following items were
identified  as ways  to  improve  kiln
operation under waste fuel conditions:

• Change  waste fuel burner configura-
   tion such that at low waste fuel rates
   the waste fuel is mixed with the coke
   to maintain a flame.
• Decrease the fan speed (i.e.,  reduce
   the draft) to lower the  02 in the kiln,
   thus lowering the sulfur in the product
   and increasing the sulfur in the stack.

Conclusions
  Constant achievement  of  at least
99.99% ORE was demonstrated for each
POHC (MeCI2, MEK, CH3 CCI3, TCE, Perc,
and toluene) in the lime kiln process.
  Emissions  of pollutants were deter-
mined and ranged as follows: particulates
0.7-1.4 kg/hr; HCI 0.04-0.26 kg/hr; S02
123-2,100 ppm; NO, 280-550 ppm; THC
1.5-10 ppm; and CO 10-5,000 ppm.
  Except for HCI, NOX, THC, MeCI2, and
toluene, emissions for pollutants were
statistically not different for baseline and
waste fuel  conditions.
  Typically, sulfur  enters  the kiln in the
petroleum  coke and exits the kiln distri-
Table4.    Waste Fuel Conditions
Run
number*
4
5
6
7
8
Chlorine
content,
% (vol.)
3.14
2.66
3.04
3.05
3.51
Sulfur
content,
%
0.10
0.08
0.065
0.06
0.11
PCB
concentration,
ppm
1.0
1.0
1.0
1.0
1.0
Heat
value,
Btu/lb
12,301
12,084
12,267
13,612
14.064
Specific
gravity,
g/cc
1.031
1.042
1.035
0.986
0.971
Feed rate,
gal/min
0.76
1.21
2.05
0.78"
2.90"
2.88
Mass rate.
g/min
2,990
4,770
8,020
2,910
10,820
10,590
*No ivsste fuel burned during Run Nos. 1, 2, and 3.
*Runs 7A-7C.
cRuns 7D-7F.

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TableS. Average Stack Emissions
Baseline
Waste fuel
Standard
Parameter and unit
Stack rate, rrf/min
Stack velocity, m/sec
Particulates
mg/dscm
kg/hr
HCI, ppm
SOi, ppm
NOx, ppm
CO. ppm
THC, ppm
Range Average
805 - 975
5.0 - 6.0

24.0 - 35.0
0.66- 1.1
0. 74 - 3.9
123 - 730
306 - 460
10 - 4,900
6.7 - 12.7
917
5.7

28.7
0.9
2.0
553
386
477
8.2
deviation Range
76
0.4

4.7
0.2
1.4
110
49
966
1.9
791 - 938
4.9 - 5.8

24.9-48.7
0.68 - 1.4
2.5 - 6.0
183 - 1.924
288 - 552
10 - 4,540
1.5 - 10.0
Average
847
5.2

35.3
1.0
4.4
596
446
599
3.5
Standard
deviation
52
0.3

8.0
0.3
1.2
240
64
1.409
1.1
Table 6. Chlorine and Sulfur Material Balance


Run
number Coke
Chlorine
Baseline * 4
Waste fuef 5
Sulfur
Baseline* 100
Waste fuef 99
* Average values of baseline

Percent to kiln
Waste Limestone
fuel feed

0 96
2 93

0 NA
1 NA
Runs 1-3.

Total
mass in.
kg/hr

23
21

59
54



Lime
product

47
34

8
10


Percent from kiln
Baghouse Stack
dust gas

52 1
65 1

29 63
25 65


Total
mass out.
kg/hr

13
20

91
70

Material
balance
closure.
%

55
105

73
77

b Average values of waste fuel Runs 4-8.
Table 7. Typical Rockwell Lime Metals Material Balance*



Metal Coke
Be 10
Ca 1
Cr 1
Fe 1
Mg <1
Ni 20
Pb 14
In 5
Percent to kiln
(by wtj
Waste Limestone
fuel feed
0 90
<1 99
<1 98
<1 99
0 99
<1 80
6 80
53 42

Total
mass in.
9/hr
25
3x106
811
13,160
2 x 106
660
<500
170


Lime
product
75
93
75
83
90
74
55
41
Percent from kiln
(bywt)
Baghouse Stack
dust gas
25 0
7 <1
25 <7
77 <7
70 <7
26 <1
45 <1
58 1

Total
mass out.
g/hr
16
3x 70s
700
73,300
2x 70s
460
<450
100


Percent
closure
64
1OO
86
1O1
700
70
90
58
* Average values for Runs 1-8.
buted in the lime product, baghouse dust,
and stack gas.
  Typically, a metal enters the kiln in the
limestone feed and exits the kiln in the
lime product and baghouse dust.
  The kiln operation fluctuated resulting
in an occasionally lower-quality  lime
product.  Improving the burner system,
reducing draft (and % 02), and allowing
operators  sufficient  time  to run the
system  may  minimize fluctuations and
improve product quality.
•&U. S. GOVERNMENT PRINTING OFFICE: 1984/559-11 I/I 0732

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      D. R. Day and L A. Cox are with Monsanto Research Corporation, Dayton, OH
        45407; ft. E. Mournighan (also the EPA Project Officer, see below) is with the
        Industrial Environmental Research Laboratory, Cincinnati, OH 45268.
      The complete report, entitled "Evaluation of Hazardous Waste Incineration in a
        Lime Kiln: Rockwell Lime Company," (Order No. PB 84-230 044; Cost: $ 16.00,
        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
United States
Environmental Protection
Agency
Center for Environmental Research
Information
Cincinnati OH 45268
     BULK RATE
POSTAGE & FEES PAID
        EPA
   PERMIT No. G-35
Official Business
Penalty for Private Use $300

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