United States
Environmental Protection
Agency
Industrial Environmental Research^'
Laboratory
Research Triangle Park NC 27711
Research and Development
EPA-600/S9-82-017 Feb. 1983
Project Summary
Proceedings: Symposium on
Environmental Aspects of Fuel
Conversion Technology—VI,
A Symposium on Coal-Based
Synfuels—October 1981
F. A. Ayer and N. S. Jones
The document summarizes or con-
tains an abstract of each presentation
made at the EPA-sponsored sympo-
sium, October 26-30, 1981, in Den-
ver, CO. The symposium provided a
forum for the exchange of ideas and
for discussion of environmentally re-
lated information on coal gasification
and liquefaction. Process developers
and users, research scientists, and
government officials reported on re-
sults achieved from research projects,
synfuels process development, inter-
agency programs, control technology
evaluation, and regulatory actions.
The program included sessions on en-
vironmental source test and evalua-
tion results for gasification, indirect
liquefaction, and direct liquefaction
processes, and water-, air-, solid waste-,
multimedia-, and product- related
environmental considerations. Approx-
imately 215 participants attended the
5-day symposium.
This Project Summary was devel-
oped by EPA's Industrial Environmen-
tal Research Laboratory, Research Tri-
angle Park. NC, to announce key find-
ings of the research project that is fully
documented in a separate report of the
same title (see Project Report ordering
information at back).
This report summarizes speakers'
presentations contained in the proceed-
ings of the EPA-sponsored Symposium
on the Environmental Aspects of Fuel
Conversion Technology - VI, a Sympo-
sium on Coal-Based Synfuels, Denver,
CO, October 26-30, 1981. The sym-
posium provided a forum for the ex-
change of ideas and for discussion of
environmentally related information on
cba) gasification and liquefaction. Pro-
cess developers and users, research
scientists, and government officials re-
ported on results from research proj-
ects, synfuels process development,
interagency programs, control technol-
ogy evaluation, and regulatory actions.
The program included sessions on
environmental source test and evalua-
tion results for gasification, indirect
liquefaction, and direct liquefaction pro-
cesses, and water-, air-, solid waste-,
multimedia- and product-related en-
vironmental considerations. Approxi-
mately 215 participants attended the
symposium.
Abstracts of speakers' remarks follow:
Session I, Part A.
Environmental Source Test
and Evaluation Results,
Gasification and Indirect
Liquefaction
Characterization of Process
Liquids and Organic
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Condensates from the Lurgi
Coal Gasification Plant at
Kosovo, Yugoslavia
K.J. Bombaugh, K.W. Lee, and
R.G. Oldham, Radian Corp.
Austin, TX 78766
S. Kapor, Institut za Primenu
Nuklearne Energy
Beograd-Zemun, Yugoslavia
Process liquids and gaseous stream
condensates from the Lurgi Coal gasifi-
cation plant at Kosovo were character-
ized to define theirorganiccomposition.
Samples of entrained liquids and
condensates were collected during
Phase II of the Kosovo source test that
was described at the preceding synfuels
symposium. These samples were char-
acterized 'by liquid chromatographic
fractionation using EPA's protocol
for a Level I source assessment. In
addition, GC/MS analyses were per-
formed on key samples to quantify their
levels of potentially hazardous PNAs, and
GC with selective detection was used to
characterize sulfur- and nitrogen-bearing
species.
This presentation discussed the
analytical results and impact that these
condensates had on the plant's dis-
charge stream severity. It also compared
the composition of liquids from the Lurgi
process with that of liquids from other
processes.
Application of Kosovo (Lurgi)
Gasification Plant Test
Results to Pollution Control
Process Design
G.C. Page, W.E. Corbett, and
R.A. Magee, Radian Corp.
Austin, TX 78766
This paper describes a test program
performed by Radian Corporation to
obtain process data to define the
pollution control technology require-
ments for Lurgi-based coal gasification
plants. This program was sponsored by
EPA's Industrial Environmental Research
Laboratory (Research Triangle Park) and
conducted at a Lurgi-based gasification
plant in the Kosovo region of Yugoslavia.
It should be emphasized that the Kosovo
plant does not reflect state-of-the-art
Lurgi technology especially in pollution
control practices. However, the uncon-
trolled process discharge streams from
the Kosovo plant are representative of
those from Lurgi-based gasification
plants.
From an assessment of the Kosovo
data, the following discharge streams
were selected to be key based on flow
rate and/or concentration of pollutants:
(1) high- and low-pressure coal lock
vent gases and ash from the gas
production section, (2) liquid depressur-
ization gases and surge tank vent gases
from tar/oil separation section, (3) HaS-
and C02-rich vent gases from the
Rectisol acid gas removal section, and
(4) extracted wastewater from the
Phenosolvan unit.
The conclusions of an engineering
evaluation of the components in those
key discharge streams and the effects
those components may have on pollution
control processes were: (1) pollution
control processes are commercially
available for treating these streams; (2)
the effects of minor and trace compo-
nents on the performance of those
control processes have not been dem-
onstrated, and there may be problems in
the direct transfer of technology from
other industries (e.g., coke ovens); (3)
the design and selection of pollution
control processes during transient and
normal operation should occur in
parallel with the base plant design;
and (4) the variability of the components
in the discharge streams must be
determined and included in pollution
control process design.
Environmental Aspects of the
GKT Coal Gasification
Process
R.E. Wetzel, GKT
43 Essen, Federal Republic of
Germany
K.W. Crawford, TRW
Redondo Beach, CA 90278
W.C. Yee, TVA
Chattanooga, TN 37401
Thermal conversion of coal is always
accompanied by the production of:
pyrolysis products; solid wastes like
ash, slag, or fly dust; different sulfur
compounds; and a number of undesired
trace compounds in the gas. The quality
and quantity of these components
depend on the applied process principle,
the composition of the reactants, and
the main process parameters (e.g.,
temperature and pressure). The GKT
high-temperature, entrained coal gas-
ification process, well-established
commercially for 30 years, offers coa
conversion with minimum environmen
tal impact.
To evaluate the operating condition;
and environmental impact when gasify
ing American coal, TVA and GK1
conducted a large-scale test with abou
5,000 short tons of Illinois No. 6 coal in <
commercial coal-to-ammonia plant ir
Greece. TRW, funded by TVA, cooperatec
in the extensive test program regarding
the environmental aspects. The favor
able results of the test runs, carried ou
in March/April 1981, and the extraordi
narily low environmental impact demon
strated, have led to TVA's decision t<
build its Murphy Hill plant based 01
GKT's technology.
Source Test of the Texaco
Gasification Process Located
at Oberhausen-Holten, West
Germany
R.G. Wetherold and R.M.
Mann, Radian Corp.
Austin, TX 78766
J. Morgan and W.C. Yee, TVA
Chattanooga, TN 37401
P. Ruprecht, Ruhrchemie AG
4200 Oberhausen-Holten,
Federal Republic of Germany
R. Diirfield, Ruhrkohle 01
und Gas GmbH
4250 Bottrop, Federal Republic
of Germany
A comprehensive environmente
characterization of water and solid
from the Ruhrkohle/Ruhrchemie co<
gasification pilot plant in Oberhauser
Holten, West Germany, has bee
conducted. Coal is gasified at the plar
with a high-pressure, entrained-be
coal gasification process. The pilot plat
tests were conducted in Novembe
1980 during gasification of Illinois No.
coal. A test plan was prepared includin
stream selection, sample collection an
chemical analyses. Multiple samples <
process waters and solids were collects
during two 12-hour environment!
balance periods. Normal pilot plat
operation was maintained during th
first period; the second incorporate
water recycle to minimize makeu
water requirements.
Samples of liquid and solid proce;
streams have been subjected to compr
hensive analyses. These efforts, undi
contract with TVA, have been perform(
-------
to provide support information on both
the process operation and environmen-
tal impact associated with a 10,000-ton
per day coal gasification plant proposed
by TVA for a northern Alabama site.
Topics addressed in the presentation
included pilot plant configuration and
operation, treatment of the process
water, and RCRA testing of solids from
the gasification and water treatment
processes.
Source Test and Evaluation of
a Riley Gas Producer Firing
North Dakota Lignite
F.L Jones, American Natural
Service Co.
Detroit, Ml 48226
W.P. Earley, Riley Stoker Corp.
Worcester, MA 01613
M.R. Fuchs, Radian Corp.
Austin, TX 78766
V.A. Kolesh, Riley Stoker Corp.
Worcester, MA 01613
A 10-ft 6-in. diameter Riley Morgan
gasifier was operated for 14 days to
convert North Dakota lignite to low Btu
gas. During that period, the gasifier was
operated at a range of load conditions,
and the product gas was transported to
a commercial-scale kiln burner in a
large combustion test chamber. Process
stream conditions and compositions
were recorded throughout the test and
were submitted to an SAM/IA analysis.
Gaseous effluent streams were found to
be well controlled due to the unique
Riley coal-feed and poke-hole systems.
Solid wastes from the process (gasifier
ash and cyclone dust) were found to be
nontoxic, noncarcinogenic, and nonmu-
tagenic. Gasifier wastewater effluent
(ash pan water) was similarly found to
be nonhazardous. Although combustion
stack gases were not monitored, sulfur
and particulate loadings in the gasifier
product gas indicated that the stack
gases would comply with current EPA
New Source Performance Standards. If
all reduced nitrogen compounds were
converted to NOx, however, these
emissions would exceed New Source
Performance Standards.
Session I, Part B.
Environmental Source Test
and Evaluation Results,
Direct Liquefaction
Environmental Program and
Plans for the EDS Coal
Liquefaction Project
R.L Thomas, Exxon Research
and Engineering Co.
Florham Park, NJ 07932
The Exxon Donor Solvent (EDS) coal
liquefaction project is a unique govern-
ment/industry arrangement for devel-
oping EDS technology to the point that
commercial plants can be designed with
an acceptable level of risk. A broad
environmental program is being advanced
within the project to address plant
emission, occupational health, and
product-related environmental concerns
associated with the direct liquefaction
of coal. The current plans, status, and
outlook for the EDS environmental
program provide an overall strategy for
the acquisition of data relating to these
concerns early in the technology
development cycle.
Sampling and Analysis of
Process and Effluent Streams
from the Exxon Donor
Solvent Coal Liquefaction
Pilot Plant
M.D. Notich and J.I. Kim,
Hittman Associates, Inc.
Columbia, MD 21045
Under contract to the U.S. EPA,
Hittman Associates performed a sam-
pling and analysis of process discharge
streams from the Exxon Donor Solvent
(EDS) coal liquefaction plant in Baytown,
TX. Twenty-four streams were sampled
and 2,200 samples were returned to
Hittman's laboratory for analysis. The
chemical analyses of these samples
included water quality parameters,
GC/MS, GC/FID, and bioassays. Analyses
were also performed to determine the
accuracy and precision of the data and
to determine the variability of stream
components due to process variations.
Preliminary results are available and
data for the source test and evaluation
report are being evaluated.
Health and Environmental
Studies of H-Coal Process
K.E. Cowser, J.L Epler, C.W.
Gehrs, M.R. Guerin, and J.A.
Klein
Oak Ridge National Laboratory
Oak Ridge, TN 37830
With the implementation of the
Energy Security Act of 1980, coal and oil
shale are expected to be principal
sources for petroleum and natural gas
substitutes. H-Coal is one of several
processes under intensive study for the
direct conversion of coal to the desired
synthetic fuels.
This paper describes the health and
environmental study program of H-Coal,
sponsored by the Department of Energy.
Presented are the results of the chemical,
biological, and ecological characteriza-
tion of products and by-products derived
from the operation of a process devel-
opment unit. These initial results
provide an informed basis for subse-
quent monitoring and testing of the
nominal 200- to 600-ton/d pilot plant at
Catlettsburg, KY.
Chemical Characterization
and Bioassay of SRC Process
Materials
W.D. Felix, D.D. Mahlum, B.W.
Wilson, W.C. Weimer, and R.A.
Pelroy
Battelle Pacific Northwest
Laboratory
Richland, WA 99352
Bioassay techniques have shown that
certain coal liquefaction process streams
and products are both mutagenic (Ames
assay) and carcinogenic. These materials
have been chemically fractionated
using a number of techniques (solvent
extraction, alumina column separation,
HPLC, Sephadex LH-20) in an attempt to
identify the constituents responsible for
the biological activity. These studies
have shown that primary aromatic
amines (PAAs) account for more than
90% of the mutagenic response in the
Ames test. Long-term skin painting and
initiation-promotion assays indicate
that the PAAs may also play a role in the
carcinogenicity of the coal-derived
materials. However, while the PAAs can
be designated as the determinant
mutagens in coal liquids, they cannot be
assigned a determinant role in skin
-------
carcinogenesis. Thus far, carcinogenicity
appears to better correlate with increas-
ing molecular weight and boiling point.
Our results also suggest that benzo(a)py-
rene is not a reliable marker compound
for carcinogenic activity.
(Only the abstract is published in the
proceedings.)
Session II. Water-Related
Environmental Considerations
Coal Conversion Wastewater
Treatment/Reuse - An
Overview
F.E. Witmer, U.S. Department
of Energy
Washington, DC 20545
Environmentally, synfuels can be
produced from coal by either low- or
high-temperature processes. Low-
temperature processes produce high
boiling liquids and tars which tend to
retain the multiple-ring structure of the
original coal "molecule," while high-
temperature processes typically produce
synthesis gas, methane, and/or light
liquids. Dry-ash moving-bed gasification
and direct liquefaction processes are
representative of low-temperature
conversion processes. Entrained gasifi-
cation is an example of high-tempera-
tures processes. Fluid-bed gasification
processes that operate at temperatures
just below the ash slagging point may
produce limited heavy liquids and fall
intermediate within the classification
regime.
Depending on the process, process
steam which is subsequently condensed
and/or gas cleanup quench waters
come into direct contact with the raw
gaseous product stream. As a conse-
quence, the resultant wastewater
associated with the low-temperature
processes is highly contaminated with
organics. The production of ammonia in
the high-temperature processes is
generally suppressed and reduced due
to "cracking." Condensate waters from
high-temperature processes usually
contain little or negligible NH3, while the
condensate waters from low-tempera-
ture processes contain high levels of
NH3. The condensate waters from both
low- and high-temperature processes
generally contain volatized and entrained
mineral matter, trace elements, and
salts, as well as adsorbed H2S, C02, and
cyanates.
Treatment of the condensate waters
from low-temperature processes poses
a special challenge due to the high and
variable level and toxic nature of the
gross organics. A portion of the total
organic carbon is biorefractory, also
causing concern. Laboratory treatability
tests have demonstrated that, with
appropriate dilution and/or pretreat-
ment (e.g., gas stripping, organic
extraction, and/or the addition of
powdered activated carbon), activated
sludge treatment processes do a reason-
able job of reducing biological oxygen
demands (BOD) and total organic
carbon (TOC) levels, and coupled with
activated carbon treatment, relatively
high quality effluent can be produced. In
a "zero discharge" mode, subsequent
concentration and reuse of the effluent
must be effected to ultimately produce a
concentrated brine or dry salt.
The questions that remain center on
the capability of this rather elaborate
treatment train to accommodate variabil-
ities in the rawfeed and on the reliability
and costs of such a system; i.e., do
viable alternatives exist? Options are
outlined with special emphasis on: (1)
improvements to biological treatment,
and (2) purely physical/chemical sys-
tems. The effect of more stringent
standards with respect to the control of
biorefractory ring-structure compounds,
trace elements, ammonia, etc., is
discussed relative to the state-of-the-
art biotreatment and these environmen-
tal control options. Areas of uncertainty
and future research are delineated
based on a recent synfuel wastewater
workshop conducted in June 1981.
Characterization of Coal
Conversion Wastewaters
Using On-Site GC/MS
C.J. Thielen and R.V. Collins,
Radian Corp.
Austin, TX 78766
This paper discusses a characteriza-
tion of a wastewater stream from a coal
gasification facility using on-siteextrac-
tion and GC/MS analysis. The objectives
of the program were to:
• Characterize the wastewater
organic components primarily for
selected priority pollutants. Ap-
pendix C, and synfuels com-
pounds.
• Investigate the stability of these
compounds during refrigerated
and ambient storage.
• Evaluate the destruction of or-
ganics by wet oxidation.
Extractable material in the wastewa
ter consisted primarily of phenols am
alkylphenols. These compounds ac
counted for about 98% of the tota
organic mass identified. Several polynu
clear aromatic (PNA) compounds wen
also identified. Deterioration in thi
composition of the sample was observe*
over a 1 -month period. This was mos
evident in the concentration of dimethyl
phenols which dropped approximate!'
75% during 2 weeks of refrigerate*
storage. Ambient sample storage pro
duced a greater decrease in the concen
tration of phenol but did not appear t<
affect the alkylphenols or the base/
neutral compounds as much as phenols
It is expected that the observed change:
in composition would hamper any off
site wastewater treatability studies will
water of this type. Treatment of.thi
wastewater by wet oxidation was alsi
evaluated and found to remove greate
than 90% of the extractable organics.
Treatment of Wastewater
from a Fixed-Bed
Atmospheric Coal Gasifier
P.C. Singer and E. Miller,
University of North Carolina
Chapel Hill, NC 27514
Previous studies using a simulate
coal conversion wastewater hav
demonstrated the feasibility of treatih
this type of waste by an activated sludg
process. Phenol concentrations wer
reduced to levels below 1 mg/l, andth
toxicity and mutagenicity of the simi
lated wastewater were reduced sut
stantially by the biological treatmen
This paper gives results of an evaluatio
of the biological and subsequent physica
chemical treatability of a real co<
conversion wastewater, along with
comparison of the results with thos
obtained using the simulated waste
water.
Coal gasification wastewater wa
obtained from a Chapman gasifier at th
Holston Army Ammunition Plant i
Kingsport, TN. The wastewater wa
diluted to 25% of full strength, supple
mented with phosphate, and subjecte
to aerobic biological treatment in
22.5-liter completely mixed activate
sludge reactor. The reactor was operate
at a solids retention time of 20 days an
a hydraulic detention time of 10 days. I
addition to characterizing the quality <
the effluent using various chemical ar
bioassay procedures, the effluent fro
the biological reactor was subjected to
-------
series of physical-chemical treatment
steps consisting of chemical coagulation,
ammonia stripping, ozonation, and
activated carbon adsorption. The chemi-
cal quality and bioassay characteristics
of these various samples are presented.
Treatment of Fossil Fuel
Derived Wastewaters With
Powdered Activated
Carbon/Activated Sludge
Technology
R.B. Ely and C.L Berndt,
Zimpro, Inc.
Mercer Island, WA 98040
The treatment of high-strength fuel
conversion wastewaters by convention-
al biological treatment processes may
be operationally troublesome and only
marginally effective from the standpoint
of treatment system stability and
performance. The addition of powdered
activated carbon to the activated sludge
process not only greatly improves pro-
duct water quality but also provides cost
savings compared to more conventional
waste treatment and carbon regenera-
tion processes.
This paper describes the powdered
carbon/activated sludge wastewater
treatment process, discusses the advan-
tages of powdered carbon addition
including performance obtained on
fossil fuel derived wastewaters, and
presents cost comparison data for
wastewater treatment and spent carbon
regeneration.
Land Treatment of Coal
Conversion Wastewaters
R.C. Sims (now with Utah
State University, Logan, UT
84322) and M.R. Overcash,
North Carolina State University
Raleigh, NC 27650
This research project investigated the
treatment potential of soil systems for
polynuclear aromatic compounds (PNAs)
present in aqueous wastes from coal
conversion processes. A protocol for
obtaining the soil assimilative capacities
for mutagenic and recalcitrant PNA
compounds was developed and, for a
subset of compounds, data were obtained
to describe: (1) rates of transformation,
including degradation, detoxication,
and possible intoxication; (2) effect of
PNA structure on transformation rate;
(3) effect of engineering management
options, including nutrient addition,
analog enrichment, surfactant addition,
and pH adjustment on transformation
rates; and (4) soil acclimation to PNAs.
A three-step protocol—including: (1)
incubation, (2) identification, and (3)
determination of mutagenic potential—
involves interfacing high-performance
liquid chromatography (HPLC) for com-
pound and metabolite identification
with the Ames Salmonella typhimurium/
mammalian microsome mutagenicity
assay for determining genotoxic po-
tential of PNA compounds and trans-
formation products in soil. Identification
(HPLC) and mutation (Ames assay) were
quantified.
Session III. Air-related
Environmental Considerations
Removal of Acid Gases and
Other Contaminants from
Coal Gas Using Refrigerated
Methanol
J.K. Ferrell, R.M. Kelly, R.W.
Rousseau, and R.M. Felder
North Carolina State University
Raleigh, NC 27650
The steam-oxygen gasification of a
New Mexico subbituminous coal was
carried out in a pilot-scale fluidized-bed
gasifier. Gas cleaning was accomplished
by a hot cyclone, a water-quench
venturi scrubber, filters, and an acid gas
removal system using refrigerated
methanol as the solvent. Results of both
gasification and gas cleaning are
described. Refrigerated methanol proved
to be effective in cleaning the gasifier-
make gas; however, several reduced
sulfur species and hydrocarbons were
detected in the absorber, flash tank, and
stripper exit gas streams over a wide
range of operating conditions. While a
variety of simple aromatics accumulated
in the recirculating methanol, essentially
no polynuclear aromatic (PNA) com-
pounds were detected. Most PNAs were
evidently removed in the gas quenching
process.
Advanced Techniques for Flue
Gas Desulfurization
C.C. Masser, M.A. Maxwell,
and T.G. Brna
Industrial Environmental
Research Laboratory, U.S. EPA
Research Triangle Park, NC
27711
In 1979 the combustion of sulfur-
bearing fuels accounted for more than
80% of the SO2 emissions in the U.S.
These emissions can be controlled to a
degree by burning low-sulfur fuels or by
pretreating the fuel to lower its sulfur
content. Currently the most widely
practiced technological control involves
scrubbing the combustion flue gases to
remove the SO2. Flue gas desulfuriza-
tion systems can be categorized as
nonregenerable (or "throwaway") and
regenerable (or producing a salable
product). The advantages and disadvan-
tages of several systems in each
category are discussed. Several recent
developments in waste disposal and
enhanced S02 removal are also pre-
sented.
Health and Environmental
Studies of Coal Gasification
Process Streams and
Effluents
C.A. Reilly, Jr., A.S. Boparai, S.
Bourne, R.D. Flotard, D.A.
Haugen, R.E. Jones, F.R.
Kirchner, T. Matsushita, M.J.
Peak, V.C. Stamoudis, J.R.
Stetter, and K.E. Wilzbach,
Argonne National Laboratory
Argonne, II 60439
The synfuels environmental research
program at Argonne National Laboratory
is investigating the impact of high-Btu
coal gasification on health and the
environment. Activities include a toxico-
logic and chemical characterization of
process streams in the gasifier and
pretreater sections of the Hygas coal
gasification pilot plant, and process
streams and workplace air from the
Grand Forks Energy Technology Center's
slagging fixed-bed gasifier facility.
Cellular assays for mutagenicity, cyto-
toxicity, and functional impairment are
performed to determine relative toxicity.
Various acute and chronic whole-
animal lexicological evaluations, includ-
ing skin tumorigenesis, are performed
for streams found to contain potential
toxicants (e.g., oils and tars). The
chemical characteristics of vapor-phase
and airborne particulate-associated
organics, as well as biologically active
materials isolated from process streams,
are investigated by physical and chemi-
cal fractionation of the samples, with
biological monitoring and detailed GC
and GC/MS analyses of the fractions.
Present data indicate that toxicants are
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present, but their levels of activity are
relatively low. As a result of these
studies, it is tentatively concluded that
with appropriate control technology and
industrial hygiene procedures, no
serious health or environmental prob-
lems appear to be associated with coal
gasification.
Gaseous Fugitive Emissions
from SynfueJs Production -
Sources and Controls
R.L Honerkamp, Radian Corp.
Austin, TX 78766
Fugitive emissions are generally
defined as emissions that are not
released through an enclosure such as
a duct or vent pipe. Fugitive emissions of
volatile organic compounds (VOCs) are
caused by process fluid leakage from
seals (valves, pumps, etc.), process fluid
purges (sampling, equipment cleaning),
and secondary emission sources (drains,
wastewater systems, towers). Most
sources of fugitive VOC emissions in the
U.S. are currently found in petroleum
production and refining facilities,
organic chemical manufacturing plants,
and coke by-product plants. Synfuels
production facilities will also have VOC
fugitive emission sources. The paper
describes the potential sources and
control options for fugitive VOC emissions
in synfuels production facilities.
Fugitive emission regulations have
been applied to California petroleum
refineries for several years, and U.S.
New Source Performance Standards
(NSPS) are currently under development
for several industries. These regulations
are based on the need to reduce fugitive
emissions because VOCs are photo-
chemical ozone precursors. Some
fugitive emissions also need to be
controlled because compounds released
in the emissions may be hazardous. U.S.
National Emission Standards for Hazard-
ous Air Pollutants (NESHAP) have been
developed for controlling fugitive emis-
sions of vinyl chloride and benzene.
VOC emissions from synfuels produc-
tion facilities may require control
because they contribute to atmospheric
ozone formation and/or because they
contain hazardous compounds. The
nature of potential hazardous compounds
will depend on variables such as the
type of process, feedstock character-
istics, and operating parameters
Fugitive emission controls can be
categorized as work practices or engi-
neering controls. Work practices would
include leak detection and leak repair
programs and good housekeeping
practices. Leak detection and repair
programs involve periodic testing to
locate significant VOC leaks and subse-
quent repairs to reduce or eliminate the
leakage. Housekeeping practices would
include procedures to minimize process
fluid spills and to expedite spill cleanup.
Engineering controls are generally
equipment substitution strategies. For
example, closed-loop sampling connec-
tions eliminate process fluid purge
emissions, and double mechanical
pump seals can be operated to minimize
emission potential. These types of
equipment would be used instead of
equipment with a greater potential to
leak VOC.
Because the emission sources (pumps,
valves, etc.) on synfuels plants will be
similar to those in existing U.S. indus-
tries, the emission control techniques
will also be applicable. The experience
that has been gained in applying fugitive
VOC emission controls will be valuable
in developing VOC control strategies for
synfuels-plants.
Control Systems for Air
Emissions from Coal
Gasification
S. Thomson, Fluor Engineers
and Constructors, Inc.
Irvine, CA 92730
This paper discusses control systems
for air emissions on coal conversion
projects. Topics include the control of
emissions from acid gas treatment
processes and the control of emissions
from gasification reactors. Alternate
control systems as well as the difficulties
involved in establishing the Best
Available Control Technology (BACT)
are also covered.
Session IV. Solid Waste-
Related Environmental
Considerations
Health Effects Bioassay
Results from Coal Conversion
Solid Wastes
M.P. Maskarinec, F.W. Larimer,
J.L Epler, and C.W. Francis
Oak Ridge National Laboratory
Oak Ridge, TN 37830
To assist EPA and DOE in identifying
solid wastes that may pose a potential
hazard to human health and environ-
ment, the Oak Ridge National Labora-
tory has conducted studies on extracts
from solid wastes obtained from various
coal liquefaction and gasification pro-
cesses. Analytical procedures to chem-
ically characterize and separate the or-
ganic and inorganic constituents were
developed. Various approaches to ex-
traction were compared. Batteries ol
health effects and environmental as-
says were applied to the extracts or theii
fractions to indicate chronic hazards
The applicability and compatibility of the
coupled chemical and biological proce
dures are evaluated with particulai
emphasis on the Ames mutageniciti
test.
A Comparison of RCRA
Leachates of Solid Wastes
from Coal-Fired Utilities and
Low- and Medium-Btu
Gasification Processes
M.R. Fuchs, D.L Heinrich, L.J.
Holcombe, and K.T. Ajmera,
Radian Corp.
Austin, TX 78766
EPA has promulgated regulation
which temporarily exclude utility waste
(including fly ash and bottom ash fror
coal-fired generating stations) fror
Subtitle C of the Resource Conservatio
and Recovery Act (RCRA) regulations
EPA, using broad interpretation c
amendments to the Act, has als
excluded coal gasification solid waste
from Subtitle C regulations, and thes
wastes are listed as nonhazardou
pending further data evaluation. Thi
paper gives comparative results (
RCRA leachates of the solid waste
from two low-Btu gasification processe
and coal-fired utility solid wastes. Th
three facilities from which solid waste
were obtained used the same lignil
feedstock. Also presented are compare
ble RCRA leachate results of soli
wastes from a medium-Btu gasificatio
process and a coal-fired power plan
both fueled with identical lignil
feedstocks. The results indicate thi
solid wastes from coal-fired utilities ar
those generated directly by low- ar
medium-Btu gasification processes ai
nonhazardous according to RCR
protocol and limits.
6
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Characterization of Solid
Wastes from Indirect
Liquefaction Facilities
C.A. Hunter, K.Y.Yu, and K.W.
Crawford, TRW
Redondo Beach, CA 90278
Gasification ash and slag are the
major solid wastes generated in indirect
coal liquefaction facilities. Smaller
amounts of spent catalysts and pollution
control sludges may also be generated.
There is a limited amount of data on the
hazardous and nonhazardous character-
istics of these solid wastes. Leachate
data for gasifier ash and slag from Lur-
gi, Wellman-Galusha, and Texaco gasi-
fication have been presented elsewhere.
The RCRA leaching characteristics of
quenched gasifier slag and dust from
commercial scale Koppers-Totzek gasi-
fication tests in Greece are presented in
this paper. The potential accumulation
of trace elements in the sludges from
biological oxidation of Lurgi gasification
condensates are estimated. Koppers-
Totzek and Texaco gasification conden-
sates will contain negligible amounts of
organics (compared to the Lurgi gasifi-
cation condensates) and will not require
biological oxidation. The potential accu-
mulation of trace elements on high
temperature shift catalyst are examined
as a function of degree of gasification
and feed coal characteristics.
Ash/Slag Residuals and
Wastewater Treatment Plant
Sludges from Synfuels
Facilities: Characterizations
and Implications for Disposal
R.D. Neufeld, G. Keleti, J.
Bern, C. Moretti, S. Wallach,
and H. Erdogen
University of Pittsburgh
Pittsburgh, PA 15261
This paper gives an overview of
research conducted at the University of
Pittsburgh in the area of coal conversion
ash and slag. Residuals were obtained
from the GFETC "slagging Lurgi type"
gasifier (two different runs), METC
(Wellman-Galusha type) pressurized
gasifier, DOE-Chapman gasifier fly ash,
and two H-Coal vacuum bottoms resid-
uals. A first screen bioassay of SRC-II
Fort Lewis coal liquefaction residuals
and sludges is also presented. In
addition, research has been conducted
at the University of Pittsburgh for the
past few years in the area of developing
a stable pretreatment and biological
treatment facility for the processing of
phenolic type coal gasification waste-
waters. During the processing of
wastewaters, sludges are produced
which are assessed for toxicity, muta-
genicity, and overall disposability.
Update on EPA's Regulatory
Views on Coal Conversion
Solid Wastes
Y.M. Garbe, U.S. EPA
Washington, DC 20460
The Resource Conservation and
Recovery Act of 1976 (RCRA) charges
EPA with the responsibility for establish-
ing a program for the management of
hazardous solid wastes. This paper
summarizes current and anticipated
RCRA regulations affecting thesynfuels
industry. Included in the various RCRA
issues pertaining to the synfuels indus-
try is a discussion of the RCRA mining
exemption. An overview is given of the Of-
fice of Solid Waste's planned research
activities to support future synfuels
solid waste regulations.
(Only the abstract is published in the
proceedings.)
Session V. Multimedia
Environmental Considerations
A Permittees View of Synfuel
Commercialization
G.L Harlow, U.S. EPA Region 4
Atlanta, GA 30365
The EPA is responsible for issuing
permits to synfuels plants for the control
of various liquid, gaseous, and solid
waste streams. These permits comprise
the Prevention of Significant Deteriora-
tion (PSD) under the Clean Air Act of
1977, the National Pollutant Discharge
Elimination System (NPDES) and the
Section 404 Dredge and Fill permits
under the Clean Water Act of 1977, and
the hazardous waste permits under the
Resource Conservation and Recovery
Act (RCRA) of 1976.
Since there will likely not be federal
regulations established by EPA set-
ting standards on requirements for
first-generation synfuels plants, the
environmental permits will have to be
individually negotiated, case by case,
with each applicant using best engineer-
ing practice. This places an unusual
burden on the permit writer who will be
negotiating with the discharger from an
uninformed and defenseless position.
To overcome this burden and to avoid
long, time-consuming delays in the
permit process, the company should
disclose in its application for permit
exactly what steps will be taken to
control air emissions, water discharges,
and hazardous wastes.
(Only the abstract is published in the
proceedings.)
Comparison of Environmental
Design Aspects of Some
Lurgi-Based Synfuels Plants
M.R. Beychok, Consultant
Irvine, CA92715
WJ. Rhodes, Industrial
Environmental Research
Laboratory, U.S. EPA
Research Triangle Park, NC
27711
This paper summarizes the current
status of proposed projects in the U.S.
which involve synfuels production
based on utilizing Lurgi coal gasification
technology.
For some Lurgi-based synfuel proj-
ects where actual plant design informa-
tion has been made available, acompar-
ison of their environmental designs is
discussed. The primary focus of the
environmental'design comparison is on
the facilities to be included for the
control and abatement of air pollutant
emissions and wastewater pollutant
discharges. Insofar as possible, the
paper also focuses on commercial-scale
project designs.
Session VI. Product-Related
Environmental Considerations
Risk Assessment of Synfuel
Technology
A.A. Moghissi, U.S. EPA
Washington, DC 20460
(No paper or abstract available.)
Premanufacture Review of
Synfuels Under TSCA
M. Hale, Jr. and C. Mazza
U.S. EPA
Washington, DC 20460
The Toxic Substances Control Act
(TSCA) requires manufacturers to notify
EPA at least 90 days before they
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produce a new chemical substance for
commercial purposes. Once notified,
EPA has 90 days, extendable for good
cause to 180 days, to review the
chemical. During the review period, the
Agency can act to prohibit or limit the
manufacture, processing, or use of a
new chemical substance where it finds
that the information available on the
substance is insufficient for a reasoned
evaluation of its risks and that (1) the
chemical may present an unreasonable
risk to human health or the environment
or (2) significant human or environmen-
tal exposure can reasonably be ex-
pected. Certain synthetic fuel products
(including certain by-products and
intermediates) may be new chemical
substances under TSCA and therefore
potentially subject to premanufacture
notice requirements. This paper outlines
TSCA premanufacture notification
requirements; it describes how "new"
chemical substances are defined; and it
discusses the types of data that might be
provided to EPA with a premanufacture
notice on a synfuel.
Methanol as a Clean Major
Fuel
P.W. Spaite, Consultant
Cincinnati, OH 45213
Methanol is considered as an alterna-
tive fuel that could be produced using
available technology to displace major
petroleum fuels in a relatively short
time. The major factors considered are:
1. Potential environmental conse-
quences of introducing methanol.
2. Status of development of meth-
anol fuel technology.
3. Cost and efficiency of synfuels
processes.
4. Potential markets.
5. Prospects of commercialization
of methanol fuels.
The paper develops an overview
perspective by identifying all important
factors in each category and presenting
enough quantitative data to permit
relative comparisons without excessive
detail.
Methanol as an Alternative
Transportation Fuel
R. Rykowski, R.D. Atkinson, D.
Heiser, J. McGuckin, D.
Fletcher, J. Alson, and M.
Rosenfeld, U.S. EPA
Ann Arbor, Ml 48105
Over the remaining years of this
century, synthetic fuels will play a key
role in the nation's drive for energy
independence. Although self-reliance is
indeed a desirable goal, many people
believe that it cannot be achieved
without significant compromises in
environmental quality. This may not be
the case. One synfuel, methanol, could
be used to replace both gasoline and
diesel fuel and yield environmental
benefits. This pa per compares methanol
with synthetic fuels from other coal
liquefaction processes in terms of the
environmental and economic conse-
quences of their use.
Project Summary—A
Compendium of Synfuel End
Use Testing Programs
M. Ghassemi, S.C. Quinlivan,
and M. Haro, TRW
Redondo Beach, CA 90278
A "Compendium of Synfuel End Use
Testing Programs," which provides
information on major recently com-
pleted, current, and planned synfuels
end use testing projects, has been devel-
oped. The compendium is intended to
promote flow of information among
various synfuels testing programs,
thereby reducing chances for duplica-
tion of effort and enabling design and
implementation of cost-effective and
systematic approaches to the collection
of appropriate environmental data in
conjunction with ongoing and planned
performance testing projects. EPA
intends to update this compendium to
include results from current and future
testing programs.
Projects described in the compendium
involve testing of shale-derived fuels,
SRC-II middle distillates, EDS fuel oils,
H-coal liquids, and methanol/indolene
mixtures in various equipment such as
utility boilers, steam generators, diesel
engines (laboratory-and full-scale), auto
engines, and various other combustors.
Published reports on various testing
efforts and discussions with test
sponsors/contractors are the sources
of data for the compendium.
Based on the data in this compendium,
the thrust of the synfuels testing
program which has been carried out to
date has been to assess equipment
performance and fuel handling charac-
teristics. Where some emissions moni-
toring has been conducted, such efforts
have been limited in scope and have
primarily emphasized measurement of
criteria pollutants (NOx, SOx, particu
lates, etc.). Essentially no data havi
been collected on emissions of noncri
teria/nonregulated pollutants.
Comparative Testing of
Emissions from Combustion
of Synthetic and Petroleum
Fuels
W.G. Tucker and J.A.
McSorley, Industrial
Environmental Research
Laboratory, U.S. EPA
Research Triangle Park, NC
27711
Procedures are being developed fc
the comparative testing of combustio
products from liquid synthetic fuels an
petroleum-based analogs. Combustio
tests at EPA's research facility in Nort
Carolina are measuring differences i
emissions from petroleum-, coal-, an
shale-derived fuels in stationary corr
bustors. Data from these tests will b
used in refining procedural guidance o
combustion testing of synfuels for Prt
manufacturing Notice (PMN) applies
tions.
Unpresented Papers
Two papers, not presented at tr
symposium, are published in the pn
ceedings.
Problems Associated with th
Analysis of Synfuels Product
Process, and Wastewater
Streams
H.C. Higman, O.K. Rohrbaugh,
R.H. Colleton, and R.A. Auel
Hittman Associates, Inc.
Columbia, MD21045
Hittman Associates, as part of i
environmental assessment of co
liquefaction technology sponsored
the U.S. EPA, performed various anal
ses on samples from the Solve
Refined Coal II (SRC-II) plant in I
Lewis, WA, and the Exxon Don
Solvent (EDS) plant in Baytown, TX. Tl
paper describes several probler
encountered in these analyses a
methods taken to mitigate them. Reco
mendations are made on approaches
avoiding such problems.
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Solvent Extraction Processing
for Coal Conversion
Wastewaters
J.R. Campbell and R.G. Luthy,
Carnegie-Mellon University
Pittsburgh, PA 15213
M.J.T. Corrondo, New
University of Lisbon
Lisboa, Portugal
This paper outlines experimental and
modeling techniques being used to
evaluate solvent extraction processing
of coal conversion wastewaters. The
project includes characterization of
organic contaminants in slagging fixed-
bed gasification process wastewater, as
well as screening studies to evaluate
removal efficiencies for these contami-
nants. Experiments are also in progress
to measure distribution coefficients for
several solvent types with phenol and
representative base- and neutral-
fraction aromatic solutes. These experi-
ments are being performed with both
clean water and wastewater systems.
Results from these experiments are
being evaluated in light of three
techniques for estimating distribution
coefficients: modified regular solution
theory as used in chemical engineering
processing, expanded solubility param-
eter approach as used in liquid-liquid
chromatography, and estimation of
octanol-water partition coefficient as
employed in environmental science.
This paper reviews results obtained to
date and explains direction for work
during the coming year.
F.A. Ayer ana N.S. Jones are with Research Triangle Institute, P. O. Box 12194,
Research Triangle Park. NC 27709
N. Dean Smith is the EPA Project Officer (see below).
The complete report, entitled "Proceedings: Symposium on Environmental
Aspects of Fuel Conversion Technology—Ml, A Symposium on Coal-Based
Synfuels-October 1981,"(Order No. PB83-128 181; Cost: $40.00; 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 Protect/on Agency
Research Triangle Park, NC 27711
U.S. GOVERNMENT PRINTING OFFICE: 1983/659 -095/581
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