United States
Environmental Protection
Agency
Hazardous Waste Engineering
Research Laboratory
Cincinnati OH 45268
Research and Development
EPA/600/S2-87/051 Sept. 1987
xe/EPA Project Summary
PCB Trial Burn Report for the U.S.
EPA Combustion Research Facility
Liquid Injection Incinerator System
Johannes W. Lee, Thomas H. Backhouse, Robert W. Ross II, and
Larry R. Waterland
This report describes a trial burn of
polychlorinated biphenyl (PCB) laden
oil and No. 2. fuel oil injected into the
liquid incinerator at the U.S. EPA Com-
bustion Research Facility in Jefferson,
Arkansas. Destruction Rate Efficiencies
(DREs) in excess of 99.99999 percent
(40CFR 761.70) were achieved in all
test cases, far exceeding the require-
ment of 99.9999 for the PCB (Aroclor).
Hydrochloric acid removal efficiencies
generally exceeded 99.9 percent. Other
emission rates of organic compounds
listed in Appendix VIM of the Resource
Conservation and Recovery Act (RCRA)
were tested and reported.
This Protect Summary was developed
by ERA'S Hazardous Waste Engineering
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
Protect Report ordering Information at
back).
Introduction
During March 5 through March 11,
1986, a trial burn was performed on the
liquid injection incinerator at EPA's
Combustion Research Facility in Jeffer-
son, Arkansas. The trial burn was per-
formed to fulfill the requirements of the
RCRA Part B permit application (40 CFR
270.62) for a new facility and to demon-
strate compliance with performance
standards specified under the Toxic Sub-
stance Control Act (TSCA) (40 CFR 761.70)
for burning PCB-laden wastes.
The specific objectives of the trial burn
tests were as follows:
• To establish the incinerator's ability
to achieve 99.9999-percent destruc-
tion and removal efficiencies (DRE)
of the PCB in the waste; attain par-
ticulate emissions of less than 180
mg/dscm corrected to 7-percent O2;
and attain HCI emissions less than
the greater of 0.5 kg/hr or 0.5 per-
cent of the total Cl (as HCI) in the
stack.
• To serve as a test vehicle to validate
the experimental Marine Incineration
Biological Assessment Sampler
(MIBAS) developed under EPA's pro-
gram for incineration at sea. The
MIBAS measures the toxicity of sea
water to aquatic organisms after the
sea water has been exposed to PCB
incineration combustion by-products.
• To obtain information on the volatile
chlorinated organic products of in-
complete combustion (PICs) from
PCB incineration.
Waste Description
The waste feed to the liquid injection
incinerator was prepared by mixing PCB-
laden oil and No. 2 fuel oil on a one-to-
one volume basis. The PCB was identified
as Aroclor 1260. Several polychlorinated
benzenes were also detected by gas
chromatography in the PCB oil. Table 1
summarizes the analytical results of the
two batches of waste feed used in the
tests.
Facility Description and
Operation
The liquid injection incinerator system
illustrated in Figure 1 consists of a primary
combustion chamber and an afterburner
chamber. The hot combustion gas leaving
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the afterburner chamber is cooled in the
liquid-sprayed quench chamber prior to
paniculate and HCI removal in down-
stream air pollution control devices
(APCD). The APCD system consists of
Venturi, packed, and ionized scrubbers in
series followed by additional paniculate
and organic emission control in the
carbon bed and high efficiency paniculate
(HEPA) filters. The incinerator is rated at
586 kW (2 x 10« Btu/hr) heat input. The
combined 5.19m3 (183 ft3) volume of the
primary chamber, afterburner chambers,
and transition duct provides a nominal
gas residence time of approximately 4.3
sec at a firing rate of 500 kW (1.7 x 106
Btu/hr) and 10-percent excess oxygen.
Seven tests were performed over seven
consecutive days with nominally identical
incinerator operation. Table 2 summarizes
the key operating data for the incinerator.
Total firing rate in the main combustion
chamber averaged 519 kW (1.77x106
Btu/hr). The PCB waste oil supplied 86
percent of the total heat input, with pro-
pane accounting for the remainder. No
fuel or PCB oil was fired in the afterburner
chamber. The average gas temperatures
in the main and afterburner chambers
were 1,240°C (2,265°F) and 1,026°C
(1,880°F), respectively, for the seven test
days. Excess oxygen measured at the
afterburner exit typically ranged between
6 and 17 percent with an average of 12
percent for the seven tests.
T»W« 1. Chemical Analysis of the Feed Waste
Waste feed mixture
Batch 1
Batch 2
Date used
3-5-86 to 3-7-86 3-8-86 to 3-1J -86
Component
Concentration (wt%)
1 ,4-Dichlorobenzene
1 ,2-Dichlorobenzene
1,2,4- Trichlorobemene
1,2,3- Trichlorobemene
1,2,3.5 +
1,2,4,5- Tetrachlorobenzene
1,2,3,4- Tetrachlorobenzene
Aroclor 1260
Chlorine (Theoretical)
High Heating Value Kcal/kg
(Btu/lb)
0.535
0.598
24.2
14.2
1.050
0.5O8
42.1
49.4
76O4
113688)
0.509
0.553
22.0
13.0
0.824
0.389
36.0
43.5
8093
(14567)
Sampling and Analysis Protocols
A detailed sampling and analysis (S&A)
protocol was undertaken to evaluate
emissions of hazardous organic and
criteria pollutants at several sample loca-
tions in the incinerator system. Table 3
summarizes the S&A protocol used during
these trial burn tests.
Test Results
Table 4 summarizes the ORE results
for Aroclor 1260 (PCB). The DREs ex-
ceeded 99.99999 percent in all test cases;
as a result they were well above the
requirements specified in 40 CFR 761.70.
Two of the three tests showed higher
PCB emissions at the afterburner exit
than those measured at the stack, possibly
indicating some scrubbing of unburned
PCB in the APCD system. HCI scrubbing
efficiencies, shown in Table 5, generally
exceeded 99.99 percent on the basis of
HCI measurements at the stack using
EPA Method 5. HCI concentration in the
gas was also measured at the inlet to the
carbon bed filter. These results showed
concentrations in the range of 1 to 20
ppm corresponding to scrubbing effici-
encies of approximately 99.9 percent.
Paniculate mass emissions were mea-
sured at the stack during four test days.
These results, summarized in Table 6,
HEPA
Filter Carbon
Bed
Filter
Building
Wall
Afterburner
Chamber
(Unfired)
Stack
(Sampling)
Sampling
Port
Quench
/~ Chamber
Ionizing
Wet
Scrubber
Packed
Column
Scrubber
Scrubber
Liquor
Tank
~7/Venturi Q
f Scrubber
*• i
Main
Chamber
Aux. Propane r
PCB/No. 2 Oil 4
Atomizing Steam _J I
Combustion —_J
Air
Figure 1. Simplified schematic of the USCPA Combustion Research Facility liquid injection incinerator system.
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Table 2. Liquid Injection Incinerator Operating Conditions During Tests
Test
Date duration
3-S-86 1104-
17.O2
3-6-86 1 1.-O6 -
16:50
3-7-86 09:50 •
14:30
3-8-86 03:45 -
13:23
PCB waste
PCB waste heat Propane
feedrate release flowrate
kg/hr kW scm/hr
(Ib/hr) (xl&Btu/hr) (SCFH)
48
36-62
(106)
(80 - 136)
50
27-57
(110)
(60 - 148)
SO
36-64
(110)
(80 - 140)
45
40-53
(100)
(88-111)
421
321 -557
(1437)
(109S - 1902)
441
241-593
(1506)
(821 - 2025)
441
321 -561
(1506)
(1095- 1916)
427
376 - 474
(1457)
(1282 - 1617)
3.4
2.6 - 3.9
(119)
(92 - 139)
2.7
2.6-3.0
(96)
(92 - 105)
2.7
2.6 - 3.0
(96)
(93 - 105)
2.8
2.4 - 3.0
(99)
(86 - 105)
Propane Combustion
heat Total heat air
release release rate flowrate
kW kW scm/min
(xlO3 Btu/hrJfxIO3 Btu/hr) fSCFM)
86
66-100
(292)
(225-341)
69
66-75
(235)
(225 - 257)
69
67-75
1235)
(228 - 257)
71
62-75
(243)
(211 -257)
506
(1729)
510
(1741)
510
(1741)
498
(1700)
9.0
8.6-9.1
(318)
(302 - 320)
8.9
8.8-9.2
(315)
(309 - 326)
9.1
9.0-9.1
(320)
(319-321)
8.8
8.6-9.1
(310)
(303-322)
Main Afterburner
Afterburner chamber chamber Stack
oxygen temperature temperature temperature
percent °C °C °C
dry (°F) (°F) (°F)
9.0
3.0 - 15.3
11.6
11.5-16.0
13.0
12.0 - 14.9
13.5
13.0 - 15.0
1262
1262-1301
(2303)
(2016-2374)
1195
1088-1195
(2183)
(1990-2447)
1239
1178-1270
(2262)
(2152-2317)
1216
1181-1257
(2220)
(2158-2295)
982
912-1067
(1799)
(1671-1953)
943
873-1060
(1730)
(1604-1940)
1012
973-1044
(1854)
(1782-1912)
1064
1045-1105
(1948)
(1913-2021)
71
68-71
(159)
(155 - 160)
69
66-71
(156)
(150 - 160)
67
64-70
(1S3)
(148 - 158)
71
71-72
1160)
(159 - 161)
52 491 2.9 73
3-9-86 09:15- 47-58 444-446 2.8-2.9 72-75 564
12:45 (115) (1675) (102) (250)
(104 -128) (1515 -1865) (100 - 104) (245 - 255) (1925)
51 478 2.9 73
3-10-86 10:08- 44-55 410-512 2.9-2.9 73-75 551
14:45 (112) (1632) (102) (250)
(96-120) (1398 - 1748) (101 - 104) (248-255) (1882)
45 427 2.9 73
3-11-86 09/03- 18-54 171-504 2.7-2.9 69-74 500
13:32 1100) (1457) (101) (248)
(40-118) (583 -1719) (96-103) (235 - 252) (1705)
8.8 1270 1056 71
8.1-9.3 11.0 1177-1363 1005-1106 70-72
(310) 8.0 - 12.0 (2318) (1932) (160)
(287 - 330) (2150-2485) (1841-2024) (158 - 162)
9.1 1267 1064 72
9.0-9.2 11.0 1239-1305 1033-1096 71-72
(320) 6.0 - 16.9 (2312) (1948) (161)
(318-323) (2262-2384) (1891-2004) (160-162)
8.9 1239 1063 71
8.8-9.0 14.0 1208-1270 1043-1070 70-71
(314) 10.5 • 17.8 (2263) (1945) (159)
(310-319) (2206-2318) (1909-1958) (158-160)
indicate concentrations in the range of
130 to 330 mg/dscm. The 225 mg/dscm
average for the four tests is above the
regulatory requirement of 180 mg/dscm.
Table 7 summarizes the measured
emission rates of other RCRA listed
(Appendix VIII) organic compounds de-
tected in the gas samples at the stack
and afterburner exit. The table lists the
highest concentration measured for each
compound and the average concentration
(shown in parenthesis) calculated from
all samples. With the exception of
methylene chloride, chloroform, bromo-
form, and 1,2-dichloroethane (plus
methylethyl ketone) all other compounds
showed average concentrations less than
10 jtg/dscm. Concentrations of all semi-
volatile compounds were higher at the
afterburner exit than at the stack, in-
dicating some scrubbing of these com-
pounds in the APCD system.
Conclusions and
Recommendations
Trial burn tests using PCB-laden oil in
the liquid injection incinerator at the
Combustion Research Facility in Jefferson,
Table 3. Sampling and Analysis Program
Test method Sample location
Analyses
VOST
Modified EPA
Method 5 (MMS)
EPA Method 5 (MS)
Continuous monitors
Afterburner exit
Stack
Afterburner exit
Stack
Stack only
Afterburner exit
Carbon bed inlet
Stack
Volatile organic compounds
Semivolatile organics
Paniculate. HCI
O* CO* NO. NO,. HCI
Analyses were performed with standard EPA methods (3. 4, 5J.
Arkansas, indicated PCB DREs in excess
of 99.9999 percent with efficient HCI
scrubbing. Average paniculate emission,
however, exceeded the requirements
specified under RCRA and TSCA regula-
tions. Additional research is recommended
to determine the impact of incinerator
operating conditions on PCB ORE and PIC
emissions. Specifically, tests should be
undertaken to evaluate the effect of waste
firing in the afterburner section as well as
operation at lower gas residence times
approaching the minimum requirements
specified under TSCA regulations.
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Table 4. Destruction and Removal Efficiencies of Aroclor 1260 in the CRF Liquid Injection Incinerator
Based on flue gas velocity data
Date
3-5-86
3-7-86
3-10-86
Sample
location
Afterburner
Stack
Afterburner
Stack
Afterburner
Stack
Total
amount of
waste
feed
(kg)
256.4
250.3
189.2
196.6
198.7
200.0
Total
amount of
Aroclor 1260
fed* units
(kg)
107.9
105.4
79.7
82.8
71.5
72.0
Sampling
period
duration
(min)
316
310
241
249
240
243
Flue gas
Aroclor 1260
concentration
(ng/dscm)
0.41
0.46
0.27
0.15
0.23
0.079
Flue gas
flowrate
(dscm/min)
21.16*
21.16
22.32"
22.32
18.61"
18.61
Total
Aroclor 1260
emitted
99.999997d
99.999997
>99.999998d
99.9999990
>99.999999d
99.9999995
"During corresponding sampling periods.
"Flue gas flowrate not measurable at this location, hence assumed to be equal to that at stack.
'Calculated based on footnote b above.
dActual OREs will be higher than these indicated DREs because of the above approximation (see footnote b).
Calculated Aroclor emissions are high because higher than actual Hue flowrates were used.
Table 5. Scrubber Efficiency and HCI Emissions
CEA analyzer at carbon bed inlet
Date
3-5-87
3-7-86
3-10-86
3-11-86
Inlet
chlorine
flowrate'
kg/hr
24.4
25.4
22.8
20.1
M
Concentration
range
mg/dscm
<1.6
<2.39
<1.76
<1.61
'ethod 5 at stact
Outlet
chlorine
flowrate
kgHCI/hr
99.99
>99.988
>99.99
>99.99
Concentration
range
ppm
average
min — max
6.5
1.2 — 14.8
10.8
3.3—19.5
12.2
4.5—17.1
—
Outlet chlorine
flowrate
kgHCI/hr
average
min — max
O.O12
O.OO2 — 0.028
0.022
0.007 — 0.039
0.021
O.O08 — 0.029
—
Scrubber
efficiency
percent
average
min — max
99.95
99.99 — 99.88
99.91
99.97 — 99.84
99.91
99.97 — 99.87
—
'As HCI.
Table 6. Particulate Emissions at the Stack
Probe rinse
Filter paper
Total
Date
3-5-86
3-7-86
3-10-86
3-11-86
Weight
(mgj
174.9
133.7
136.7
1O0.9
Particulate
concentration
in sample gas
(mg/dscm)
306.0
166.2
225.2
166.2
Emission
rate
(kg/hr)
0.388
0.165
0.251
0.174
Weight
fmg)
15.9
9.5
15.7
11.9
Particulate
concentration
in sample gas
(mg/dscm)
27.8
8.8
25.6
19.6
Emission
rate
(kg/hr)
0.035
0.012
0.029
0.021
Weight
(mg)
190.8
143.2
152.4
112.8
Particulate
concentration
in sample gas
(mg/dscm)
334
132
251
186
Emission
rate
(kg/hr)
0.423
O.I 77
O.280
O.I 95
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Tab/o 7. Organic Emissions, pg/dscm
Organic pollutant
March 5
March 7
March 10 and 11
Average for
all tests
Stack
Afterburner
exit
Stack
Afterburner
exit
Stack
Afterburner
exit
Stack
Afterburner
exit
Volatile organics"
Methylene chloride
1,1 -dichloroethylene
1,1-dichloroethane
t-1,2-dichloroethylene
Chloroform
1,2-dichloroethane and
2-butanone*
1,1.1 -trichloroethane
Carbon tetrachloride
Bromodichloromethane
1,2-dichloropropane
T- 1,3-dichloropropene
Trichloroethylene
Benzene
1,1,2-trichloroethane and
chlorodibromomethane *
Bromoform
Tetrachloroethylene and
1,1,2,2-tetrachloroethane*
Toluene andhepane
Chlorobenzene
Semivolatile organics*
>290 (>98f >290 O145) >300 (170)
4.8(2.6)
B
1.7(0.81)
>100(45)
79(64)
B
11(4.7)
B
12(4.0)
5.9 (2.0)
28(13)
59 (53)
B
54(21)
14(7.1)
15(5.0)
0.8(0.27)
13 (5.9)
B
10 (4.8)
32(21)
45(26)
B
B
B
7.4 (3.0)
>116f>69)
16(5.3)
2.3(0.77)
55(18)
B
B
4.5 (1.5)
35 (14)
2.2 (1.9)
42 (19)
B
18 (10)
B
B
9.3 (3.1)
32(11)
2.6(1.5)
12(4.1)
>62 O22)
B
B
25 (15)
B
14(4.6)
B
155(114)
24 (8.0)
7.2(2.4)
B
36(29)
61 (27)
B
B
2.3 (1.8)
B
B
15(12)
B
5.9 (2.0)
>88(31)
B
8.0(5.8)
9.9 (6.0)
97(58)
0.54 (0.18)
B
1.0(0.5)
14 (8.0)
31 (28)
B
3.7(2.2)
B
18(4.5)
11(10)
8.3 (3.6)
0.61 (0.40)
B
15(13)
B
B
0.72(0.64)
22(20)
B
B
B
21(11)
B
B
9.4(7.6)
2.6(1.7)
B
1.6
6.3
0.44
21
31
0.13
2.6
8,0
1.8
2.6
>78
5.1
0.72
3.2
19
20
B
B
4.9
0.90
13(12)
11 (8.8)
>83O21)
B
15 (14) 6.4 (4.4)
0.56(0.53) 8.5(5.9)
24
B
16
5.3
7.9
O.27
8.2
0.91
6.0
B
3.9
8.4
1,3-dichlorobenzene
1,2-dichlorobenzene
1 ,4-dichlorobenzene
1,2,3-trichlorobenzene
1 ,2,4-trichlorobenzene
1 ,2,3,4-tetrachlorobenzene
1 ,2,3,5/4,5-tetrachlorobenzene
B
0.05
B
0.03
0.41
O.O04
B
B
0.59
1.1
0.36
0.97
O.85
O.13
B
B
B
B
B
0.048
B
B
B
B
B
B
0.082
B
B
B
B
0.010
0.078
0.004
0.003
B
6.3
0.58
0.29
0.52
0.68
0.11
B
0.017
B
0.013
0.14
0.019
0.001
B
2.3
0.56
0.22
0.50
0.54
0.08
day.
^Compounds elute at the same retention time.
B — Below guantitation limit (typically <1 pg/dscm).
> — Greater than calibration range of gas chromatograph.
Johannes W. Lee, Thomas H. Backhouse, Robert W. Ross II, and Larry R.
Water/and are with Acurex Corporation. Jefferson, AR 72O79.
Robert Mournighan is the EPA Project Officer (see below).
The complete report entitled "PCB Trial Burn Report for the U.S. EPA Combustion
Research Facility Liquid Injection Incinerator System," (Order No. PB 87-
208 799/AS; Cost: $18.95, 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:
Hazardous Waste Engineering Research Laboratory
U.S. Environmental Protection Agency
Cincinnati, OH 45268
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United States Center for Environmental Research
Environmental Protection Information
Agency Cincinnati OH 45268
Official Business
Penalty for Private Use $300
EPA/600/S2-87/051
0000329 PS
U S eHVlR PfOTeCTIOH
_
" 406M
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