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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