United States
Environmental Protection
Agency
Industrial Environmental Research
Laboratory
Research Triangle Park NC 27711
Research and Development
EPA-600/S9-81-006 Sept. 1981
Project Summary
Symposium Proceedings:
Environmental Aspects of Fuel
Conversion Technology, V
(September 1980, St. Louis, MO)
F. A. Ayer and N. S. Jones, Compilers
*
The report documents presentations
at the fifth EPA-sponsored symposium
on the environmental aspects of fuel
conversion technology, in St. Louis,
MO, 9/16-19/80. The symposium
served as a colloquium on environ-
mental information related to coal
gasification, indirect liquefaction, and
direct liquefaction. The program
included sessions on program ap-
proach, environmental assessment,
and environmental control, including
the development of EPA's pollution
control guidance documents. Process
developers and users, research scien-
tists, and State and Federal officials
participated in the symposium.
This Project Summary was devel-
oped by EPA's Industrial Environmen-
tal Research Laboratory. Research
Triangle Park, NC. 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).
This report summarizes the proceed-
ings of the fifth EPA symposium on
Environmental Aspects of Fuel Conver-
sion Technology, held September 16-
19, 1980, in St. Louis, MO.
The purpose of the symposium,
sponsored by EPA's Industrial Environ-
mental Research Laboratory at Research
Triangle Park, NC, was to discuss
environmentally related information on
coal gasification and liquefaction.
Approximately 250 participants, includ-
ing process developers, process users,
environmental groups, governmental
representatives, and research scientists,
attended the 4-day symposium.
Source and ambient multimedia test
results from pilot through commercial-
scale coal gasification and liquefaction
facilities were presented, as well as
evaluations of environmental control
technologies, results of laboratory
research, and the status of methodolo-
gies for environmental assessment.
Development of EPA's Pollution Control
Guidance Documents for coal indirect
liquefaction, direct liquefaction, and
low-Btu gasification was highlighted.
Abstracts of the speakers' remarks
follow.
Keynote Address
Kurt W. Riegel, Associate
Deputy Administrator
Office of Environmental
Engineering and Technology
U.S. EPA, Washington, D.C.
20460
Since last year's meeting two things,
which can be expected to spur synthetic
fuels development, have occurred. The
price of oil has again almost doubled
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and President Carter has signed into
law the Synthetic Fuels Corporation Bill
which authorizes up to $20 billion to
encourage the growth of the industry.
In spite of sporadic Agency funding
for research on the environmental
effects of synthetic fuels production, a
core effect has been maintained that
has enabled EPA to meet its commit-
ments to formulate environmental
protection guidelines for emerging
synfuels technologies. The Alternate
Fuels Group and Priority Energy Project
Group have been established by the
Administrator and have functioned to
coordinate EPA's activities in this effort
to use "best engineering judgement" to
provide the basis for evaluation of
permit applications on accelerated
projects in lieu of operating data on
existing plants.
The major outputs in this effort are a
series of Pollution Control Guidance
Documents (PCGDs), one for each of the
major synfuel product areas: gasifica-
tion/indirect liquefaction, direct lique-
faction, oil shale, and biomass. These
are targeted for the user groups: permit
reviewers (both in the EPA regional
offices and in comparable state govern-
ment agencies), process developers or
plant operators, and EPA regulatory
offices which will use the data for
standards preparation.
I thank you for your contributions to
and interest in these efforts and your
participation in this symposium.
Session I. General Approach
Robert P. Hangebrauck,
Chairman
Industrial Environmental
Research Laboratory
U.S. EPA, Research Triangle
Park, NC 27711
The Synthetic Fuel Program of
the Fuel Process Branch of
IERL-RTP
T. Kelly Janes, Chief
Industrial Environmental
Research Laboratory
U.S. EPA, Research Triangle
Park, NC 27711
This paper deals with the overall
research effort being conducted by the
Fuel Process Branch of EPA's Industrial
Environmental Research Laboratory at
Research Triangle Park, NC. This effort
has been divided into three categories:
(1) development of suitable methodolo-
gies for environmental assessment of
these technologies, (2) problem defini-
tion through data acquisition, and (3)
research facilities to assess control
technology acceptability.
EPA/IERL-RTP Program for
Direct Liquefaction and
Synfuel Product Use
Dale A. Denny
Industrial Environmental
Research Laboratory
U.S. EPA, Research Triangle
Park, NC 27711
The direct liquefaction program at
EPA/IERL-RTP covers those synfuel
processes which add hydrogen to coal
and form liquid hydrocarbon products
directly. The processes currently under
study include SRC-II, Exxon Donor
Solvent, and H-Coal. SRC-I is also
included in the program because of its
similarity to SRC-II even though the
main product from that process is a
solid. The synfuel use program covers
products from coal and shale synfuel
processing systems. Current and planned
IERL-RTP activities in the area of direct
coal liquefaction and synfuel product
use are described. The relationship of
these activities to process developers,
regulatory programs, other governmen-
tal agencies, and other EPA research
activities is discussed.
Update of EPA/IERL-RTP
Environmental Assessment
Methodology
Garrie L Kingsbury
Research Triangle Institute
Research Triangle Park,
NC 27709
and
N. Dean Smith
Industrial Environmental
Research Laboratory
U.S. EPA, Research Triangle
Park, NC
EPA's IERL-RTP has developed a
systematic approach for performing
each aspect of environmental assess-
ment to allow for consistent data
gathering and interpretation. Environ-
mental assessment requires the deter-
mination of contaminant levels associ-
ated with point source discharges and
comparison of those determinations
with target control levels. Procedures
for conducting phase environmental
assessments involving Level 1 and
Level 2 chemical analyses and bioassays
have been formalized. Multimedia
Environmental Goals (MEGs) reflecting
potential toxicity of specific chemicals
provide the target values used for
comparison. Source Analysis Models
(SAMs) delineate discharge stream
severities based on the components
present and mass flow rates. The Level
1/Level 2 chemical analysis approach
has been coupled with the categorical
system for organizing chemicals ad-
dressed by MEGs.
The computerized Environmental
Assessment Data System (EADS) at
IERL-RTP is used to store environmental
assessment data and to provide links
between characterization and target
goals. Eventually, EADs will be used to
automate large portions of the assess-
ment data analysis.
I
The Permitting Process for
New Synfuel Facilities
Terry L. Thoem, Director
Energy Policy Coordination Office
U.S. EPA, Region 8, Denver,
CO 80295
The U.S. EPA and the various state
departments of health are involved in a
joint partnership with shared responsi-
bilities for protecting the environment
during the development of synthetic
fuels. Legislation in the form of the
Clean Air Act, Clean Water Act, Resource
Conservation and Recovery Act, Safe
Drinking Water Act, and the Toxic
Substances Control Act provide the
framework for EPA's regulatory respon-
sibilities. The current status of imple-
menting regulations and agency policies
vis-a-vis these Acts is provided in this
paper. Also, important aspects of state
environmental regulations are provided.
Permit applications for synthetic fuel
facilities are being received by EPA
regional offices and by state agencies.
Synfuel EISs are being reviewed.
Decisions on Best Available Control
Technology are being made. These
engineering judgements are also dis-
cussed in this paper.
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*
The TV A Ammonia from
Coal Project
P.C. Williamson
Division of Chemical
Development
TVA, Muscle Shoals, AL 35660
TVA's Ammonia from Coal Project
involves retrofitting a coal gasification
process to the front end of its existing
225-ton-per-day ammonia plant. The
purpose of the project is to develop
design and operating data to assess the
technological, economic, and environ-
mental aspects of substituting coal for
natural gas in the manufacture of
ammonia. Preliminary operation of the
facility was begun in September 1980.
In the absence of specific environmental
guidelines for coal gasification proc-
esses, TVA's approach to the potential
environmental problem is to meet or
exceed the emission control require-
ments for specific components; e.g.,
sulfur compounds, particulates, and
aqueous discharges. Also, TVA's facility
contract specified limits on certain
discharges based on anticipated guide-
lines. In addition to a discussion of the
emissions control activities, a program
is described that examines the environ-
mental health and safety aspects of the
Ammonia from Coal Project.
Environmental Control
Options for Synfuel Processes
F.E. Witmer
Environmental and Safety
Engineering Division
U.S. DOE, Washington,
DC 20545
Ultimately, the large scale production
of synfuels from U.S. coal and oil shale
will become a reality. The U.S. DOE has
a charge to foster the commercialization
of energy conversion technology that is
environmentally acceptable. "Environ-
mental acceptability" is perceived to
extend beyond meeting environmental
compliance standards at a given plant
and to include the "acceptability" of
subtle, longterm health and ecological
effects and the composite of low level
environmental effects associated with
an aggregate of synfuel installations.
DOE has a hierarchy of site-specific
environmental assessments integral to
DOE development and demonstration
activity. The objective of these assess-
ments is to provide a data base for a
determination of environmental readi-
ness by the Assistant Secretary for
Environment. An evaluation of the
adequacy of the environmental control
technology is a key component of these
determinations.
In assessment of control adequacy,
many alternative approaches present
themselves. Some of these control
options result from a natural synergism
of combining process needs; e.g., an
auxiliary power plant that recovers flue
gas S02 in a concentrated stream can be
advantageously coupled to H2S recovery
from the conversion process to produce
by-product sulfur via Claus, or an
entrained-type gasifier can be included
with a series of Lurgi gasification units
to handle rejected coal fines and oxidize
highly contaminated condensate waste-
waters. Other control options follow for
making controls more cost-effective
and/or environmentally superior. Waste-
water reuse to extinction (zero dis-
charge) and the catalytic incineration of
process tail gases are examples of
improvements over conventional tech-
nology. In the case of small, site-
oriented industrial gasifiers, process
simplicity and reliability are driving
forces for improved controls or the
absence thereof; e.g., ingasifier sulfur
scavenging to eliminate subsequent
HzS cleanup or "dry-quenching" of
product gas to eliminate the difficulty of
wastewater treatment.
This presentation overviews a number
of select environmental control options
whose technical and economic feasibil-
ity has been recently established. The
direction that future resultant control
technology is expected to take is
outlined.
Technical and Environmental
Aspects of the Great Plains
Gasification Project
Gary N. Weinreich
American Natural Service
Company
Detroit, Ml 48226
The Great Plains Gasification Project
will be the first commercial-size synthetic
fuels plant constructed in the U.S.
Construction of the first phase began in
July 1980 and, when completed in
1984, will produce 137.5 million cubic
feet per day of substitute natural gas
(SNG). Producing this quantity of gas
requires 13,000 tons of North Dakota
lignite per day and water at the rate of
4,400 gallons per minute.
Planning for the project has been
ongoing for 7 years. An integral part of
the technical planning has been the
design and selection of environmental
controls. The plant is designed for zero
discharge of process wastewaters to
surface streams. Extensive air pollution
control equipment is designed to meet
all applicable emission standards and
ambient air quality standards. Compli-
ance will be maintained with the PSD
Class I increments at the Theodore
Roosevelt National Park, 100 kilometers
west of the plant site.
The gasification process to be used
was developed by Lurgi, an engineering
firm in West Germany. The major
downstream process units were aiso
developed and perfected by Lurgi. Other
patented processes incorporated in the
design of the Great Plains project are
U.S. Steel's Phosam-W process for
removing ammonia from process waste-
water and Northwest Gas Board's
Stretford process for converting HkS to
elemental sulfur. Two American engi-
neering companies, CE Lummus Com-
pany and Kaiser Engineers, are the
architect/engineers for the project.
Many of the technical uncertainties
surrounding a new venture such as this
have been resolved through a technical
consulting agreement with SASOL, the
South African gasification company
that has produced synthetic fuels via the
Lurgi process for over 20 years. Great
Plains shipped 12,000 tons of North
Dakota lignite to South Africa for
gasification testing in 1975, the results
of which formed the basis for the
gasification design being used today.
Session II. Environmental
Assessment: Direct
Liquefaction
D. Bruce Henschel, Chairman
Industrial Environmental
Research Laboratory
U.S. EPA, Research Triangle
Park, NC27711
Preliminary Results of the Fort
Lewis SRC-II Source Test
Jung I. Kim and
David D. Woodbridge
Hittman Associates, Inc.
Columbia, MD 21045
As part of EPA's environmental
assessment of the SRC-II coal liquefac-
-------
tion technology, a source test and evalu-
ation study was conducted to charac-
terize multimedia environmental streams
associated with the SRC pilot plant at
Fort Lewis, WA.
Although the SRC-II pilot plant is not
considered a miniature version of
commercial facilities, environmental
implications of the SRC-II technology
can be determined with proper engi-
neering evaluation, and sampling and
analytical strategies.
The program consists of chemical and
biological characterization of the SRC-II
process and waste streams. Chemical
analyses were performed to identify and
quantitate potentially toxic inorganic
and organic compounds. Biological
tests were also performed to provide
both health effects and ecological
effects of the SRC-II streams on mam-
malian organisms and ecosystems.
These two tests complement each other
to better define the SRC-II streams
relative to their environmental signifi-
cance.
Chemical/Biological
Characterization of SRC-II
Product and By-products
W.D. Felix, D.D. Mahlum,
W.C. Weimer, R.A. Pelroy, and
B.W. Wilson
Pacific Northwest Laboratory
Richland, WA 99352
Biological and chemical tests in
concert with engineering analyses of
plant operations have been used to
provide data for the assessment of
health and environmental effects of a
mature coal liquefaction industry. This
report describes the methodology
whereby biological testing is used to
guide the chemist in the analysis of
fractions of selected pilot plant mater-
ials. The principal components of an
unmodified distillate blend from the
SRC-II process are two- and three-
ringed aromatic and heteroatomic
species. Phenolic and polynuclear
aromatic components are generally
present at higher levels than expected
in petroleum crudes. Biotesting, with
the Ames test as the primary first-tier
method, revealed mutagenic activity.
Chemical fractionation in conjunction
with Ames testing implicates the
primary aromatic amines as the com-
pound class of primary concern. Chemi-
cal biotesting of a hydrotreated distillate
blend showed a significant reduction of
the primary aromatic amines as well as
polynuclear aromatic hydrocarbons.
Hydrotreating also can result in the
reduction of sulfur and oxygen-contain-
ing compounds; e.g., thiophenes and
phenols.
Low-No* Combustors for
Alternate Fuels Containing
Significant Quantities of Fuel-
bound Nitrogen
W.D. Clark, D.W. Pershing,
G.C. England, and M.P. Heap
Energy and Environmental
Research Corporation
Santa Anna, CA 92705
This paper summarizes data generated
in two EPA-sponsored programs con-
cerned with the development of low-
NOX combustors for high nitrogen
containing fuels. EPA Contract 68-02-
3125 is concerned with NO« production
and control from liquid fuels containing
significant quantities of bound nitrogen.
It was found that fuel nitrogen content is
the primary composition variable af-
fecting fuel NO formation and that
emissions from both petroleum and
alternative liquid fuels correlate with
total fuel nitrogen content. Conditions
were identified which allow high-
nitrogen fuels to be burned satisfactorily
with minimal NOX emissions. Certain
coal-derived fuel gases may contain
ammonia. Data is presented from a
series of bench-scale reactors designed
to minimize the conversion of this
ammonia to NO,. Lowest NO* emissions
were produced in a rich/lean combustor
utilizing either a diffusion flame or a
catalyst in the fuel-rich primary stage.
Problem Oriented Report:
Utilization of Synthetic Fuels:
An Environmental Perspective
E.M. Bonn, J.E. Cotter,
J.O. Cowles, J. Dadiani,
R.S. Iyer, and J.M. Oyster
TRW, Energy Systems and
Planning Division
McLean, VA22102
This paper discusses the potential
environmental problems arising from
the refining, transportation, storage,
and utilization of fuels produced by a
synthetic fuel industry. Scenarios
defining possible buildup rates for
synfuel products from oil shale and coal
conversion are developed to scope the
magnitude of potential exposures. The
market infrastructure for the use of
these products is examined and the
potential public health risks during the
handling, transportation, and utilization
of these synfuel products are evaluated.
Significant issues regarding environ-
mental impacts and the need for
regulatory attention are discussed.
Session III: Environmental
Assessment: Gasification and
Indirect Liquefaction
Charles F. Murray, Chairman
TRW
Redondo Beach, CA 90278
Environmental Test Results
from Coal Gasification
Pilot Plants
N.A. Holt, J.E. McDaniel,
T.P. O'Shea
Electric Power Research Institute
Palo Alto, CA 94303 |
Environmental awareness and the
world oil situation are having a profound
impact on the U.S. Electric Power
Industry. "Environmental acceptability"
has been redefined and is emerging as
one of the major criteria for selection of
a power generation process to satisfy
increasing load demand or to replace
retired units. Furthermore, the fact that
the cost of fuel has risen in real terms
dictates that more fuel efficient plant
configurations be deployed. Fuel effi-
ciency and environmental tolerability
come only at the expense of increased
monetary cost.
These fundamental changes certainly
are creating problems for the power
industry but they are also creating
opportunities for new and more appro-
priate power generation processes.
EPRI has high expectations that
combined cycle power systems fueled
by gas from coal will be cleaner and
more efficient than the competing
processes for equivalent capital cost.
Advantages accrue to these Gasification-
Combined Cycle (GCC) systems primarily
from the relative ease of cleaning fuel
gas, the benign nature of the waste,
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1
products, and the inherent and proven
high thermodynamic efficiency of the
combined cycle configuration.
These and other advantages are
discussed. Coal gasification processes
are identified which most effectively
capitalize on these advantages. Environ-
mental test results on these processes
are summarized. Finally, the plans for
commercial scale demonstration of a
GCC system are reviewed. This demon-
stration is a critical milestone since no
technology can be considered to be a
real option until it has been operated at
an appropriate scale.
COS-HzS Relationships in
Processes Producing
Low/Medium-Btu Gas
M.B. Faist, R.A. Magee, and
M.P. Kilpatrick
Radian Corporation
Austin, TX 78758
The chemical aspects of the distribu-
tion of sulfur between H2S and COS in
the product gas from the gasification of
coal are examined. Comparing actual
gasifier measurements with equilibrium
computations shows that the gas
stream becomes frozen corresponding
to equilibrium values at high tempera-
ture, most likely corresponding to the
reactor exit. This implies a sulfur distri-
bution with a higher COS concentration
than expected. The conversion of COS
to HaS occurs mainly by COS hydrolysis,
which is very slow at low temperatures.
Finite rate studies indicate that an
effective catalytic COS hydrolysis rate
constant of 10~17 to 1CT16 cmVmol sec
will allow the reaction to reach >95
percent equilibrium in small enough
residence time to allow reasonable
reaction vessel sizes.
It is found that the achievable H2S/
COS equilibrium ratio is determined
from the product of the locally frozen
HaO/COa ratio and the COS hydrolysis
equilibrium constant. The governing
parameters for the HaO/COa equilibrium
ratios are the temperature, pressure,
and the gas stream (H/C) and (0/C)
ratios. The higher the (H/C) ratio and
the lower the (0/C) ratio, the larger the
H2O/COa ratio and thus the larger the
H2S/COS ratio. Moreover, raising the
(H/C) ratio and lowering the(O/C) ratio
also increases the achievable CH4
equilibrium concentration from a cata-
lytic methanation module.
Behavior of a Semibatch Coal
Gasification Unit
W.J. McMichael and
D.G. Nichols
Research Triangle Institute
Research Triangle Park,
NC 27709
This paper describes the transient
behavior of a laboratory scale fixed-bed
gasifier operated in a semibatch mode.
The operation is batch with respect to
the coal feed and continuous with
respect to gas flows. Various coals
ranging from lignite to bituminous were
gasified using steam/air mixtures at 1.4
MPa (200 psia) and approximately
900°C. The transient behavior of the
reactor temperature at various coal bed
depths was examined. Test results from
nine tests involving five coals are
reported. The data presented include
the rate of production of various
gasification products, including CH4,
CO, Hz, benzene, toluene, xylene, HaS,
COS, and thiophene, as a function of
run time. It was found that the majority
of the CH4, the minor hydrocarbons, and
sulfur species were evolved during coal
devolatilization. These data were ana-
lyzed using a simple kinetic model
which assumes that the rate of produc-
tion of a compound at any time is
proportional to the (potential) amount of
that compound remaining in the coal.
This model explains the data reasonably
well during the devolatilization period. It
was found that the specific rate of
production of individual species was
practically the same for all coals and
gasification products considered; the
ultimate yield was dependent on coal
type. The ultimate yield of (a) CH4 or
benzene, and (b) sulfur species roughly
paralleled the volatile and sulfur
contents of the coals, respectively.
Carbon Conversion, Make Gas
Production, and Formation of
Sulfur Gas Species in a Pilot-
scale Fluidized-bed Gasifier
M.J. Purdy, J.K. Ferrell,
R.M. Felder, S. Ganesan, and
R.M. Kelly
North Carolina State University
Raleigh, NC 27650
The steam-oxygen gasification of a
pretreated Western Kentucky No. 11
bituminous coal was- carried out in a
pilot-scale fluidized-bed gasifier. This
paper describes the experiments and
summarizes measured carbon conver-
sions, sulfur conversions, make gas
production rates, and the results of
material balance calculations on total
mass and major elements (C, H, 0, N,
and S). The development of a single-
stage kinetic model for the gasifier is
outlined, and correlations of the ex-
perimental results using this model are
presented. Quantities of sulfur gas
compounds formed in the gasifier at
different operating conditions are
summarized and a first ana lysis of these
results is presented.
Modderfontein Koppers-Totzek
Source Test Results
J.F. Clausen and C.A. Zee
TRW, Systems and Energy
Division
Redondo Beach, CA 90278
A source test program was conducted
at a Koppers-Totzek (K-T) coal gasifica-
tion facility operated by AECI Limited at
Modderfontein, Republic of South
Africa. The EPA's interest in the K-T
process stems from the fact that the
process economics and demonstrated
commercial reliability make it a very
viable prospect for some U.S. applica-
tions. The responsibilities for sampling,
analysis, and engineering descriptions
of the Modderfontein plant were shared
between TRW and GKT, Gessellschaft
fur Kohle-Technologie mbH of Essen,
Federal Republic of Germany. GKT is
the wholly owned subsidiary of the
German-based parent company which
is the developer and licensor of the K-T
process. EPA's phased approach for
environmental assessment was fol-
lowed. Level 1 and Level 2 data were
collected along with priority pollutant
screening data. Much of the effort was
focused on wastewater streams. The
wastewater treatment, consisting of a
clarifier and settling pond, was adequate
to produce a final discharge that had
lower pollutant levels than the fresh
input waters supplied to the plant. The
complete data are presented in this
paper along with brief descriptions of
the K-T process and the Modderfontein
plant. The Source Test and Evaluation,
intended as an initial effort, was
somewhat limited in scope.
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An Environmentally Based
Evaluation of the Multimedia
Discharges from the Lurgi Coal
Gasification System at Kosovo
K.J. Bombaugh, W.E. Corbett,
K.W. Lee, and W.S. Seames
Radian Corporation
Austin, TX 78766
An international program has been
under way in the Kosovo region of
Yugoslavia to characterize the environ-
mental problems associated with a
commercial Lurgi coal gasification
system. The study was conducted over a
3-year pjeriod as a cooperative endeavor
between scientists from Yugoslavia and
U.S. EPA/Radian Corporation. It was
undertaken because the Lurgi gasifica-
tion process has a significant potential
for use in the U.S. In this study, the
plant's key streams (feed, process,
product, and discharge) were character-
ized, and key pollutants in the plant's
gaseous, aqueous, and solid discharges
were identified and quantified. Multi-
media discharges were prioritized
according to both mass flow and
discharge severity.
This paper focuses on the severity of
the discharges, as determined by the
EPA-IERL SAM/IA model for evaluating
pollutants on the basis of their potential
for causing adverse health effects. Key
pollutants in each discharge medium
are identified and significant streams,
as prioritized, are discussed.
Study results indicate that all dis-
charge media (gaseous, aqueous, and
solid) present a significant potential for
polluting the environment and also that
effective controls for many discharge
streams are imperative.
Ambient Air Downwind of the
Kosovo Gasification Complex:
a Compendium
Ronald K. Patterson
Environmental Sciences
Research Laboratory
U.S. EPA, Research Triangle
Park, NC 27711
In an attempt to obtain environmental
impact data for a commercial scale coal
gasification facility, the Aerosol Re-
search Branch of EPA's ESRL-RTP
conducted a 16-day continuous ambient
air study in the Kosovo Region of
Yugoslavia. Five sampling sites were
established around and —2 km outside
the fence line of the Kosovo medium-
Btu Lurgi gasification complex.
Organics in total particulate matter;
total and fine particle mass, inorganics,
and elemental species; trace metal in
size-fractionated particles; and vapor-
phase organics were determined.
Physical and chemical analyses were
carried out on particulate matter using
gravimetric analysis, ion chromatogra-
phy, and scanning electron microscopy.
Elemental analysis was done using the
inductively coupled argon plasma
emission technique, proton-induced x-
ray emission, and combustion analysis.
Both particle catches and vapors
trapped on Tenax resins were subjected
to organic analysis using gas chroma-
tography. The chromatographic fractions
were identified and quantified using
flame ionization detection, sulfur and
nitrogen specific detectors, and mass
spectrometry. A comprehensive quality
assurance and quality control program
was implemented to ensure the validity
of the samples collected and analyzed.
A number of U.S. and Yugoslavian
laboratories participated in the ambient
air sampling and analysis phases of this
study. This paper is a compendium of
the major results and conclusions
obtained by the participant laboratories.
Characterization of Coal
Gasification Ash Leach ate
Using the RCRA Extraction
Procedure
Kar Y. Yu
TRW, Inc.
Redondo Beach, CA 90278
and
Guy M. Crawford
Radian Corp.
Austin, TX 78758
Gasification ash constitutes the
single largest solid waste stream from
coal gasification facilities, and its
disposal is subject to regulations
promulgated under RCRA. Ashes from a
Lurgi gasifier, Wellman-Galusha gasi-
fier, and Texaco gasifier were subjected
to the RCRA Extraction Procedure test.
The results are reviewed in light of
similar data on boiler ashes. Those
findings indicate that these materials
will not be considered toxic based on the
100X primary drinking water standard
criteria.
Comparison of Coal
Conversion Wastewaters
R.V. Collins, K.W. Lee, and
D.S. Lewis
Radian Corporation
Austin, TX 78758
This paper presents analytical results
from the aqueous process condensates
from an oxygen-blown, lignite-fired
Lurgi gasifier, an air-blown, bitumi-
nous-fired Chapman gasifier, and a
coke oven process. Results show strong
similarities between the two gasifier
process condensates. The similarities
include gross chemical parameters and
concentrations of specific organic
compounds. Extraction of the three
condensates using diisopropyl ether
resulted in a 99+ percent removal of
total phenols and a 75 percent average
removal of the total organic carbon
(TOC). Further extraction with an
exhaustive technique removed an
average of only 9 percent of the
remaining TOC from the two gasifier
waters. The <500 MW to >500 MW
ratio was approximately 2 for the
remaining refractory organics. The
results of a brief study using activated
carbon to remove the refractory organics
indicated that the TOC levels could be
further reduced, but the levels remained
relatively high. The occurrences of eight
nitrogen-containing organic species
were compared using a gas chromato-
graph equipped with a Hall Electrolytic
Conductivity Detector in the nitrogen-
specific mode. The occurrences of
phenolic species were also compared
using a gas chromatograph equipped
with a flame ionization detector. The
three process condensates contained
the same phenolic and nitrogen hetero-
cyclic compounds.
Session IV: Environmental
Control
Forest 0. Mixon, Jr., Chairman
Research Triangle Institute
Research Triangle Park,
NC 27709
flanking of Potential Pollutants
from Coal Gasification
Processes
D.G. Nichols and D.A. Green
Research Triangle Institute
Research Triangle Park, NC 27709
i
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Potential pollutants associated with
coal gasification processes were studied
based on data from EPA's environmental
assessment research program. An
environmental assessment methodology
based on health and ecological Multi-
media Environmental Goals (MEGs) is
described and applied to product, by-
product, process, and waste streams. A
list of chemical species that were
measured or qualitatively identified in
coal gasification streams is given.
Maximum concentrations of each quan-
titated species in each medium (solid,
liquid, gas, tar) are given. Production
factors have been computed and nor-
malized on the basis of coal input rate to
facilitate comparisons. Chemical species
have been ranked by potential hazard to
health and ecology. Priorities for
monitoring, regulation, and control
technology development may be estab-
lished from these lists.
Effect of Sludge Age on the
Biological Treatability of a
Synthetic Coal Conversion
Wastewater
P.C. Singer, J.C. Lamb, III,
F.K. Pfaender, R. Goodman,
B.R. Marshall, S.R. Shoaf,
A.R. Hickey, and L. McGeorge
University of North Carolina
Chapel Hill, NC 27514
Aerobic biological processes appear
to be the focal point of any overall
scheme for treating coal conversion
wastewaters since a significant number
of the major constituents of these
wastes are biodegradable. Accordingly,
suitable design and operating criteria
for biological treatment facilities need to
be developed. The studies described in
this paper were conducted using a
synthetic wastewater which was for-
mulated to be representative, in its
organic composition, of actual waste-
waters from coal gasification and coal
liquefaction processes. The wastewater
contains 28 organic compounds, in-
organic nutrients, and pH-buffers.
The synthetic coal conversion waste-
water was fed to several bench-scale
activated sludge reactors, operated at
different solids retention times (sludge
ages). Effluents from the reactors were
analyzed by gas chromatography and
high-performance liquid chromatog-
raphy to assess the degree of removal of
the various constituents in the rawf eed,
and to identify reaction products
following biological treatment. Addi-
tionally, acute toxicity studies using
fathead minnows were conducted to
evaluate the biological impact of the
treated wastewaters on aquatic life.
Acute mammalian cytotoxicity and
Ames mutagenicity analyses were also
performed on the reactor effluents to
assess their potential impact on human
health. This paper presents selected
results of some of these analyses.
Treatment and Reuse of Coal
Conversion Wastewaters
Richard G. Luthy
Carnegie-Mellon University
Pittsburgh, PA 15213
This paper presents a synopsis of
recent experimental activities to
evaluate processing characteristics of
coal conversion wastewaters. Treatment
studies have been performed with high-
Btu coal gasification process quench
waters to assess enhanced removal of
organic compounds via powdered acti-
vated carbon/activated sludge treat-
ment, and to evaluate a coal gasification
wastewater treatment train comprised
of sequential processing by ammonia
removal, biological oxidation, lime-soda
softening, granular activated carbon
adsorption, and reverse osmosis. In
addition, treatment studies are in
progress to evaluate solvent extraction
of gasification process wastewater to
recover phenolics and to reduce waste-
water loading of priority organic pollu-
tants. Biological oxidation of coal
gasification wastewater has shown
excellent removal efficiencies of major
and trace organic contaminants at
moderate loadings; addition of powdered
activated carbon provides lower effluent
COD and color. Gasification process
wastewater treated through brblogical
oxidation, lime-soda softening, and
activated carbon adsorption appears
suitable for reuse as cooling tower
makeup water. Solvent extraction is an
effective means to reduce organic
loadings to downstream processing
units. In addition, preliminary results
have shown that solvent extraction
removes chromatographable organic
contaminants to low levels.
Pilot Plant Evaluation of H2S,
COS, and COz Removal from
Crude Coal Gas by Refrigerated
Methanol
R.M. Kelly, R.W. Rousseau,
and J.K. Ferrell
North Carolina State University
Raleigh, NC 27650
Acid gas removal systems are a
necessary part of coal gasification
processes. Carbon dioxide must be
removed from gasifier product gas to
improve the energy content of the gas
and several sulfur compounds must be
taken out to protect downstream process
catalysts as well as reduce potential
sulfur emissions.
At North Carolina State University, an
integrated coal gasification/gas clean-
ing test facility is being used to study the
environmental and process implications
of several different acid gas removal
solvents. Details of the plant facilities
and operating procedures may be found
in a recent EPA technical report (Ferrell
et al., EPA-600/7-80-046a, March
1980). This paper presents some of the
initial results from acid gas removal
pilot plant operation, discusses several
aspects of methanol use for acid gas
removal, and outlines future experi-
mental work on this part of the process.
Pollution Control Guidance
Document for Low-Btu
Gasification Technology:
Background Studies
W.C. Thomas, R.C. Page, and
D.A. Dalrymple
Radian Corporation
Austin, TX 78758
The U.S. EPA is currently preparing a
Pollution Control Guidance Document
(PCGD) for low-Btu gasification (LBG)
facilities which use atmospheric-
pressure, fixed-bed gasifiers. The PCGD
is intended to aid industry and govern-
ment in their efforts to commercialize
LBG technology in an environmentally
acceptable manner. This paper presents
some of the preliminary results of
background studies performed to sup-
port the development of the LBG PCGD.
A model plant approach was used to
assess the environmental control needs
for LBG facilities. The plant configuration
and coal feed combinations for which
pollution controls were identified and
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evaluated were selected based on
existing and proposed plants in the U.S.
The major variables examined were coal
feed type (anthracite, lignite, and high-
and low-sulfur bituminous coals) and
degree of product gas purification
(production of hot, cooled, and desul-
furized low-Btu gas). In all, 11 combina-
tions of these variables (i.e., model
plants) were selected for study. Each
model plant had a nominal capacity of
45 MJ/s (150 x 106 Btu/hr) of low-Btu
gas.
Multimedia pollutant sources and
pollutants of potential concern were
identified and quantified for each model
plant. The bases for these determina-
tions were field test data and calculated
emissions projections. The EPA's low-
Btu gasification environmental assess-
ment program was the major source of
the field test data, but results from other
government and industry test programs
were also used.
Control/disposal options were identi-
fied and evaluated for each discharge
stream. Factors that were considered
included the need for control, current
industry practices, control equipment
performance, capital investment re-
quirements, annual operating costs,
energy impacts, and secondary environ-
mental discharges.
Development of a Pollution
Control Guidance Document
for Indirect Coal Liquefaction
K.W. Crawford
TRW, Inc.
Redondo Beach, CA 90278
and
WJ. Rhodes
Industrial Environmental
Research Laboratory
U.S. EPA, Research Triangle
Park, NC 27711
and
W.E. Corbett
Radian Corporation
Austin, TX 78758
Synfuels present both an opportunity
and a problem for EPA in terms of
developing a new environmentally
acceptable industry. The opportunity is
for EPA to encourage environmental
controls to be incorporated/developed
as an integral part of the first plant
designs rather than as "add on"
technology in an existing industry. The
8
problem is that an adequate data base
for promulgation of defensible regula-
tions for synfuel plants does not now
exist and will likely not exist until after
the first plants have been constructed
and operated for some period of time.
EPA has responded to this situation with
the "Pollution Control Guidance Docu-
ment (PCGD)" concept, in which the
best thinking of the various EPA R&D
program and regional offices is to be
provided to permitters and to industry in
the form of "guidance" for an interim
period rather than as regulations.
The Indirect Liquefaction (IL) PCGD is
one of the first such documents which
EPA is preparing with the technical
support of various contractors. TRW,
Radian, Versar, and RTI are involved in
the preparation of the data base for the
first technical draft of the IL PCGD.
This paper summarizes the technology
basis for control levels identified.
Initial Effort on a Pollution
Control Guidance Document:
Direct Liquefaction
J.E. Cotter, C.C. Shih, and
B. St. John
TRW, Inc.
Redondo Beach, CA 90278
Development of the pollution control
guidance document (PCGD) for direct
coal liquefaction is proceeding in
parallel with the permitting and con-
struction of the first demonstration-size
liquefaction plant, the SRC-II unit in Ft.
Martin, WV. In addition to the SRC-II
process, the PCGD will provide guidance
for the other major liquefaction tech-
nologies: SRC-I, H-Coal, and Exxon
Donor Solvent.
The control technology'guidance will
be related to baseline designs prepared
for each of the four liquefaction
processes, sized at 100,000 bbls/day
production. The baseline designs are
composed of material balance flow-
sheets and uncontrolled waste stream
calculations, using plant configurations
which are most likely to occur in future
commercial size plants. Variations of
the baseline designs will be considered
if they affect control decisions. A range
of feed coals have been selected for the
baseline cases, with at least one
common coal type that could be used by
all four processes. The present effort is
focused on identification of the pollu-
tants of concern using pilot-plant test
data from coal liquefaction developers,
DOE, and EPA sponsored testing pro-
grams. These data will be evaluated
with a variety of engineering analysis
methodologies, so that the subsequent
examination of control options can be
carried out.
The range of control options—air,
water, solid waste—will be selected
from those methods that have a known
track record in related industrial appli-
cations; e.g., petroleum refining, coke
ovens, and mining.
The control technologies will be
characterized parametrically according
to the inlet stream compositions and
quantities, and their percentage release
of specific pollutants. Finally, the cost of
control will be developed according to
the same parameters, with a range of
costs obtained depending on the com-
plexity and efficiency of control.
F. A. Ayer and N. S. Jones, compilers, are with Research Triangle Institute,
Research Triangle Park. NC 27709.
N. Dean Smith is the EPA Project Officer (see below).
The complete report, entitled "Symposium Proceedings: Environmental Aspects
of Fuel Conversion Technology, V (September 1980, St. Louis, MO)," (Order
No. PB 81 -245 045; Cost: $44.00, subject to change} wit/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
Research Triangle Park. -NC 27711
. S. GOVERNMENT PRINTING OFFICE: 1981/559-092/3324
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