EPA/600/9-90/012
March 1990
OPERATIONS AND RESEARCH
AT THE U.S. EPA INCINERATION RESEARCH
FACILITY: ANNUAL REPORT FOR FY89
By
L. R. Waterland
Acurex Corporation
Environmental Systems Division
Incineration Research Facility
Jefferson, Arkansas 72079
EPA Contract 68-03-3267
Project Officer
R. C. Thurnau
Waste Minimization, Destruction and Disposal Research Division
Risk Reduction Engineering Laboratory
Cincinnati, Ohio 45268
RISK REDUCTION ENGINEERING LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
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DISCLAIMER
This material has been funded wholly or in part by the U.S. Environmental Protection Agency
under Contract No. 68-03-3267 to Acurex Corporation. It has been subjected to the Agency's
review, and it has been approved for publication as an EPA document. Mention of trade names
or commercial products does not constitute endorsement or recommendation for use.
11
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FOREWORD
Today's rapidly developing and changing technologies and industrial
products and practices frequently carry with them the increased generation of
materials that, if improperly dealt with, can threaten both public health and
the environment. The U.S. Environmental Protection Agency is charged by
Congress with protecting the Nation's land, air, and water resources. Under a
mandate of national environmental laws, the Agency strives to formulate and
implement actions leading to a compatible balance between human activities and
the ability of natural systems to support and nurture life. These laws direct
the EPA to perform research to define our environmental problems, measure the
impacts, and search for solutions.
The Risk Reduction Engineering Laboratory is responsible for planning,
implementing, and managing research, development, and demonstration programs
to provide an authoritative, defensible engineering basis in support of the
policies, programs, and regulations of the EPA with respect to drinking water,
wastewater, pesticides, toxic substances, solid and hazardous wastes, and
Superfund-related activities. This publication is one of the products of that
research and provides a vital communication link between the researcher and
the user community.
This document reviews the accomplishments at the Incineration Research
Facility (IRF) in Jefferson, Arkansas, during Fiscal Year 1989. In that
twelve-month period, a major facility expansion and reconfiguration was
completed. Upon completion of the construction, incineration research and
testing at the Facility was resumed. Data for hazardous waste incinerator
regulation development for the Office of Solid Waste and a Superfund site
remediation treatability study for Region I and the Office of Emergency and
Remedial Response were the major activities in Fiscal Year 1989.
E. Timothy Oppelt, Director
Risk Reduction Engineering Laboratory
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ABSTRACT
The U.S. Environmental Protection Agency's Incineration Research
Facility in Jefferson, Arkansas, is an experimental facility which houses two
pilot-scale incinerators and the associated waste handling, emission control,
process control, and safety equipment, as well as on-site laboratory
facilities.
During Fiscal Year 1989, a major facility expansion and reconfiguration
construction effort was completed. Upon completion of the construction,
incineration testing at the Facility was resumed. Hazardous waste incinerator
trace metal emission regulation development for the Office of Solid Waste and
a Superfund site remediation treatability study for Region I and the Office of
Emergency and Remedial Response were major activities during the fiscal year.
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TABLE OF CONTENTS
DISCLAIMER
FOREWORD iii
ABSTRACT iv
1 INTRODUCTION 1
2 FACILITY UPGRADE CONSTRUCTION AND INCINERATION SYSTEM
RECONFIGURATION 4
2.1 FACILITY UPGRADE CONSTRUCTION 5
2.2 INCINERATION SYSTEM RECONFIGURATION 7
3 TRACE METAL EMISSION AND DISCHARGE TESTING IN THE
ROTARY KILN SYSTEM WITH THE VENTURI SCRUBBER/PACKED
COLUMN SCRUBBER AIR POLLUTION CONTROL SYSTEM 9
3.1 TEST PROGRAM 10
3.1.1 Synthetic Test Mixture 10
3.1.2 Test Conditions 10
3.1.3 Sampling and Analysis 15
3.2 TEST RESULTS 17
3.2.1 Trace Metal Discharge Distributions 17
3.2.2 Metal Distributions in Scrubber System 17
3.2.3 Effect of Incinerator Operating Conditions 19
3.2.4 Particle Size Distribution 22
3.2.5 Metal Particle Size Distribution 22
3.2.6 Chromium Valence State Distributions 24
3.3 CONCLUSIONS 24
TRACE METAL EMISSION AND DISCHARGE TESTING IN THE
ROTARY KILN SYSTEM WITH THE IONIZING WET SCRUBBER 27
4.1 TEST PROGRAM 27
4.1.1 Synthetic Waste Mixture 27
4.1.2 Test Conditions 30
4.1.3 Sampling and Analysis 30
4.2 TEST RESULTS 32
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TABLE OF CONTENTS (CONCLUDED)
Section page
5 INCINERABILITY TEST OF A CONTAMINATED SUPERFUND
SITE SOIL 41
5.1 TEST PROGRAM 41
5.1.1 Test Soil Characteristics 42
5.1.2 Muffle Furnace Test Plan 42
5.1.3 Incineration Testing 42
5.2 TEST RESULTS 45
5.2.1 Muffle Furnace Tests 45
5.2.2 Incineration Test Results 51
6 THIRD PARTY TESTING 56
7 EXTERNAL COMMUNICATIONS 57
8 PLANNED EFFORTS FOR FY90 61
REFERENCES 63
VI
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FIGURES
Number Page
1 Upgraded incineration research facility plan view 6
2 Schematic of the IRF rotary kiln system for the venturi/packed column
scrubber trace metal tests 11
3 Actual versus target operating temperatures for parametric trace
metal tests 14
4 Sampling summary for the chromium valence state and parametric
trace metals test series 16
5 Distribution of metals in discharge streams 18
6 Apparent venturi/packed column scrubber efficiencies for trace metals ... 19
7 Cadmium discharge distributions for the parametric trace metal tests .... 20
8 Lead discharge distributions for the parametric trace metal tests 21
9 Afterburner exit flue gas size distributions for the parametric
trace metal tests 22
10(a) Hazardous constituent trace metal size distributions in afterburner
exit flue gas particulate for the parametric trace metal tests 23
10(b) Nonhazardous trace metal size distributions in afterburner exit flue gas
particulate for the parametric trace metal tests 23
11 Schematic of the IRF rotary kiln system for the IWS trace metal tests .... 28
12 IWS test sampling protocol 33
13 Actual versus target operating conditions for the IWS trace metal tests ... 40
14 Sampling matrix 46
15 TCLP leachate As concentration versus soil and ash concentration 52
Vll
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TABLES
Number Page
1 Design characteristics of the IRF rotary kiln system for the
venturi/packed column scrubber trace metal tests 12
2 Integrated feed metal concentrations for the parametric
trace metals test series 13
3 POHC concentrations in clay/organic liquid feed 13
4 Total chromium discharge distributions for the chromium valence
state test series 25
5 Hexavalent chromium fraction for the chromium valence state test
series 25
6 Design characteristics of the IRF rotary kiln system for the IWS trace
metal tests 29
7 Target metal spike concentrations for the IWS tests 31
8 Target test conditions 32
9 Sampling and analysis matrix for the IWS trace metal tests 34
10 Multiple metals train impinger system reagents for the parametric trace
metal tests 38
11 Actual versus target operating conditions for the IWS tests 39
12 Soil arsenic and lead content 43
13 Semivolatile POHCs in the composite soil sample 43
14 Muffle furnace test samples 44
15 Target incineration test conditions 44
16 Sampling and analysis matrix summary for the Superfund soil
incineration tests 47
17 Muffle furnace test results 49
18 Muffle furnace test metal volatility at 982°C 50
19 Actual versus target operating conditions for the Baird and McGuire
incineration tests 53
20 Preliminary ash As and Pb data for the Baird and McGuire incineration
tests 55
viii
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TABLES (CONCLUDED)
Number Page
21 IRF program reports and presentations in FY89 58
22 Visitors to the IRF 59
IX
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SECTION 1
INTRODUCTION
The U.S. Environmental Protection Agency's (EPA) Incineration Research Facility
(IRF) in Jefferson, Arkansas, is an experimental facility which currently houses two pilot-scale
incinerators (a rotary kiln incineration system and a liquid injection incineration system) and
their associated waste handling, emission control, process control, and safety equipment. The
IRF also has onsite laboratory facilities for waste characterization and analysis of process
performance samples.
The objectives of research projects conducted at the IRF have been and continue to be
as follows:
• To develop technical information on the performance capability of the hazardous
waste incineration process to assist EPA Regional Offices and state environmental
agencies in the review, assessment, and issuance of reasonable and responsible
permits for regulated hazardous waste incineration facilities, and to assist waste
generators and incinerator operators in the preparation of permit applications
• To develop incinerator system performance data for regulated hazardous wastes
to support current Resource Conservation and Recovery Act (RCRA) incinerator
regulations and performance standards, and to provide a sound technical basis for
any necessary future standards
• To promote an understanding of the hazardous waste incineration process and
develop methods to predict the performance of incinerators of varying scale and
design for the major classes of incinerable hazardous wastes as a function of key
process operating variables. These methods would also help to simplify and
perhaps reduce the cost of permit and compliance testing.
• To develop methods of improving reliability and control of the incineration
process, including the use of destruction and removal efficiency (DRE) surrogates
• To provide a means of conducting specialized test burns (particularly for high
hazard or special waste materials so as Superfund site wastes) in support of
specific Regional Office permitting or enforcement actions and Regional Office
or private party Superfund site remediation efforts
• To test the performance of new or advanced incinerator components or
subsystems, or emission control devices
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During much of fiscal year 1989 (FY89, October 1,1988, to September 30, 1989), testing
activities were on hold while a major facility expansion and reconfiguration construction effort
was completed. This construction effort included:
• Constructing a building encompassing the existing 3,100-ft2 building to specifically
provide containment areas for blowdown storage tanks and expanded drummed
hazardous waste storage, storage areas for facility equipment not in use, and
additional workspace area such that the new plus existing building enclosed area
is brought to 15,200 ft2
• Relocating the rotary kiln incineration system (RKS) completely inside the existing
building and installing the ionizing wet scrubber, originally installed with the liquid
injection incineration system (LIS), so that it could be used with the RKS
• Installing a new carbon bed/HEPA filter secondary air pollution control system,
located within the existing 3,100-ft2 building, on the RKS
These efforts were largely completed by July 1989.
Upon completion of most of the major facility construction efforts, testing activities at
the facility resumed. In the final 10 weeks of FY89, incineration test activities were underway
for 6 weeks. Fifteen shakedown or incineration tests of nominally 4- to 8-hour duration were
performed. On an annual basis this level of testing productivity was down from that experienced
during FY87 and FY88.1'2 However, when the fact that the facility was only available for testing
for 10 weeks of the FY is considered, the level of testing productivity achieved during the
available time period in FY89 compares favorably to the level of productivity achieved during
the preceding two FYs.
Two major EPA Program/Regional Office programs were supported through test
activities in FY89.
• The hazardous waste incinerator trace metal emission regulation development
program within the Office of Solid Waste (OSW) via testing of the fate of several
trace metals fed to the RKS with an ionizing wet scrubber (IWS) for particulate
and acid gas control
• The Superfund site remediation program within the Office of Emergency and
Remedial Response (OERR) as administered by EPA Region I via treatability
testing of contaminated soil from the Baird and McGuire Superfund site in
Massachusetts
In addition, the results of a companion series of trace metal fate tests in the RKS with a venturi
scrubber/packed column scrubber for particulate and acid gas control, completed at the end of
FY88, were assembled and reported in FY89.
Activities completed during FY89 are discussed in more detail in the following sections.
Section 2 describes the facility construction, reconfiguration, and upgrade efforts completed;
Section 3 discusses the results of the trace metal, venturi/packed column scrubber tests reported
in FY89; Section 4 outlines the trace metal/IWS tests completed in July/August 1989; and
Section 5 describes the Region I Superfund soil treatability tests completed in September 1989.
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During FY89 a new initiative to identify and respond to potential third party users of
the IRF was begun. The Federal Technology Transfer Act specifically allows for the use of
Government facilities and equipment in joint projects with private sector concerns. In response,
the IRF operations and research contract was modified in FY89 to allow this type of usage.
Several third party inquiries were pursued during the year; three advanced to the proposal stage.
These are discussed in Section 6.
Finally, Section 7 discusses external communication activities associated with the facility
and its operation. Section 8 closes with an outline of plans for activities to be completed in
FY90.
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SECTION 2
FACILITY UPGRADE CONSTRUCTION AND INCINERATION
SYSTEM RECONFIGURATION
When the IRF was conceived, its primary use was expected to be performance of
pilot-scale incineration research using synthetic hazardous waste mixtures (soups). The facility
was constructed with that objective in mind. Thus, there was minimal provision for hazardous
waste or hazardous waste incineration residuals storage, and the onsite building facilities were
appropriate for an onsite staff of 14 doing incineration research at a moderate pace.
During FY86, the pace of testing efforts was accelerated significantly, and the staff size
increased appropriately.3 Continued acceleration of testing efforts and increases in onsite staff
size continued into FY87 and FY88 so that by FY88 the onsite staff had grown to 19 full-time
individuals. The test schedule completed in FY87 and FY88 encompassed 25 to 26 weeks of
testing (periods of incinerator system operation).1'2 Most of this testing was performed while
firing listed hazardous wastes. This increase in pace of test effort, operating staff size, and
frequency of actual hazardous waste testing exceeded the realistic capabilities of the physical
plant at the facility. Thus, it was decided early in 1987 to plan and initiate several facility
expansion efforts to bring the physical plant to a form which could handle the increased test
demands and substantially increased incidence of actual hazardous waste testing.
Initial facility expansion planning was completed in FY87. The conceptual design for
the upgraded facility was completed in January 1988 by the architect contracted to perform this
effort. The detailed design and contractor bid specification package was completed in
April 1988. A bid solicitation from the National Center for Toxicological Research (NCTR), the
host facility for the IRF, was issued in July 1988. The contract to perform the construction was
awarded in September.
Construction was initiated in October 1988, the beginning of FY89. The original
construction contract completion was scheduled for the second quarter of FY89. However,
owing to an unusually high frequency of inclement weather during the fall and early winter of
1988/89, it became clear that the construction schedule would slip into the third and perhaps
early fourth quarter of FY89. It was then decided to embark upon a reconfiguration of the
incineration systems at the facility so that one complete system could be located entirely within
the original facility building. This action would allow testing activity to resume relatively
independently of the new building completion schedule.
The new building construction and facility expansion efforts are discussed in Section 2.1.
Section 2.2 outlines the incineration system reconfiguration efforts completed.
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2.1 FACILITY UPGRADE CONSTRUCTION
The specific physical plant modifications and additions which were implemented in FY89
included:
• Upgrading the former outside air pollution control system area to approved
RCRA containment area status
• Adding liquid waste storage tank containment area
• Adding substantially increased containerized waste storage area
• Adding waste processing and general work areas
• Erecting a steel-walled building over all added containment and work areas,
including the existing incinerator building
• Constructing a new visitor paved parking area and providing nearby utilities for
relocated office space
Figure 1 is a plan view of the new building showing the additional enclosed containment
and work areas. The existing building, which was enclosed within the new building, is also shown
in the figure. As indicated, the total building area under roof has been expanded from the
former 3,100 ft2 to 15,200 ft2.
As noted in the introductory paragraphs to Section 2, the contract to perform the
building construction was awarded in September 1988. A contract start date of October 17 was
specified. During the first two weeks of FY89, the IRF staff dismantled all equipment placed
outside the former building to allow the contractor free access to all outside areas. This effort
included:
• Relocating various office and storage trailers to locations which would not
interfere with construction activities
• Relocating the temporary scrubber blowdown storage tanks
• Dismantling the RKS air and fuel supply measurement and control valving system
(gas train)
• Dismantling all outside air pollution control system (APCS) equipment
• Removing the RKS dump stack
• Installing the RKS heat exchanger system coolant/air heat exchanger and surge
tank on the pad previously prepared for them
In addition, all instrumentation in the instrument laboratory in the former building was relocated
to new space made available by NCTR so that this equipment could remain accessible and
operational during construction.
Building construction activities were initiated on schedule with site grading completed
by the end of October. Concrete building foundation footings and grade beams were installed
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during November and into December. However, unusually high precipitation during December
prevented completion of the concrete floor slabs. High precipitation continued through the
winter, resulting in increasing construction delays. The concrete floor slabs were not completed
until March 1989. The metal building frame was erected by the end of April. The metal shell
with roof was completed in May. Final completion of the building, with the exception of a few
remaining details, occurred in August, compared to an original schedule of March.
Since the expansion completed in FY89 represents a major modification to the facility,
modification of its hazardous waste management permit is required. This modification is
specifically required before the additional waste management units (the tank storage area and
the additional containerized waste storage area) are put into operation. Accordingly, an
application for a major modification to the facility's permit was submitted to the Arkansas
Department of Pollution Control and Ecology (ADPCE) on August 29, 1988. A notice of
deficiencies (NOD) was received from ADPCE on December 29. A revised application was
submitted on January 25, 1989. The current review schedule provides for issuing a draft permit
modification for public comment by early 1990.
22 INCINERATION SYSTEM RECONFIGURATION
In the configuration that existed prior to starting construction of the expanded facility,
the two IRF incineration systems (the RKS and the LIS) were located inside the existing IRF
building.2 The primary APCS for the RKS, consisting of a venturi scrubber/packed column
scrubber combination, was also located inside the building. However, the primary APCS for the
LIS, comprised of a packed column scrubber and an ionizing wet scrubber (IWS), and the
secondary APCS, consisting of a carbon bed absorber and a HEPA filter, were located outside
the building. All this outside equipment was dismantled in preparation for the new building
construction. This resulted in the inability to operate either incineration system during the
major portion of the new building construction period.
Original construction plans were to complete the new building concrete floor as quickly
as possible, at the latest by mid-January 1989. With the concrete floor completed, the IRF staff
could reassemble the APCS systems in their former locations (although now on concrete) and
reestablish the capability to perform incineration testing. However, it became clear in November
1988 that new building construction efforts were likely to fall behind schedule. In addition, the
initial series of tests planned for FY89 testing required installing the IWS system, formerly with
the LIS, so that it could be used with the RKS.
Recognizing that construction efforts were likely to continue to fall behind schedule, and
that some amount of equipment reconfiguration associated with the RKS would be required in
any event, it was decided to assemble a complete RKS with IWS and secondary APCS within
the existing building. This would allow testing in the RKS to proceed relatively independently
of the construction contractor's schedule. This effort required:
• Removing the LIS from the existing building
• Relocating the IWS in the existing building and connecting it to the RKS
• Relocating the ID fan in the existing building
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• Installing new RKS burners with a burner fuel and air supply flow measurement
and control valve system
• Installing a new secondary APCS in the existing building
• Reconfiguring and installing required new flue gas ductwork and stack, scrubber
system plumbing, and process control system wiring
A new burner with air and fuel control system (gas train) was required since the system
in place at the start of construction was owned by the existing burner system vendor, American
Combustion, Inc. It had been installed on the RKS specifically for use in the Superfund
Innovative Technology Evaluation (SITE) test program completed in FY88.2 This system was
returned to American Combustion. It was decided by joint EPA/IRF staff discussion not to
replace the originally installed RKS burner system (replaced by the American Combustion
system for the SITE program) because the original system was not sufficiently flexible.
It was also decided to install a completely new secondary APCS because the original
APCS had presented problems in past system operation, and its carbon packing had reached the
end of its useful life.
The LIS was removed from the building in November 1988. Reconfigured system design
efforts proceeded during December 1988 and January 1989, and equipment procurement was
completed in February. Equipment installation and system fabrication efforts proceeded from
March through June. New system startup occurred in early July, and shakedown was completed
by mid-July. The new system was placed into test operation in late July.
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SECTION 3
TRACE METAL EMISSION AND DISCHARGE TESTING IN THE
ROTARY KILN SYSTEM WITH THE VENTURI SCRUBBER/PACKED
COLUMN SCRUBBER AIR POLLUTION CONTROL SYSTEM
The RCRA hazardous waste incinerator performance standards promulgated by EPA
in January 1981 established particulate and HC1 emission limits and mandated 99.99 percent
destruction and removal efficiency (DRE) for principal organic hazardous constituents (POHCs).
However, subsequent risk assessments have suggested that, of the total risk to human health and
the environment from otherwise properly operated incinerators, hazardous constituent trace
metal emissions may pose the largest component. Currently, the data base on trace metal
emissions from incinerators available to support regulations is very sparse.
In response to these data needs, an extensive series of tests was conducted at the IRF
to support OSW (R. Holloway, S. Garg, coordinators) in the investigation of the fate of trace
metals fed to a rotary kiln incinerator equipped with a venturi scrubber/packed column scrubber
for particulate and acid gas control.
A primary objective of the tests was to investigate the fate of five hazardous constituent
trace metals fed in a synthetic solid waste matrix, as a function of incinerator operating
temperatures and feed chlorine content. These five metals were arsenic, barium, cadmium,
chromium, and lead (As, Ba, Cd, Cr, and Pb, respectively).
In addition, as part of the Risk Reduction Engineering Laboratory (RREL) program
to support trace metal emission regulation development, a separate OSW-sponsored effort by
another EPA contractor (C. C. Lee, coordinator) is developing a numerical model to aid in
predicting the relative distribution of trace metals in incinerator discharges. Thus, a second
objective was to supply data to evaluate the predictive capabilities of this model and to perhaps
guide further model refinement. To support this objective, the tests also included four
nonhazardous constituent trace metals, namely, bismuth, copper, magnesium, and strontium (Bi,
Cu, Mg, and Sr).
Finally, in the absence of information on the predominant valence state of chromium
in incinerator discharges, risk assessments have generally assumed that the entire discharge is
in the more toxic hexavalent form. This assumption has resulted in specifying conservative
chromium emission limits in the regulatory development process. Hence, another objective of
this program was to develop data on the valence state of chromium discharges as a function of
chlorine and chromium valence state in the feed.
The actual tests were completed at the end of FY88.2 However, data reduction,
interpretation, and reporting occurred in FY89. An outline of the test program and test results
is given in the following subsections.
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3.1 TEST PROGRAM
The test program consisted of both an eight-test parametric trace metals series (Tests 4
through 11) in which the test waste feed contained nine metals, and a three-test chromium
valence state series (Tests 1, 2, and 3) in which the feed contained either Cr( + 3) or Cr( + 6).
All tests were performed in the rotary kiln incinerator system (RKS) at the IRF.
Figure 2 gives a simplified schematic of the RKS configuration used for these tests, and
Table 1 summarizes its design characteristics. The system consists of a rotary kiln chamber, a
transition section, and a fired afterburner chamber. The primary air pollution control system
(APCS) for these tests consisted of a quench section, a venturi scrubber, and a packed column
scrubber. In addition, the originally installed air pollution control system, consisting of a carbon-
bed adsorber and a HEPA filter, was in place to ensure that organic compound and particulate
emissions were negligible during less-than-optimal test conditions.
3.1.1 Synthetic Test Mixture
The synthetic waste fired during the test program was composed of a clay absorbent
containing 30 percent (weight) organic liquids. Trace metals, in aqueous solution form, were
metered onto the solid, which was fed to the rotary kiln via a screw feeder.
Table 2 lists the metal concentrations of the synthetic feed waste for each test.
Chromium inherently present in the clay contributed about 50 percent of the actual feed
chromium. Magnesium in the clay accounted for virtually all of the actual feed magnesium.
The organic liquid, a mixture of toluene and varying amounts of tetrachloroethylene and
chlorobenzene, supplied the heat content and POHC. It also introduced chlorine at levels
ranging from zero to nominally 8 percent by weight. The analyzed fractions of these organics
are listed in Table 3.
3.1.2 Test Conditions
For all tests, the clay/organic liquid was fed at about 63 kg/hr (140 Ib/hr). The aqueous
metal solution was injected at 1 L/hr. Estimated solids residence time in the kiln was 1 hour.
The test variables for the parametric tests were feed chlorine content (0, 4, and 8 percent), kiln
temperature (816°, 871°, and 927°C), and afterburner temperature (982°, 1093°, and 1204°C).
The three levels for these variables constituted a factorial experimental matrix.
For the three chromium valence state tests, waste-feed chromium valence state and
chlorine contents were varied. Two tests had trivalent chromium feed. One of these had no
chlorine while the other had nominally 8-percent chlorine in the feed. The third test had
hexavalent chromium and no chlorine in the feed. Incinerator operating conditions during these
tests were held constant: kiln temperature at about 870°C, afterburner temperature at about
1093°C.
For all tests, excess air was targeted at 11.5- and 7.5-percent oxygen in the kiln and the
afterburner exit flue gas, respectively. These were successfully maintained within ±1.5 percent
for all tests. Figure 3 illustrates the actual and target incinerator temperatures. For all tests,
the primary air pollution control system operated at design conditions, with venturi pressure
drop at 5.0 to 6.2 kPa (20 to 25 inches W.C.) and scrubber pH averaging 7.1.
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TABLE 1. DESIGN CHARACTERISTICS OF THE IRF ROTARY KILN SYSTEM FOR
THE VENTURI/PACKED COLUMN SCRUBBER TRACE METAL TESTS
Characteristics of the Kiln Main Chamber
Length, outside 2.61 m (8 ft 7 in)
Diameter, outside 1.22 m (4 ft)
Length, inside 2.44 m (8 ft)
Diameter, inside 0.95 m (3 ft 1-1/2 in)
Chamber volume 1.74 m3 (61.4 ft)3
Construction 0.63 cm (0.25 in) thick cold rolled steel
Refractory 12.7 cm (5 in) thick high alumina castable refractory, variable depth
to produce a frustroconical effect for moving solids
Rotation Clockwise or counterclockwise 0.2 to 1.5 rpm
Solids retention 1 hr (at 0.2 rpm)
time
Burner American Combustion Burner, rated at 880 kW (3.0 MMBtu/hr) with
dynamic O2 enhancement capability
Primary fuel Propane
Feed system
Liquids Positive displacement pump via water-cooled lance
Sludges Moyno pump via front face, water-cooled lance
Solids Metered twin-auger screw feeder or fiber pack ram feeder
Temperature 1,010°C (1,850°F)
Characteristics of the Afterburner Chamber
Length, outside 3.05 m (10 ft)
Diameter, outside 1.22 m (4 ft)
Length, inside 2.74 m (9 ft)
Diameter, inside 0.91 m (3 ft)
Chamber volume 1.80 m3 (63.6 ft3)
Construction 0.63 cm (0.25 in) thick cold rolled steel
Refractory 15.24 cm (6 in) thick high alumina castable refractory
Gas residence time 1.2 to 2.5 sec, depending on temperature and excess air
Burner American Combustion Burner rated at 440 kW (1.5 MMBtu/hr) with
dynamic O2 enhancement capability
Primary fuel Propane
Temperature 1,200°C (2,200°F)
Characteristics of the Air Pollution Control System
System capacity
Inlet gas flow 107 m3/min (3773 acfm) at 1200°C (2200°F) and 101 kPa (14.7 psia)
Pressure drop
Venturi scrubber 7.5 kPa (30 in WC)
Packed column 1.0 kPa (4 in WC)
Liquid flow
Venturi scrubber 77.2 L/min (20.4 gpm) at 69 kPa (10 psig)
Packed column 116 L/min (30.6 gpm) at 69 kPa (10 psig)
pH control Feedback control by NaOH solution addition
12
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TABLE 2. INTEGRATED FEED METAL CONCENTRATIONS FOR THE PARAMETRIC
TRACE METALS TEST SERIES
Metal concentration (ppm)
Indigenous Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 Test 7 Test 8 Test 9 Test 10
Meul (in clay) (9/29/89) (9/28/89) (9/26/89) (9/14/88) (8/25/88) (9/16/88) (8/30/88) (9/7/88) (9/9/88) (9/20/88)
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TABLES. POHC
Test
Mixture 1
Target
Composition
Measured composition
4
Mixture 2
Target
Composition
Measured composition
6
8
9
10
Mixture 3
Target
Composition
Measured composition
3
11
47
54
180
10
89 93
1.7
490
60
36 46 38 38 37 57
44 53 53 55 56 54
110 180 130 160 190 180
6988 9 10
77 85 85 89 89 90
370 480 480 510 500 480
40 50 51 53 52 58
17,700 17,600 16,700 17,000 17,700 17,900 16,200
330
CONCENTRATIONS
Test Date Toluene
28.6
9/29/88 27.9
9/28/88 27.9
9/14/88 23.2
21.7
8/25/88 16.7
9/16/88 20.5
8/30/88 19.7
9/07/88 17.1
9/09/88 16.5
9/20/88 22.5
14.9
9/26/88 15.9
9/22/88 14.6
200 270 250 270 290 330
IN CLAY/ORGANIC LIQUID FEED
Weight percent in mixture
Chlorine
Tetrachloroethylene Chlorobenzene content*
0 0 0
0 00
0 00
0 00
3.4 3.4 4
3.0 3.6 3.7
3.6 3.5 4.2
3.2 3.2 3.8
3.1 3.0 3.6
2.9 2.9 3.4
3.9 3.8 4.6
6.9 6.9 8
7.5 6.7 8.5
7.1 6.9 8.3
Test 11
(9/22/88)
52
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480
49
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290
Based on measured tetrachloroethvjene and chlorobenzene concentrations.
13
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14
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3.13 Sampling and Analysis
Figure 4 identifies the sampling locations for the tests. Continuous emission monitors
(CEMs) were arranged to monitor O2, CO, CO2, NOX, and total unburned hydrocarbon (TUHC)
concentrations at the kiln exit, the afterburner exit, the scrubber exit, and the stack. Other
samples collected were feed, scrubber blowdown water, kiln ash, and flue gas at the afterburner
and scrubber exits. Samples were also collected at the stack for evaluating hazardous waste
management permit compliance. Since the target analytes differed for the two test series, the
sampling and analysis matrix was tailored specifically for each series.
For the parametric trace metal tests, composite feed samples were subjected to ultimate,
volatile organic, and trace metal analyses. Virgin clay samples were subjected to trace metal
analyses to determine background metal concentrations. Composite kiln ash samples were
collected and subjected to metal analysis.
Flue gas sampling at the afterburner exit consisted of volatile organic sampling train
(VOST) sampling and a variation of a Reference Method 17 train which allowed collection of
large paniculate mass, HC1, and any trace metals not collected in the paniculate. At the
scrubber exit, a VOST and a Method 5 train modified for trace metal capture collected samples
for volatile organic and metal analyses, respectively. At the stack, a Method 5 train sampled for
HC1 and particulate for permit compliance.
The sampling trains for metals capture (the variations of the Method 17 and Method 5
trains noted above) included impingers charged with a 5 percent nitric acid/10 percent hydrogen
peroxide solution. These impingers were included to ensure that any metal not collected with
the particulate (i.e., metal in the vapor phase at the particulate collection temperature or metal
dissolved in moisture carryover from the particulate collection section of the sampling train)
would be captured in the impinger.
For the chromium-valence tests, composite feed samples were subjected to ultimate,
volatile organic, and total chromium analyses. Composite grab samples of chromium spike
solution, scrubber blowdown, and kiln ash were collected during each test for total chromium and
Cr( + 6) analyses.
Flue-gas sampling employed two variations of a Method 5 train. At the afterburner exit,
one train with impingers containing 0.1N NaOH followed by HNO3/H2O2 sampled for
particulate load and total chromium. Simultaneously, a second train with me filter removed
sampled for Cr( + 6) and, during test 3, HC1. Impingers in this train contained 0.1N NaOH,
which was believed better able to preserve Cr( + 6). A similar arrangement was duplicated at the
scrubber exit.
The VOST samples were subjected to purge and trap GC/FID for organic analysis. The
grab composite samples of feed, ash, scrubber liquor, and the Method 5 and Method 17 train
samples were subjected to inductively coupled argon plasma (ICAP) spectroscopy or atomic
absorption (AA) spectroscopy methods for metal analysis.
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32 TEST RESULTS
32.1 Trace Metal Discharge Distributions
When subjected to incineration conditions, the metals are expected to vaporize to
varying degrees, depending on their volatilities. Figure 5 shows the amounts of metal found in
each discharge stream, normalized to the total found in the three discharge streams, namely,
kiln ash, scrubber exit flue gas, and scrubber liquor. In Figure 5, the bar for each metal
represents the range in the fraction accounted for by each discharge stream over all eight
parametric tests, with the average fraction from all tests noted by the midrange tic mark. Metal
discharge distribution data in Figure 5 is plotted versus the metal's volatility temperature. A
metal's volatility temperature is the temperature at which a principal vapor species of the metal
has a vapor pressure of 1Q-6 atm. Figure 5 shows that the more volatile metals, i.e., those having
lower volatility temperatures (Cd, Bi, and Pb), tend to be less prevalent in the kiln ash. The
more refractory metals, i.e., those with higher volatility temperatures (Ba, Cu, Sr, Cr, and Mg)
tend to be found predominantly in the kiln ash. This observation is consistent with expectation.
The notable exception, arsenic, exhibited unexpected refractory behavior and remained
predominantly in the kiln ash. Arsenic's plotted volatility temperature is that for As2O3. The
fact that arsenic was observed to be significantly less volatile than expected, based on the As2O3
volatility temperature, suggests that As2O3 was not a predominant arsenic species in the
incinerator and that some other, less volatile species (perhaps an arsenate) was the favored
arsenic compound. An alternative explanation is that strong chemical interaction occurred
between arsenic and the clay feed matrix.
It is interesting to note the sharp break in observed volatility between lead and bismuth
(average kiln ash fractions of 20 to 32 percent) and barium (average kiln ash fraction of
77 percent). Six of the eight parametric tests were performed with kiln temperature of 870°C,
one at 825°C, and one at 930°C. These temperatures are right in the range of the volatility
temperature change from 621°C (Bi) and 627°C (Pb) to 849°C (Ba).
322 Metal Distributions in Scrubber System
The above observations suggest that substantial portions of the volatile metals escaped
the incinerator. For effective control, these need to be captured by the venturi and packed
column scrubber system. Figure 6 shows that this may not be the case. The apparent scrubber
collection efficiency averaged only 36 to 45 percent for the volatile metals (Cd, Bi, and Pb).
Collection efficiencies for the most refractory metals (Sr, Mg, and Cr) averaged greater than
65 percent. This behavior is consistent with expectation. Most metal vaporized at some point
in the incinerator will ultimately condense when the flue gas is cooled to its scrubber exit
temperature of about 75°C. Condensation occurs via fume formation, or condensation onto
available flue gas particulate. Fume formation results in very fine particulate. Condensation
onto available particulate results in concentrating the metal in fine particulate, since
condensation is a per unit of surface area event, and the surface-area-to-mass ratio is increased
in fine particulate. Both mechanisms tend to concentrate volatilized metal in fine particulate.
Since venturi scrubbers collect coarse particulate at greater efficiency than fine particulate, a
poorer efficiency in collecting volatile metals is expected.
This same mechanism may explain the poor observed collection efficiency for arsenic
and, perhaps, copper. The above discussion noted that arsenic was observed to be relatively
refractory based on its high kiln ash fraction. However, any amount carried in entrained flyash
17
-------
KILN ASH
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Figure 5. Distribution of metals in discharge streams.
18
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100
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Variable: Kiln Exit Temperature
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Figure 7. Cadmium discharge distributions for the parametric trace metal tests.
20
-------
Variable Kiln Exit Temperatur
Variable Afterburner Exit Temperature
Variable Feed Chlorine Content
Scrubber Exit Gas
Scrubber Liquor
Figure 8. Lead discharge distributions for the parametric trace metal tests.
21
-------
3.2.4 Particle Size Distribution
Figure 9 shows that the afterburner exit particle size distributions for all tests were
roughly log normal. The absence of chlorine in the waste appears to shift the particles to a
larger size distribution. This is consistent with the expectation that the presence of chlorine
increases the volatility of the feed inorganic constituents. In such a case, condensation of
volatilized inorganic compounds would tend to produce finer particles.
32.5 Metal Particle Size Distribution
Trace metal contents in four size fractions in afterburner exit particulate (nominally <2,
2 to 4, 4 to 10, and > 10 /im) were analyzed. Figure 10(a) shows the average fractions of arsenic,
barium, cadmium, chromium, and lead that were distributed over the four size ranges. Similar
results for the four nonhazardous constituent metals, bismuth, copper, magnesium, and
strontium, are shown in Figure 10(b).
It appears that the more volatile metals, bismuth and barium, tend to concentrate on
the finer particles. The relatively nonvolatile metals, chromium, copper, magnesium, and
strontium, tend to concentrate on the larger particles. This observation is consistent with the
volatilization/condensation mechanism discussed previously.
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Figure 9. Afterburner exit flue gas size distributions for the parametric trace metal tests.
22
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Figure 10(b). Nonhazardous trace metal size distributions in afterburner exit flue gas
particulate for the parametric trace metal tests.
23
-------
3.2.6 Chromium Valence State Distributions
Chromium discharge distributions for the focused chromium valence state tests,
expressed as fractions of total measured chromium, are tabulated in Table 4. It is clear that, in
these tests as well, chromium remained predominantly in the kiln ash (greater than 80 percent
of the total measured). The scrubber exit flue gas and blowdown liquor streams combined
accounted for less than 5 percent of the discharged chromium with no feed chlorine. With
chlorine in the feed, the flue gas chromium fraction doubled to about 4 percent. Similarly, the
scrubber blowdown liquor chromium fraction increased to about 11 percent.
Table 5 summarizes the fraction of the total chromium in feed and discharge streams
analyzed as being Cr( + 6). As shown, the feed was 52 percent Cr( + 6) for the test with Cr( + 6)
spiked into the feed and was analyzed as 2 percent Cr( + 6) for the tests with Cr( + 3) spiked into
the feed. For all tests, the kiln ash chromium was comprised of negligible amounts of Cr( + 6).
The scrubber exit flue gas Cr( + 6) fraction was the same (12 to 16 percent) regardless
of whether Cr( + 6) was present in the feed, provided there was no feed chlorine. In contrast,
for the case in which the feed contained chlorine, roughly half the scrubber exit flue gas
chromium was Cr( + 6). This would be expected if some of the entrained paniculate chromium
from the kiln vaporized in the hotter afterburner and reacted with the flue gas chlorine to form
chromyl chloride (CrO2Cl2), a relatively stable compound with chromium as Cr( + 6).
The scrubber liquor Cr( + 6) fraction for the test with Cr( + 6) in the feed was
significantly higher than for the other two tests with only Cr( + 3) in the feed. This is as expected
if some of the chromium in the scrubber inlet flue gas was present as soluble Cr( + 6) species
(CrO4= and Cr2O7=).
33 CONCLUSIONS
Test conclusions include:
• The observed metal volatilities, based upon normalized discharge distribution data,
generally agree with theoretical predictions based on volatility temperature. A
notable exception was arsenic, which is theoretically the most volatile metal; it
exhibited one of the lowest observed volatilities.
• Cadmium, bismuth, and lead were relatively volatile, with an average of less than
32 percent of the discharge metal accounted for by the kiln ash. Barium, copper,
strontium, chromium, magnesium, and arsenic were more refractory, with greater
than 75 percent of the metal discharge accounted for by the kiln ash.
• Apparent venturi/packed column scrubber collection efficiencies decrease as
metal volatility increases
• Increasing feed chlorine content measurably increased the volatility of the volatile
metals (cadmium, lead, and bismuth) and of copper (less volatile)
• Consistent with expectation, increasing kiln temperature tends to slightly decrease
the fraction of volatile metal accounted for by the kiln ash
24
-------
TABLE 4. TOTAL CHROMIUM DISCHARGE DISTRIBUTIONS FOR THE
CHROMIUM VALENCE STATE TEST SERIES
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Apparent scrubber Cr
removal efficiency
TABLE 5.
Composite feed
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total Cr fraction (percent of measured)
Test 1 Test 2 Test 3
Cr( + 6) feed, no Cl Cr( + 3) feed, no Cl Cr( + 3) feed, 8.5% feed Cl
95.5 95.2 84.4
1.3 1.8 4.2
3.2 3.0 11.4
100.0 100.0 100.0
71 63 73
HEXAVALENT CHROMIUM FRACTION FOR THE CHROMIUM
VALENCE STATE TEST SERIES
Cr( + 6)/totaI Cr(percent)
Test 1 Test 2 Test 3
Cr( + 6) feed, no Cl Cr( + 3) feed, no Cl Cr(+3) feed, 8.5% feed Cl
52 2 2
0.3 0.2 0.1
12 16 48
57 21 28
25
-------
• Discharge distributions of the nonvolatile metals were generally unaffected by
variations in the test variables over the range tested
• Afterburner exit flue gas particle size distributions were roughly log-normal; the
presence of chlorine appeared to shift the particles to a finer distribution
• In the scrubber exit flue gas, chromium exists predominantly in the trivalent form
regardless of valence state in the feed, provided the feed contained no chlorine;
its hexavalent fraction increased in the test where chlorine was present in the feed
Test results were documented in the test report:
• D. J. Fournier, Jr., W. E. Whitworth, Jr., J. W. Lee, and L. R. Waterland, "Pilot
Scale Evaluation of the Fate of Trace Metals in a Rotary Kiln Incinerator with
a Venturi Scrubber/Packed Column Scrubber," draft April 1989, revised
October 1989.
In addition, test results were presented in two technical papers:
• L. R. Waterland, D. J. Fournier, Jr., W. E. Whitworth, "Pilot-Scale Testing to
Evaluate the Fate of Trace Metals in Rotary Kiln Incineration." Presented at the
1989 Summer National AIChE Meeting, Philadelphia, Pennsylvania. August 1989.
• G. J. Carroll, R. C. Thurnau, R. E. Mournighan, L. R. Waterland, J. W. Lee, and
D. J. Fournier, Jr. "The Partitioning of Metals in Rotary Kiln Incineration,"
presented at the Third International Conference on New Frontiers for Hazardous
Waste Management, Pittsburgh, Pennsylvania. September 1989.
26
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SECTION 4
TRACE METAL EMISSION AND DISCHARGE TESTING IN THE ROTARY
KILN SYSTEM WITH THE IONIZING WET SCRUBBER
Section 3 discussed the results from a series of tests to evaluate the fate of trace metals
in a rotary kiln incinerator equipped with a venturi scrubber/packed column scrubber for
particulate and acid gas removal. As noted in Section 3, the primary objective of the tests was
to establish a data base of emission and residual discharge trace metal composition to support
OSW hazardous waste incinerator trace metal regulation development. To this end, data on the
relative performance of different APCSs in controlling flue gas emissions of the trace metals of
concern are of high interest to OSW. Thus, a second series of trace metal evaluation tests was
completed during FY89 with an IWS used instead of the venturi scrubber/packed column
scrubber combination for particulate and acid gas control.
The IWS test series consisted of nine tests and was completed over a 4-week period
from late July to mid-August 1989. In addition to supporting the OSW objectives noted above,
a sampling team supported by EPA's Atmospheric Research and Emissions Assessment
Laboratory (AREAL, T. Ward, coordinator) performed simultaneous sampling during several
tests of flue gas emissions as part of a metals sampling method validation study. The following
subsections discuss the scope of the tests performed and preliminary test results.
4.1 TEST PROGRAM
This test program was conducted in the RKS after its reconfiguration (discussed in
Section 2.2). The major differences in the RKS configuration for this test program compared
to the venturi/packed column scrubber test program discussed in Section 3 were:
• A new burner with fuel and air supply flow measurement and control system was
installed prior to this test program
• The IWS was installed and used as the primary APCS instead of the
venturi/packed column scrubber
Figure 11 is a simplified schematic of the RKS configuration employed for these tests; Table 6
gives the design characteristics of the key system components.
4.1.1 Synthetic Waste Mixture
The basic feed material for these tests was essentially the same as that used for the
venturi/packed column scrubber tests discussed in Section 3. It consisted of an organic liquid
mixture containing toluene and varying amounts of chlorobenzene and tetrachloroethylene, to
vary mixture chlorine content, combined with a clay absorbent in the ratio of 0.4 kg organic
liquid to 1 kg clay. As for the venturi/packed column scrubber tests, feed chlorine content was
27
-------
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28
-------
TABLE 6. DESIGN CHARACTERISTICS OF THE IRF ROTARY KILN SYSTEM
FOR THE IWS TRACE METAL TESTS
Characteristics of the Kiln Main Chamber
Length, outside 2.61 m (8 ft - 7 in)
Diameter, outside 1.22 m (4 ft)
Length, inside 2.44 m (8 ft)
Diameter, inside 0.95 m (3 ft - 1-1/2 in)
Chamber volume 1.74 m3 (61.4 ft3)
Construction 0.63 cm (0.25 in) thick cold rolled steel
Refractory 12.7 cm (5 in) thick high alumina castable refractory, variable
depth to produce a frustroconical effect for moving solids
Rotation Clockwise or counterclockwise 0.2 to 1.5 rpm
Solids retention time 1 hr (at 0.2 rpm)
Burner North American burner, rated at 590 kW
(2.0 MMBtu/hr) with liquid feed capability
Primary fuel Natural gas
Feed system
Liquids Positive displacement pump via water-cooled lance
Sludges Moyno pump via front face, water-cooled lance
Solids Metered twin-auger screw feeder or fiber pack ram feeder
Temperature 1,010°C (1,850°F)
Characteristics of the Afterburner Chamber
Length, outside 3.05 m (10 ft)
Diameter, outside 1.22 m (4 ft)
Length, inside 2.74 m (9 ft)
Diameter, inside 0.91 m (3 ft)
Chamber volume 1.80 m3 (63.6 ft3)
Construction 0.63 cm (0.25 in) thick cold rolled steel
Refractory 15.24 cm (6 in) thick high alumina castable refractory
Gas residence time 1.2 to 2.5 sec depending on temperature and excess air
Burner North American burner rated at 590 kW (2.0 MMBtu/hr) with
liquid feed capability
Primary fuel Natural gas
Temperature 1,200°C (2,200°F)
Characteristics of the Ionizing Wet Scrubber APCD
System capacity 85 m3/min (3,000 acfm) at 78°C (172°F) and 101 kPa (14.7 psia)
inlet gas flow
Pressure drop 1.5 kPa (6 in we)
Liquid flow 15.1 L/min (4 gpm) at 345 kPa (50 psig)
pH control Feed back control by NaOH solution addition
29
-------
a test variable. The three target chlorine concentrations in the clay/organic liquid mixture
were 0, 4, and 8 percent.
As also done in the venturi/packed column scrubber tests, most of the trace metals
were introduced into the feed by adding them in aqueous solution to the clay/organic liquid
mixture at the head of the kiln screw feeder. Since the clay contained sufficient quantities of
chromium and magnesium (equivalent to about 50 ppm Cr and 1.7 percent Mg in the final
feed mixture), these were not added to the aqueous spike solution. Solution concentrations
of several of the other metals differed somewhat from the concentrations used in the
venturi/packed column scrubber tests. Table 7 summarizes the target feed metal
concentrations (Cr and Mg excepted) for the IWS tests.
4.12 Test Conditions
The test variables for the test series were the same as those for the parametric
venturi/packed column scrubber tests. These were the chlorine content of the feed synthetic
waste, kiln temperature, and afterburner temperature. Seven specific combinations of these
as test points were tested based on a factorial experimental design for three variables varied
over three levels. One test condition was tested in triplicate to give a measure of
measurement precision and to serve as the trial burn for the RKS/IWS system configuration.
Feed mixture chlorine content was varied from 0 to 8 percent, kiln temperature from
targets of 816° to 927°C (1500° to 1700°F), and afterburner temperature from targets of 982°
to 1204°C (1800° to 2200°F). Table 8 gives the target values for each of the test variables for
the seven test points specified by the factorial experimental design algorithm. The seventh
and eight test points were the replicates of Test Point 4.
All tests were to be performed at the same nominal kiln exit flue gas O2
(11.5 percent), afterburner exit flue gas O2 (8.0 percent), and synthetic waste feedrate
(63 kg/hr (140 Ib/hr) of which 18 kg/hr (40 Ib/hr) is the organic liquid matrix).
No chromium valence state testing was performed in this test series.
4.13 Sampling and Analysis
The sampling and analysis protocol employed for these tests was essentially the same
as that employed in the parametric venturi/packed column scrubber tests as discussed in
Section 3.1.3. In general, sampling for each test consisted of obtaining:
• A composite sample of all feed materials (clay/organic liquid and aqueous
metal spike solution)
• A composite sample of the kiln ash
• Several samples of the scrubber blowdown water over time
• Samples of the flue gas at the afterburner and scrubber exits for particulate
collection by size (afterburner exit only) and for metal capture in the
particulate and backup impinger train
• Samples of the flue gas at the afterburner and scrubber exits for volatile
organic hazardous constituents using a volatile organic sampling train (VOST)
30
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TABLE 8. TARGET TEST CONDITIONS
Feed mixture Cl Kiln exit Afterburner exit
Test content, percent temperature, °C (°F) temperature, °C (°F)
1 0 871 (1600) 1,093 (2000)
2 4 816 (1500) 1,093 (2000)
3 4 927 (1700) 1,093 (2000)
4 4 871 (1600) 1,093 (2000)
5 4 871 (1600) 982 (1800)
6 4 871 (1600) 1,204 (2200)
T 4 871 (1600) 1,093 (2000)
8a 4 871 (1600) 1,093 (2000)
9 8 871 (1,600) 1,093 (2,000)
aTest points 7 and 8 are replicates of test point 4
• Continuous monitor sampling of flue gas O2, CO2, and NOX and total unburned
hydrocarbon (TUHC) at the kiln, afterburner, and scrubber exits and in the stack
Figure 12 identifies the nominal location of the sampling points. Table 9 summarizes the specific
sampling and analysis procedures used.
All the sampling and analysis procedures noted in Table 9 are standard methods with
the exception of the sampling methods for flue gas metals. The Methods 17 and 5 procedures
used to collect flue gas samples for metals analysis at the afterburner exit and IWS exit,
respectively, employed reference method sampling trains with impinger contents formulated for
metal capture. Impinger contents used were as noted in Table 10.
In addition, Method 17 train at the afterburner exit collected particulate in an oversized
thimble placed within the sampling probe. After obtaining the total particulate weight, the
particulate in these samples was divided according to terminal velocities in air using a centrifugal
classifier. This device is described in the ASME Power Test Code 28.7 After classification,
individual size cut samples were combined into five size ranges for analysis. The five size ranges
are nominally < 2, 2 to 4, 4 to 10, 10 to 30, and >30 /im.
42 TEST RESULTS
As noted in the introductory paragraphs to Section 4, the tests were completed in
mid-August 1989. Table 11 lists the test incinerator operating conditions achieved (temperatures
and flue gas O2 levels) and compares these to respective target conditions. Figure 13 presents
a graphical summary of the incinerator temperature data from Table 11.
Figure 13 illustrates that average kiln temperatures achieved compared favorably with
target kiln temperatures (within 16°C (79°F)) for all tests except Test 1. For this test, average
kiln temperature was 25°C (52°F) higher than target. Average afterburner temperature was
within 10°C (18°F) of target for all tests at the midpoint target afterburner temperature (1093°C
32
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TABLE 10. MULTIPLE METALS TRAIN IMPINGER
SYSTEM REAGENTS FOR THE
PARAMETRIC TRACE METAL TESTS
Impinger
number Reagent Quantity
1 Empty
2 0.1N NaOH 100 mL
3 5 percent HNO3 and 100 mL
10 percent H2O2
4 5 percent HNO3 and 100 mL
10 percent H2O2
5 Silica gel 750g
(2000T)). However, average afterburner temperature was 35°C (63°F) higher than the target
982°C (1800°F) low afterburner temperature test and 42°C (75°F) lower than the target
1204°C (2200°F) high afterburner temperature test.
Comparing Figure 13 with Figure 3 shows that the variations in incinerator
temperatures over a test were greater for the IWS tests than for the analogous
venturi/packed column scrubber tests. The venturi/packed column scrubber tests were
performed with an automated process control system in place (the American Combustion
system noted in Section 2.2). This system was returned to the vendor, as also discussed in
Section 2.2. Its replacement at the time of the IWS tests was a manual system which did not
allow fine tuned control of incinerator operation. In addition, this test series was completed
immediately after the installation of a new burner and burner management system in the
RKS. The tests exhibiting the greatest variations in test temperature were tests 9 and 4.
These were the first two tests performed after system restart. The lesser variations in
operating temperatures in subsequent tests reflect increased operating experience with a new
system.
The data in Table 11 show that average afterburner exit flue gas O2 achieved agreed
well with the target level of 8.0 percent. Kiln exit flue gas O2 was generally higher than the
target level of 11.5 percent. However, it was generally comparable from test to test at about
12.5 percent.
At the end of FY89, test sample analyses and data evaluation and interpretation
were underway. These will be completed and test results reported in FY90.
38
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Figure 13. Actual versus target operating conditions for the IWS trace metal tests.
40
-------
SECTION 5
INCINERABILITY TEST OF A CONTAMINATED
SUPERFUND SITE SOIL
One of the primary missions of the IRF is to support EPA Regional Offices in
evaluations of the potential of incineration as a treatment option for contaminated soils at
Superfund sites. One priority site in Region I is the Baird and McGuire site in Holbrook,
Massachusetts. EPA Region I (M. Sanderson, P. Fitzsimmons, Region I; J. Ehresmann, COE,
Coordinators) requested that test burns of contaminated soil from this site be performed at the
IRF during FY89 to support evaluations of the suitability of incineration as a treatment
technology for this soil.
With respect to the incinerability evaluation, the primary concern is whether incineration
will effectively destroy the organic contaminants in the soils. A secondary concern relates to the
fact that the site soil is contaminated to varying degrees with arsenic and lead. The fate of
arsenic and lead in soil when it is subjected to incineration is currently unknown.
The purpose of these tests was to evaluate the incinerability of the Baird and McGuire
site soils with regard to organic constituent destruction and to identify the distribution of arsenic
in the discharge streams during incineration of arsenic-contaminated soil. The test burn was
designed to evaluate the effects of varying incinerator operating conditions on organic
contaminant destruction and on the fate of arsenic in the soil. Determining the effectiveness
of the air pollution control system in removing any flue gas arsenic and lead was also a test
objective. Analysis of the bottom ash will indicate whether treatment by incineration will
generate a soil environmentally suitable for redeposit at the Superfund site during full-scale
remediation.
5.1 TEST PROGRAM
The test program for the Baird and McGuire soil evaluation had two components.
Initially a series of bench scale experiments was performed to evaluate the leachability
characteristics of the arsenic and the lead in the soil after incineration as a function of the
arsenic/lead concentration in the soil. Incineration of soil samples was simulated by heating
them to incineration temperatures in a muffle furnace.
The second component of the test program consisted of a set of five incineration tests
in the RKS at the IRF. These tests were aimed at determining the fate of the arsenic and lead
in the soil as a function of kiln temperature and kiln excess air level. These tests were
performed in the RKS with the IWS in place as the primary APCS. A schematic of the RKS
in this configuration is provided in Figure 11; the design characteristics of the system are
summarized in Table 6.
41
-------
5.1.1 Test Soil Characteristics
Contaminated soil for the tests was excavated from the site during August 1989. Three
soil types were obtained for testing. For the muffle furnace tests, relatively small (about 5 kg)
samples each of soil from an area known to contain soil with high levels of arsenic contamination
and from an area known to be relatively uncontaminated by arsenic were obtained. For the
parametric incineration tests, a bulk sample (nominally 1350 kg or 3000 Ib) was excavated, mixed
at the site in an attempt to give a uniform sample, and packaged into six 55-gal drums.
The two muffle furnace samples and a characterization sample of each of the
incineration test drums were forwarded to the IRF, the former for muffle furnace testing and
the latter for characterization analyses prior to accepting the bulk shipment for testing. The two
muffle furnace test samples were analyzed for arsenic and lead and subjected to toxicity
characteristic leaching procedure (TCLP) extraction with extracts analyzed for arsenic and lead.
Results are summarized in Table 12. As shown, the highly contaminated soil contained about
650 ppm As and 45 ppm Pb. The background (uncontaminated) soil contained negligible
(<5 ppm) As and 14 ppm Pb. Most of the As and Pb in both soils was relatively immobile
with respect to TCLP extraction.
The characterization samples received were composited into a single sample which was
analyzed for semivolatile POHCs. Results are shown in Table 13. Of the semivolatile organic
hazardous substance list (HSL) compounds, only p,p'-DDT and its derivatives were found above
method detection limits.
5.12 Muffle Furnace Test Plan
As noted in the introduction to Section 5, the fate of arsenic and lead during
incineration of the site soil is uncertain. In an actual site remediation via incineration, soil with
very high arsenic/lead levels can be blended with soil of low arsenic/lead contamination to give
an incineration feed which results in a low concentration of leachable arsenic in the kiln ash.
But, the a priori unknown is how low the feed arsenic concentration must be.
The objective of the muffle furnace tests was to develop the data to suggest appropriate
maximum feed arsenic/lead concentrations. In the tests performed, nine samples were prepared,
as outlined in Table 14. Each sample was heated in a muffle furnace at 982°C (1800°F) for
1 hr. The weight loss (moisture and volatiles) was determined for each sample. Then each
resulting ash was analyzed for As and Pb, and TCLP leachates of each were also analyzed for
As and Pb.
5.13 Incineration Testing
A separate series of pilot-scale incineration tests was also performed in the RKS at the
IRF. The primary objectives of these tests were to establish that incineration effectively destroys
the organic contaminants in the soil, and to evaluate the fate of arsenic and lead during
incineration as a function of incineration conditions.
The incineration condition test variables were kiln temperature and kiln excess air
level. Kiln temperature was to have been varied from 816 to 982°C (1500 to 1800°F) and excess
air from a kiln exit flue gas O2 of 6 to 10 percent in the matrix shown in Table 15.
42
-------
TABLE 12. SOIL ARSENIC AND LEAD CONTENT
Soil concentration
(mg/kg)
Sample
Contaminated soil
Sample
Duplicate
Average
Background soil
Sample
Duplicate
Average
As
600
710
655
<5
<5
<5
Pb
59
31
45
13.4
14.4
14
TCLP leachate |
concentration o
(mg/L) ffi
As Pb
0.53 <0.05
<0.07 <0.05
TABLE 13. SEMIVOLATILE POHCs IN THE COMPOSITE SOIL SAMPLE
Compound
p.p'-DDT
p,p'-DDE
p.p'-DDD
Methoxychlor
All others
Concentration 8
(mg/kg)
650
48
240
58
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43
-------
TABLE 14. MUFFLE FURNACE TEST SAMPLES
Contaminated soil
Uncontaminated soil
(<5 ppm As) (% wt)
Additive
r i
1
2
3
4
5
6
7
8
9
100
80
60
50
40
20
0
100
100
0
20
40
50
60
80
100
0
0
Add 2% lime
to pH > 12
Add 2%
alum3
'Ferric ammonium sulfate, FeNH4(SO4)2
TABLE 15. TARGET INCINERATION TEST CONDITIONS
Test
Kiln exit temperature
Kiln exit O2 level
(percent)
1
2
3
4
5
816 (1500)
816 (1500)
982 (1800)
982 (1800)
Repeat best conditions identified
10
6
10
6
during Tests 1 through 4 for removing
arsenic from soil
44
-------
In all tests, soil was fed to the kiln in fiber-pack drums via the RKS ram feeder system.
Drums containing about 5.0 kg (11 Ib) of soil were fed at the rate of one drum every 5 min., for
a soil feedrate of 60 kg/hr (132 Ib/hr). Kiln rotation rate was set to give a nominal kiln solids
residence time of 0.5 hr.
The sampling protocol employed for each test consisted of:
• Obtaining a sample of the scrubber blowdown composited from three grab samples
of the scrubber blowdown taken at hourly intervals over the test period
• Obtaining a composite sample of the kiln ash
• Continuously measuring O, concentrations downstream of the kiln; O2 and TUHC
concentrations in the afterburner exit; CO, CO2, NOX, and TUHC concentrations
at the ionizing wet scrubber exit; and O2, CO, CO2, and TUHC concentrations in
the stack
• Sampling flue gas downstream of the scrubber system for particulate and arsenic
using a variation of Method 5
• Sampling the flue gas at the scrubber system exit for semivolatile POHC and
pesticides using Method 0010
• Sampling the stack for particulate and HC1 using Method 5 to comply with permit
requirements
Scrubber exit flue gas was sampled using the same variation of a Method 5 train as
specified for multiple metals sampling used in the past trace metal tests as discussed in
Sections 3 and 4. Figure 14 identifies the nominal location of the sampling points. Table 16
summarizes the specific sampling and analysis procedures used.
52 TEST RESULTS
52.1 Muffle Furnace Tests
The muffle furnace tests were performed over a one week time period in early
September 1989. Table 17 summarizes the results of these tests in terms of calculated and
measured test sample As and Pb content. Several points are illustrated by the data in Table 17.
The first is that a relatively constant fraction (about 25 percent) of the soil weight consists of
volatile matter (moisture plus volatile organic) for all mixtures of contaminated/background soil.
The second is that the ash resulting from the muffling of soil mixtures (no lime or alum
additives) has a relatively constant lead content of about 5 ppm. This occurs despite soil mixture
lead contents varying from 14 to 45 ppm. Further, a negligible amount of this ash lead is
leachable in the TCLP procedure.
The soil As and Pb contents shown in Table 17 can be corrected for the volatile matter
content to give corresponding As/Pb concentrations in the nonvolatile (ash) fraction of each
soil mixture. These corrected concentrations represent the ash concentrations which would be
expected if none of the As/Pb in the soil volatized in the muffle furnace environment.
Comparing these corrected concentrations to measured concentrations gives an indication of the
fraction of As/Pb present in the soil which volatilized in the high temperature muffle furnace
environment. This comparison is tabulated in Table 18.
45
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The data in Table 18 show that a significant fraction of both the As and Pb in the soil
volatilized in the muffle furnace at 980°C (1800°F), as evidenced by actual ash concentrations
being uniformly less than expected (no volatilization) ash concentrations. Of perhaps greater
interest is the dependence of both As and Pb volatility (fraction volatilized, or 1 minus the
fraction remaining with the ash). Only about 25 percent of the As volatilized (75 percent
remained with the muffle furnace ash) for the low As content soil mixture. However, up to
50 percent volatilized for the higher As content mixtures. Similar behavior was seen for Pb,
although, as noted above, a relatively constant 5 ppm Pb ash resulted for all soil mixtures.
The addition of lime to the contaminated soil clearly decreased the volatility of the As,
while the addition of alum significantly increased its volatility. Neither additive effected Pb
volatility.
Table 17 noted the TCLP leachate concentration for each ash resulting from the muffle
furnace tests. Figure 15 plots the ash TCLP leachate As concentration as a function of both
original soil mixture and the resulting ash As concentration. The data in Figure 15 show that
a constant fraction of the resultant ash As was mobile as measured by the TCLP leaching
procedure. This is indicated by the straight line through the ash data points in Figure 15. Since
the TCLP leaching procedure involves producing 20g of leachate per g of ash leached, the
quantity of As leachable per g of ash leached is known. The slope of the least square's fit of the
ash data points in Figure 15 corresponds to a constant 64 percent of the ash As being leachable.
The curve for the soil data points in Figure 15 falls along the ash curve at low soil As
concentration. At these low soil concentrations, a high fraction of the soil As remained with the
resultant muffle furnace ash. However, at higher soil mixture As concentrations, a greater
fraction of the soil As volatilized; a lesser fraction remained in the resultant ash. This is
reflected in the increased deviation of the soil curve from the ash relationship shown in
Figure 15.
The addition of lime decreased the As volatility in the soil as noted above, and also
decreased the fractional leachability of the resultant ash As. The addition of alum to the soil
increased As volatility as noted above, but did not affect the resultant ash As fractional
leachability.
The data in Figure 15 suggest that the ash resulting from incinerated soil as produced
in the muffle furnace tests would meet the TCLP limit associated with the land disposal
restriction of 5 mg/L for soils with As concentrations below about 150 ppm. The data suggest
that soils with high As content could be treated with lime and still give an acceptable ash TCLP
leachate.
All ash TCLP leachate Pb concentrations were nondetectable (<0.05 mg/L) regardless
of initial soil Pb content or whether lime or alum was added to the soil.
522 Incineration Test Results
The first four (of a planned five) pilot-scale incineration tests of the bulk sample Baird
and McGuire site soil were completed during the final week of FY89. Table 19 summarizes the
incinerator test operating conditions achieved and compares these to respective target conditions.
The data in the table show that average kiln temperatures and exit flue gas O2 levels were
slightly higher than target values, although the agreement with target conditions was quite good.
Actual afterburner operating conditions also agreed quite well with target operation.
51
-------
o
<
DC
LU
O
o
o
LU
<
IE
O
<
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_!
Q.
IE
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14
12
10
ADDITIVE
NONE
2% LIME
2% ALUM
SOIL ASH
D •
op
c\i
in
Q
CO
LU
A A
TCLP LIMIT
800
Figure 15. TCLP leachate As concentration versus soil and ash concentration.
52
-------
TABLE 19. ACTUAL VERSUS TARGET OPERATING CONDITIONS FOR THE BAIRD
AND MCGUIRE INCINERATION TESTS
Parameter
Kiln temperature, °C (°F)
Target
Test average
Test range
Afterburner temperature, °C (°F)
Target
Test average
Test range
Kiln exit flue gas O2, %
Target
Test average
Test range
Afterburner exit flue gas O2, %
Target
Test average
Test range
Test 1
(9-26-89)
816 (1500)
832 (1529)
794-851
(1462 - 1563)
1093 (2000)
1094 (2002)
1086- 1101
(1987 - 2014)
10
11.3
9.6 - 17.7
7.5
7.9
6.7 - 8.7
Test 2
(9-29-89)
816 (1500)
844 (1552)
823 - 862
(1514-1584)
1093 (2000)
1089 (1993)
1081 - 1098
(1978 - 2008)
6
6.8
1.9-9.6
7.5
6.3
4.9 - 7.9
Test 3
(9-27-89)
982 (1800)
994 (1822)
975 - 1016
(1787- 1861)
1093 (2000)
1105 (2021)
1095- 1113
(2003 - 2035)
10
10.4
8.8- 11.6
7.5
7.4
5.7 - 8.6
Test 4
(9-28-89)
982 (1800)
994 (1822)
976 - 1017
(1789- 1863)
1093 (2000)
1099 (2009)
1092- 1104
(1977 - 2020)
6
7.5
4.2 - 9.5
7.5
7.3
5.5-8.1
53
-------
Ash As and Pb concentrations and ash TCLP leachate As and Pb concentrations
achieved for various operating conditions were to be used to support the decision on which
operating conditions would be repeated as a replicate test 5. Thus, these analyses were
performed on a very rapid turnaround basis. Preliminary test results from these analyses are
summarized in Table 20.
The data in Table 20 show that the soil feeds for all four initial tests were quite
comparable with respect to contaminant metal concentrations. The soil feeds contained between
80 and 94 ppm As and between 16 and 27 ppm Pb. The interesting features of the data in
Table 20 are the significant variations in kin ash metal content and ash TCLP leachate
concentrations with the test variables. For the low kiln temperature tests (816°C (1500°F)
target), kiln ash As and Pb concentrations were essentially the same as soil feed concentrations.
However, for the high kiln temperature tests (982°C (1800°F) target), kiln ash As and Pb
concentrations were significantly reduced. This would be as expected; higher kiln temperatures
would lead to a greater potential for metal volatilization. Of further interest is the variation
in As leachability with kiln excess air level. For both high excess air tests (target kiln exit flue
gas O2 of 10 percent), the ash TCLP leachate As contents were less than for the tests at low kiln
excess air (target kiln exit flue gas O2 of 6 percent).
The data for Pb agree quite well with the results from the muffle furnace tests. In the
muffle furnace tests, which were conducted at the same temperature as the high kiln
temperature tests, resulting ash Pb concentrations were about 5 ppm regardless of soil Pb
concentration. The two high kiln temperature tests resulted in kiln ash with Pb concentrations
of 6 and <2 ppm. Further, the ash TCLP leachates were uniformly devoid of Pb, as measured
in the incineration tests.
However, the data for As differ in many respects from the muffle furnace test results.
The muffle furnace tests results would predict that a soil feed with As content in the 80 to
94 ppm range would yield an ash with about the same As content when incinerated at 982°C
(1800°F). This result was observed for the low kiln temperature tests (816°C (1500°F) target),
but not for the high kiln temperature tests which were conducted at the muffle furnace test
temperature (982°C (1800°F) target). Arsenic was apparently more volatile in the incineration
tests than was observed in the muffle furnace tests. In addition, the muffle furnace tests
suggested that the fraction of ash As extractable in the TCLP procedure would be about
60 percent regardless of ash As content. This was not observed in any incineration test.
A final point of interest is seen in the data in Table 20. The fraction of soil feed
collected as kiln ash is noted in the table for each test. If the incineration test feeds contained
25 percent volatile matter as observed for the muffle furnace test soils, then 75 percent of the
soil feed would be collected as kiln ash in the absence of any paniculate carryover from the kiln
into the afterburner. The fact that the kiln ash discharge fractions noted in Table 20 are
uniformly less than 75 percent is consistent with the expectation that significant paniculate
carryover occurs. Kiln ash discharge fractions ranged from 36 to 60 percent in the tests. The
interesting point is that the observed discharge fractions correlated with kiln gas velocity, or
flowrate, which is noted in Table 20. The lowest kiln ash fraction occurred for the test with the
highest kiln flue gas flowrate (the high temperature, high excess air test). Larger kiln ash
discharge fractions occurred for the tests with lower kiln flue gas flowrates. This is as expected.
Larger kiln gas velocities or flowrates would lead to greater paniculate carryover and
correspondingly lower kiln ash discharge fractions.
Based on the preliminary results discussed above, it was decided to perform a replicate
test (Test 5) at the low kiln temperature, high kiln excess air condition (Test 1 condition), since
54
-------
TABLE 20. PRELIMINARY ASH As AND Pb DATA FOR THE BAIRD AND MCGUIRE
INCINERATION TESTS
Parameter
Kiln temperature, °C (°F)
Kiln exit flue gas O2, %
Arsenic concentrations
Soil feed (mg/kg)
Kiln ash (mg/kg)
Kiln ash TCLP leachate (mg/L)
Fraction of kiln ash As leachable (%)a
Lead concentrations
Soil feed (mg/kg)
Kiln ash (mg/kg)
Kiln ash TCLP leachate (mg/L)
Fraction of soil feed discharged as kiln ash (%)
Kiln exit flue gas flowrate, dscm/minb
Kiln exit flue gas flowrate, m3/minc
Test 1
(9-26-89)
832 (1529)
11.3
83
80
0.37
9
21
16
<0.05
52
5.97
22.8
Test 2
(9-29-89)
844 (1552)
6.8
82
80
1.2
30
16
15
<0.05
60
2.86
11.1
Test 3
(9-27-89)
994 (1822)
10.4
94
35
0.33
19
27
6
<0.05
36
7.92
34.8
Test 4
(9-28-89)
994 (1822)
7.5
80
28
1.2
86
16
<2
<0.05
60
4.93
21.6
in
P
Q
a TCLP leachate prepared by extracting lOOg kiln ash into 2 kg leachate.
b Calculated based on fuel composition and exit flue gas O2 (kiln exit flue gas flowrate not directly
measured in tests).
c Based on average kiln temperature noted in table, also dry basis (neglects flue gas moisture).
this gave an ash with low TCLP leachate As concentration and low As carryover into the flue
gas. Test 5 was completed on October 5, 1989.
Remaining test sample analyses, data evaluation and interpretation, and test reporting
will be completed in FY90.
55
-------
SECTION 6
THIRD PARTY TESTING
The recently passed Federal Technology Transfer Act allows for the use of government
facilities and equipment in joint projects with private sector concerns. The IRF represents a
unique facility with capabilities unavailable anywhere else in the U.S. Furthermore, the
hazardous waste incineration research and testing arena is quite active. Thus, the potential
demand for such third party joint projects is expected to be quite significant.
The RREL policy established during FY89 was to encourage and even solicit third party
use of the IRF. Accordingly, the IRF operations and research contract was modified in FY89
to provide for this type of usage, and initial efforts to identify appropriate joint third party
projects were undertaken.
Toward this end a facility capabilities brochure was prepared. This brochure will be
printed and distributed in FY90. The focus of the brochure is to outline the capabilities of the
IRF and the type of testing which has and can be performed, and solicit third party inquiries.
Although no active solicitation of third party interest occurred during FY89 (this will
begin in FY90) several unsolicited contacts were established. These included:
• Westinghouse Environmental Services—regarding incinerability testing of glycol
recovery sludge
• Ebasco Services Incorporated—regarding incinerability testing of wastes from the
Sand Springs Superfund site in Oklahoma
• International Technology Corporation (IT)—regarding an evaluation of alternate
air pollution control scrubbers
• Chemical Waste Management, Inc.—regarding incinerability testing of a biological
sludge from leachate treatment
• Waste-Tech Services—regarding general incineration testing capabilities
• Haynes International—regarding corrosion testing
Discussions with Westinghouse, IT, and Chemical Waste Management led to the
preparation of a test program proposal, and requests for proposals are expected from Ebasco
and Waste-Tech in FY90. None of the test program proposals prepared to date have culminated
in an agreement to perform a joint test program. However, the expectation is that FY90 will
see the initiation of third party IRF use.
56
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SECTION 7
EXTERNAL COMMUNICATIONS
During FY89, six reports were prepared and submitted, and seven technical papers were
presented. These are listed in Table 21. This level of external communication and technology
transfer is comparable to levels experienced over the preceding two years and testifies to the
high level of important research being supported at the IRF.
Table 22 lists some of the visitors to the facility during FY89. The length of the list
attests to the visibility to the incineration research community of the work being performed at
the facility.
57
-------
TABLE 21. IRF PROGRAM REPORTS AND PRESENTATIONS IN FY89
i r~
Reports g
i-
• Waterland, L. R., J. W. Lee, and R. W. Ross, II. "Pilot-Scale Incineration Tests of Wastewater o
C/5
Treatment Sludge from Pentachlorophenol Wood Preserving Processes (K001)." Draft October w
1988.
• Waterland, L. R.. "Operations and Research at the U.S. EPA Combustion Research Facility,
Annual Report for FY'88." Draft November 1988, revised December 1988.
• Waterland, L.R., and J. W. Lee. "Technology Evaluation Report SITE Demonstration Test,
American Combustion Pyretron Thermal Destruction System at the U.S. EPA's Combustion
Research Facility." EPA/540/5-89/008a, March 1989.
• Waterland, L. R., C. I. Okoh, and A. S. McElligott. "SITE Program Applications Assessment of
Superfund Applications for the American Combustion Inc. Pyretron Oxygen Enhanced Burner."
EPA/540/5-89/008b, March 1989.
• Waterland, L. R. and A-K. M. Siag. "Pilot-Scale Evaluation of SF6 Injection for Compliance
Monitoring of Hazardous Waste Incinerators." Draft March 1989.
• Fournier, Jr., D. J., W. E. Whitworth, and L. R. Waterland. "Pilot-Scale Evaluation of the Fate of
Trace Metals in a Rotary Kiln Incinerator with a Venturi Scrubber/Packed Column Scrubber."
Draft April 1989, revised October 1989.
Papers and Presentations
• Waterland, L. R., and A-K. M. Siag. "Pilot-Scale Evaluation of SF6 Injection for Compliance
Monitoring of Hazardous Waste Incinerators." Presented at the 1989 Spring Meeting of the
Western States Section of The Combustion Institute, Paper WSS-89-34, Pullman, Washington,
March 1989.
• Thurnau, R. C., J. W. Lee, and L. R. Waterland. "The U.S. EPA Combustion Research Facility."
Presented at the Fifteenth Annual Research Symposium on the Remedial Action, Treatment, and
Disposal of Hazardous Waste, Cincinnati, Ohio, April 1989.
• Mournighan, R. E., M. K. Richards, and H. Wall. "Incinerability Ranking of Hazardous Organic
Compounds." Presented at the Fifteenth Annual Research Symposium on the Remedial Action,
Treatment, and Disposal of Hazardous Waste, Cincinnati, Ohio, April 1989.
• Waterland, L. R., J. W. Lee, A-K. Siag, and L. J. Stalcy. "Pilot-Scale Testing of SF6 as a
Hazardous Waste Incinerator Surrogate." Presented at the 82nd AWMA Annual Meeting and
Exhibition, Paper 89-23B.4, Anaheim, California, June 1989.
• Waterland, L. R., D. J. Fournier, Jr., W. E. Whitworth. "Pilot-Scale Testing to Evaluate the Fate
of Trace Metals in Rotary Kiln Incineration." Presented at the 1989 Summer National AIChE
Meeting, Philadelphia, Pennsylvania, August 1989.
• Carroll, G. J., R. C. Thurnau, R. E. Mournighan, L. R. Waterland, J. W. Lee, and D. J. Fournier,
Jr. "The Pardoning of Metals in Rotary Kiln Incineration." Presented at the Third International
Conference on New Frontiers for Hazardous Waste Management, Pittsburgh, Pennsylvania,
September 1989.
• Waterland, L. R., J. W. Lee, and L. J. Staley. "Pilot-Scale Incineration Testing of an Oxygen-
Enhanced Combustion System." Presented at the Third International Conference on New
Frontiers for Hazardous Waste Management, Pittsburgh, Pennsylvania, September 1989
58
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TABLE 22. VISITORS TO THE IRF
Person
J. Oesterle
D. McNeilly
D. Green
M. Stowers,
T. Hasting
R. Loftin
D. Cordle,
G. Kemosek
J. F. Angelo,
J. R. Petersen
R. Novak,
R. Miller
R. Sawyer,
G. Gupta
B. Keough
O. L. Holland
R. Hall,
R. Mourninghan
T. Ward
C. Wen
G. Carroll,
J. Burkart,
H. Wilson,
J. Welch,
A. O'Hare,
B. Young
M. McCorkle,
M. Kourehdar
T. Ward,
S. Steinsberger,
T. Ovellette,
L. Huang,
S. Helms
J. Trease,
A. Belivear
Affiliation
Ebasco
NCCI
Arkansas Department
of Pollution Control
and Ecology (ADPCE)
Earth Technology
Corp.
U.S. Department of
Agriculture
ERM
John Zink
IT Corp.
Enviresponse
ADPCE
Hydrosonics
EPA/AEERL
EPA/RREL
EPA/ARE AL
Entropy
Environmentalists
EPA/RREL
EPA/RREL
EPA/OARM
EPA/OARM
Booz, Allen
Booz, Allen
ADPCE
EPA/AREAL
Entropy
Environmentalists
U.S. Army COE
Metcalf and Eddy
Date
10-17-88
10-20-88
11-18-88
11-14-88
01-31-89
02-20-89
03-09-89
03-16-89
03-16-89
03-22-89
03-30-89
05-01-89
06-22-89
07-25-89
through
07-27-89
07-27-89
07-31-89
through
08-03-89
09-05-89,
09-06-89
Purpose of visit
Facility tour, discuss third party test program
Facility tour
Annual RCRA inspection
Region VI visual inspection
Facility tour
Facility tour
Facility tour, discuss possible third party
testing
Facility tour, discuss third party test program
Facility tour
Inspect construction progress, discuss permit
modification
Discuss use of pilot scrubber in test program
Facility tour, project review
Site survey for collaborative AREAL testing
Perform environmental compliance audit
Facility familiarization tour
Perform simultaneous trace metal sampling
under AREAL collaboration during IWS
trace metals tests
Witness Region I Superfund site soil muffle
furnace tests
in
o
Q
(f)
111
59
-------
TABLE 22. concluded
Person
M. Richards
E. Poncelet
Affiliation
EPA/RREL
National Agency for
Date
09-12-89,
09-13-89
09-14-89
C\J
Purpose of visit 8
Facility tour discusses preparation for Region w
I Superfund site soil incineration tests
Facility tour
Waste Disposal and
Recovery, France
G. Carroll, EPA/RREL 09-21-89, Witness Region I test scoping tests
H. Wall 09-22-89
R. Mourninghan, EPA/RREL 09-27-89, Witness Region I Superfund soil tests
C. Dempsey, 09-28-89
R. Thumau
J. Trease, U.S. Army COE 09-28-89 Witness Region I Superfund soil tests
J. Ehresmann, U.S. Army COE
A. Belivear, Metcalf & Eddy
J. Tovamickey, Metcalf and Eddy
C. Frudkin EPA/Region I
60
-------
SECTION 8
PLANNED EFFORTS FOR FY90
Two major test programs were completed in late FY89: the IWS/trace metal tests
discussed in Section 4, and the Baird and McGuire Superfund site soil incinerability tests for
Region I, discussed in Section 5. As of the end of FY89, only partial results were available for
these tests. Thus, as noted in Sections 4 and 5, remaining test sample analyses, test data
reduction and interpretation, and test reporting efforts will continue into FY90. Draft test
report submittal for both programs is scheduled for January 1990.
In addition, during FY89 several activities under the facility construction and equipment
upgrade effort were not completed before testing activities were reinitiated in July 1989. These
efforts will be completed during FY90 and include:
• Replacing the refractory in the kiln chamber of the RKS
• Completing the reconfiguration of the RKS APCS, including:
— Relocating the venturi scrubber/packed column scrubber to more suitable
floor space in the former IRF building area
— Installing a refractory-lined length of ductwork between the afterburner exit
and the relocated quench section of the RKS; this will provide a straight
section of refractory lined ductwork of sufficient length to allow isokinetic
sampling of hot afterburner exit flue gas
— Completing the installation of the RKS scrubber liquor heat exchanger system
• Installing and bringing into operation the automated process control system
purchased in FY89
The kiln refractory replacement will be completed in October 1989. Remaining efforts
to complete the RKS APCS reconfiguration which do not interfere with testing in the RKS will
be performed in early FY90. When the reconfiguration effort reaches the point where no
further work can proceed while still operating the system, it will be removed from service and
the reconfiguration completed. It is expected that this period of downtime will require 4 to
6 weeks beginning in March 1990. The installation, configuration, and shakedown of the
automated process control system will be scheduled so that it will be finished at the completion
of the entire APCS reconfiguration effort.
With respect to test activities, six major test programs are planned for FY90. These
include:
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• Incinerability testing of contaminated soils from the Purity Oil Sales and McColl
Superfund sites in Region IX (R. Blank,!. Blevins, Coordinators). Initial planning
for these tests was begun in FY89. Tests of three materials from the Purity Oil
Sales site and two materials from the McColl site are planned for December 1989.
• Parametric testing of the POHC surrogate soup defined by UDRI, is to be
performed in January 1990. A systematic evaluation of the relationship between
heated and unheated total hydrocarbon monitors is planned in conjunction with
these tests.
• Residuals characterization tests to establish best demonstrated ava ilable technology
treatment standards for spent potliners from the primary reduction of aluminum,
listed waste K088, (R. Turner, J. Berlow, Coordinators); planned to be performed
in February 1990
• Parametric testing of an organic test mixture including compounds from the entire
range of the incinerability index ranking developed by UDRI, planned for
April 1990. An evaluation of the accuracy, precision, and reliability of a
continuous HC1 monitor is planned in conjunction with these tests.
• Testing of the fate of trace metals in the RKS using a third APCS (a Hydrosonics
scrubber, a spray dryer/fabric filter combination, or an electrostatic precipitator
are candidates), planned to be performed in May 1990. A test matrix designed
to evaluate the form and feed method of the metals introduced is planned for
these tests.
• Parametric testing of a soil matrix for CERCLA restoration by incineration,
and/or another Superfund site waste, planned for July and August 1990
Special studies to be defined, additional Regional Office support, or private sector third
party testing have been scheduled for in August and September 1990.
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REFERENCES
1. Waterland, L. R., "Operations and Research at the U.S. EPA Combustion Research
Facility: Annual Report for FY87," December 1987.
2. Waterland, L. R., "Operations and Research at the U.S. EPA Combustion Research
Facility: Annual Report for FY88," December 1988.
3. Waterland, L. R., "Operations and Research at the U.S. EPA Combustion Research
Facility: Annual Report for FY86," December 1986.
4. Harris, J. C, et al., "Sampling and Analysis Methods for Hazardous Waste Incineration,"
EPA-600/8-84-002, February 1984.
5. "Test Methods for Evaluating Solid Waste: Physical/Chemical Methods," EPA SW-846,
3rd Ed., November 1986.
6. "Quality Assurance Project Plan for Evaluating the Fate of Trace Metals in Rotary Kiln
Incineration with Ionizing Wet Scrubber Particulate/Acid Gas Control," June 1989.
7. Lentzen, D. E., et al., "IERL-RTP Procedures Manual: Level 1 Environmental
Assessment (Second Edition)," EPA-600/7-78-201, October 1978.
8. "Standard Methods for the Examination of Water and Wastewater," 16th Edition,
APHA, AWWA, WPCF, 1985.
9. 40 CFR Part 268, Appendix I.
10. 40 CFR Part 60, Appendix A.
11. "Determining the Properties of Fine Particulate Matter," ASME Power Test Code 28.
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