&EPA
United States
Environmental Protection
Agency
Office of Research and
Development
Washington, DC 20460
EPA/600/R-93/087
June 1993
Operations and
Research at the
U.S. EPA Incineration
Research Facility
i
Annual Report for FY92
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EPA/60Q/R-93/087
June 1993
OPERATIONS AND RESEARCH AT
THE U.S. EPA INCINERATION RESEARCH
FACILITY: ANNUAL REPORT FOR FY92
By
L. R. Waterland
Acurex Environmental Corporation
Incineration Research Facility
Jefferson, Arkansas 72079
EPA Contract 68-C9-0038
EPA 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
Printed on Recycled Paper
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NOTICE
The information in this document has been funded wholly or in part by the United
States Environmental Protection Agency under Contract 68-C9-0038 to Acurex Corporation. It
has been subjected to the Agency's peer and administrative 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 bf 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 1992. In the twelve-month period, three major test
programs were completed at the facility. Two major EPA Program/Regional Office programs
were supported through test activities: the hazardous waste incinerator regulation development
program with the Office of Solid Waste (OSW), and the Superfund site remediation program
within the Office of Emergency and Remedial Response (OERR) as administered by EPA
Regions 2 and 5. In addition, two bench-scale treatability test series were completed: one in
support of Region 6 and one in support of the U.S. Army Corps of Engineers Waterways
Experiment Station. The report outlines all efforts completed or ongoing at the facility during
FY92. :
E. Timothy Oppelt, Director
Risk Reduction Engineering Laboratory
111
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ABSTRACT
The U.S. Environmental Protection Agency's Incineration Research Facility (IRF) in
Jefferson, Arkansas, is an experimental facility that houses two pilot-scale incinerators and the
associated waste handling, emission control, process control, and safety equipment; as well as
onsite laboratory facilities.
During fiscal year 1992, three major test programs were completed at the facility: an
evaluation of the incinerability of two contaminated sludges from the Bofors-Nobel Superfund
site for Region 5, an evaluation of the incinerability of PCB-contaminated soil from the Scientific
Chemical Processing Superfund site for Region 2, and an evaluation of the effects of repeated
incinerator waste feed cutoffs on incinerator particulate, HC1, trace metal, and organic
constituent emissions for the Office of Solid Waste and the EPA incinerator permit writers. In
addition, two bench-scale treatability test series in the thermal treatment unit installed at the IRF
during FY91 were completed: treatability testing of contaminated soils from the Popile and the
American Creosote Superfund sites for Region 6 under the Superfund Technical Assistance
Response Team Program, and treatability testing of contaminated sediments from New York
Harbor for the U.S. Army Corps of Engineers Waterways Experiment Station.
Results of two test programs completed in FY91 were reported during FY92: an
evaluation of the incinerability of five contaminated soils from the Drake Chemical Superfund
site for Region 3, and an evaluation of the incinerability of arsenic-contaminated soil from the
Chemical Insecticide Corporation Superfund site for Region 2. The report outlines all efforts
completed or ongoing at the facility during FY92.
IV
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CONTENTS
Section
1
2
NOTICE ii
FORWARD iii
ABSTRACT iv
FIGURES x
TABLES xi
INTRODUCTION 1
INCINERATION OF CONTAMINATED SODLS FROM THE DRAKE
CHEMICAL SUPERFUND SITE 4
2,1 TEST PROGRAM ; 5
2.1.1 Test Facility :. 5
2.1.2 Test Waste Description '. 5
2.1.3 Test Conditions > 5
2.1.4 Sampling and Analysis Procedures :. 7
2.2 TEST RESULTS :. 9
2.2.1 Inorganic-Contaminated-Soil Tests 9
2.2.2 Organic-Contaminated-Soil Tests 14
2.2.3 Participate and HC1 Emissions Data 15
2.3 CONCLUSIONS 16
FATE OF TRACE METALS IN THE ROTARY KILN SYSTEM WITH A
CALVERT FLUX-FORCE/CONDENSATION SCRUBBER 19
3.1 TEST PROGRAM i 21
3.1.1 Synthetic Test Mixture i. 22
3.1.2 Test Conditions '•. 23
3.1.3 Sampling and Analysis 25
3.2
TEST RESULTS 25
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CONTENTS (continued)
Section Page
4 INCINERATION OF ARSENIC-CONTAMINATED SOILS FROM THE
CHEMICAL INSECTICIDE CORPORATION SUPERFUND SITE 34
4.1 TEST PROGRAM 35
4.1.1 Test Soil Description 35
4.1.2 Test Conditions 35
4.1.3 Sampling and Analysis 35
4.2 TEST RESULTS 36
4.2.1 Organochlorine Pesticides Analysis Results 36
4.2.2 Arsenic and Other Trace Metal Distributions 38
4.2.3 Particulate and HC1 Emissions 44
4.3 CONCLUSIONS 44
5 INCINERATION OF CONTAMINATED SLUDGES FROM THE
BOFORS-NOBEL SUPERFUND SITE 46
5.1 TEST PROGRAM 47
5.1.1 Test Waste Description 47
5.1.2 Test Conditions 47
5.1.3 Sampling and Analysis 47
5.2 TEST RESULTS 48
5.2.1 Volatile Organic Constituents 48
5.2.2 Semivolatile Organic Constituents 50
5.2.3 POHC DREs 50
5.2.4 Trace Metals 52
5.2.5 Particulate and HC1 57
5.3 CONCLUSIONS 57
INCINERATION OF PCB-CONTAMINATED SOILS FROM THE
SCIENTIFIC CHEMICAL PROCESSING SUPERFUND SITE . . .
60
6.1
TEST PROGRAM 61
6.1.2 Test Waste Description 61
6.1.2 Test Conditions 61
VI
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CONTENTS (continued)
Section
Page
6.1.3 Sampling and Analysis [ 62
6.2 TEST RESULTS ; 62
6.2.1 PCB Analysis Results and DREs : 62
6.2.2 Volatile Organic Constituent Analysis Results and Contaminant
DREs , 64
6.2.3 Semivolatile Organic Constituent Analysis Results : 66
6.2.4 Trace Metal Analysis Results and Discharge Distributions 66
6.2.5 , Particulate and HC1 Emissions Data i 69
i
6.3 CONCLUSIONS ' 71
7 BENCH-SCALE TREATABILETY TESTING OF CONTAMINATED SOIL
FROM TWO WOOD PRESERVING PLANT SUPERFUND SITES 74
7.1 TEST PROGRAM 74
7.1.1 Test Facility Description . 74
7.1.2 Feed Preparation and Sample Collection 76
7.1.3 Test Conditions '. 76
!
7.2 TEST RESULTS j 76
7.2.1 Proximate and Elemental Composition ; 78
7.2.2 Semivolatile Organic Constituents ; 78
7.2.3 Organochlorine Pesticides 81
7.2.4 Volatile Organic Constituents 81
7.2.5 Trace Metals ! 81
7.3 TEST CONCLUSIONS 85
8 EVALUATION OF THE IMPACTS OF REPEATED WASTE FEED
CUTOFFS 87
8.1 TEST PROGRAM 88
8.1.1 Test Waste Description 88
8.1.2 Test Conditions ; 88
8.1.3 Sampling and Analysis 90
Vll
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CONTENTS (concluded)
Section page
8.2 TEST RESULTS 90
8.2.1 POHC Analysis Results and DREs 90
8.2.2 Trace Metal Analysis Results 93
8.2.3 Particulate and HC1 Emission Data 96
8.3 CONCLUSIONS 97
9 THIRD-PARTY TESTING 101
9.1 BENCH-SCALE TREATABILITY TESTING OF
CONTAMINATED NEW YORK HARBOR SEDIMENTS 101
9.2 ROTARY KILN INCINERATION TESTING OF SIMULATED
LOW-LEVEL MIXED WASTE 102
10 EXTERNAL COMMUNICATIONS 104
11 PLANNED EFFORTS FOR FY93 109
REFERENCES 112
Vlll
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FIGURES
Number Page
1 Schematic of the IRF rotary kiln incineration system 6
2 Schematic of the Calvert Scrubber System 22
3 Mercury partitioning to the scrubber liquor versus waste feed chlorine
content ;. 28
4
The IRF TTU 75
IX
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TABLES
Number
1 Target versus actual operating conditions for the Drake Chemical soil tests ... 7
2 Soil feed and ash collected 8
3 Test sample trace metal concentrations 10
4 Trace metal distributions 13
5 Apparent scrubber collection efficiencies 14
6 Organic analysis results for feed samples 15
7 Volatile organic constituent concentrations in kiln ash and scrubber liquor
samples 16
8 Target trace metal integrated feed concentrations 24
9 Target test conditions 24
10 Summary of metal discharge distributions in the kiln ash, quench exit flue
gas, scrubber exit flue gas, and scrubber liquor 26
11 Summary of metal mass balance closure around kiln ash and scrubber
discharges 27
12 Metal discharge distributions and mass balance closure 29
13 Normalized metal discharge distributions 31
14 Target incinerator test and operating conditions 36
15 Organochlorine pesticide analysis results 37
16 Organochlorine pesticide decontamination effectiveness 39
17 Organochlorine pesticide DREs 40
18 Arsenic removal efficiencies 40
19 Trace metal analysis results 41
20 Trace metal distributions 42
x
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TABLES (Continued)
Number Page
21 Arsenic distributions \ 43
22 Normalized arsenic distributions : 44
23 Target versus actual operating conditions 48
24 Concentrations of volatile organic constituents for the Lagoon 3 sludge tests . 49
25 Concentrations of volatile organic constituents for the Lagoon 8 sludge tests . 51
26 Destruction and removal efficiencies (percent) for the principal organic
hazardous constituents : 52
I
27 Concentrations of trace metals for the Lagoon 3 sludge tests ' 53
28 Concentrations of trace metals for the Lagoon 8 sludge tests 55
29 Normalized trace metal distributions—percent of metal measured . . .: 56
30 PCB analysis results i 63
31 PCB decontamination effectiveness ; 63
32 PCB DREs 64
33 Volatile organic constituent DREs : 65
34 Trace metal analysis results 67
35 Normalized trace metal distributions 70
36 Flue gas particulate levels 70
37 Flue gas HC1 levels 71
38 Actual versus target operating conditions 77
39 Soil proximate and elemental composition analysis results 79
XI
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TABLES (Concluded)
Number
40 Soil feed and ash collected 79
41 Semivolatile organic constituent analysis results and decontamination
effectiveness 80
42 Organochlorine pesticide analysis results and decontamination effectiveness ... 82
43 Volatile organic constituent analysis results and decontamination
effectiveness for the American Creosote soil tests 83
44 Volatile organic constituents analyzed in TCLP leachate samples 84
45 Trace metals analyzed in test program samples 84
46 Trace metal analysis results 85
47 Scrubber exit flue gas POHC concentrations and POHC DREs 91
48 Trace metal analysis results 94
49 Normalized trace metal distributions , . 95
50 Apparent scrubber trace metal collection efficiencies 98
51 Flue gas particulate levels 98
52 Flue gas HC1 levels 99
53 Test conditions 102
54 IRF program reports and presentations in FY92 105
55 Visitors to the IRF 107
Xll
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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 that 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
• 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 such as Superfund site wastes) in support of
specific Regional Office permitting or enforcement actions and Regional Office
or private party Superfund site remediation efforts :
i
• To test the performance of new and advanced incinerator components and
subsystems, and emission control devices '.
I
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Fiscal year 1992 (FY92, October 1, 1991 through September 30, 1992) saw the
continuation of production-paced incineration testing at the IRF. During the year, three major
test programs and two bench-scale treatability test series were completed. These test programs
focused on the objectives above.
Two major EPA Program/Regional Office programs were supported through test
activities in FY92.
• The hazardous waste incinerator regulation development program within the
Office of Solid Waste (OSW), via testing to evaluate the impacts of repeated
waste feed cutoff events on incinerator emissions
• The Superfund site remediation program within the Office of Emergency and
Remedial Response (OERR) as administered by
— EPA Region 5, via incineration treatability testing of contaminated sludges
from the Bofors-Nobel Superfund Site in Muskegon, Michigan
— EPA Region 2, via incineration treatability testing of PCB-contaminated soil
from the Scientific Chemical Processing Superfund Site in Carlstadt, New
Jersey
— EPA Region 6, via bench-scale incineration treatability testing of
contaminated soils from the American Creosote Superfund Site in Winnfield,
Louisiana, and the Popile Superfund Site in El Dorado, Arkansas
— EPA Region 2, via bench-scale incineration treatability testing of
contaminated marine sediments from New York Harbor
In addition, the results of two series of incineration treatability tests of contaminated
soils from two Superfund Sites, completed in support of EPA Regions 2 and 3 during FY91, were
assembled and reported in FY92. The results of a series of tests to evaluate the fate of trace
metals fed to a rotary kiln incinerator equipped with a Calvert Flux Force/Condensation
scrubber system, also completed in FY91, were assembled in FY92 and a preliminary report was
issued. Finally, the test planning documents (test plan and Quality Assurance Project Plan
(QAPP)) for a series of tests to evaluate the effectiveness of the treatment of contaminated soils
by a rotary kiln incinerator operated at low to moderate temperatures, to be performed in FY93,
were completed.
Activities completed during FY92 are discussed in more detail in the following sections.
Section 2 discusses results of the Drake Chemical Superfund Site treatability tests. Section 3
discusses the Calvert scrubber trace metal tests. Section 4 presents results from the Chemical
Insecticide Corporation Superfund Site treatability tests. Section 5 discusses the results of the
Borfors-Nobel Superfund Site treatability tests. Section 6 presents results of the Scientific
Chemical Processing Superfund Site tests. Section 7 discusses the results of the Popile and
American Creosote Superfund Site bench-scale treatability tests. Section 8 presents results from
the waste feed cutoff evaluation tests. Section 9 outlines third-party test solicitation efforts and
projects agreed to. Section 10 discusses external communication activities associated with the
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facility and its operation. Section 11, the final section, presents an outline of plans for activities
to be completed in FY92.
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SECTION 2
INCINERATION OF CONTAMINATED SOILS FROM
THE DRAKE CHEMICAL SUPERFUND SITE
One of the primary missions of the EPA's IRF is to support Regional Offices in
evaluations of the potential of incineration as a treatment option for contaminated soils and
sediments at Superfund sites. One priority Superfund site is the Drake Chemical site, in Lock
Haven, Pennsylvania. EPA Region 3 and the U.S. Army Corps of Engineers (USAGE)
(R. Schrock, Region 3, D. Johnson, USAGE coordinators) requested that test burns be
conducted at the IRF to support evaluations of the suitability of incineration as a treatment
technology for the contaminated soils and sediments at the site.
The Drake Chemical Superfund Site, covering approximately 12.5 acres, was a chemical
manufacturing facility from 1951 to 1982. According to site investigation data, as a result of
these activities, the soils at the Drake site are contaminated to varying degrees With various
organic constituents and several hazardous constituent metals. With respect to the incinerability
evaluation, the primary objective was to determine whether treatment of the soils by incineration
would generate a residue environmentally suitable for redeposit, without further treatment, at
the site during full-scale remediation. Therefore, one primary concern was whether incineration
could effectively destroy the organic contaminants in the soils. Equally important was the fate
of the trace metals when the soils were subjected to incineration.
This test program was designed to evaluate the effectiveness of varying incinerator
operating conditions on organic contaminant destruction and the effects of these varied
conditions on the distributions of the trace metals in the discharge streams. Specific questions
answered in this test program were:
• Can rotary kiln incineration effectively destroy the organic contaminants in the
site soils?
• Will the kiln ash (treated soil) from incineration of the site soils have
characteristics that will allow it to be backfilled (redeposited), without further
treatment, at the site?
• Can the incineration treatment of the site soils be performed in compliance with
the hazardous waste incinerator performance standards?
• What is the fate of the contaminant trace metals in the incineration of the site
soils?
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• What are the effects of incineration temperature on contaminant metal fate and
kiln ash characteristics?
This test program, as originally conceived, was to have consisted of an initial phase of
nine tests and an optional phase of four additional tests. The results from the initial-phase
testing, specifically the toxicity characteristics exhibited by the incinerator residuals, were to guide
the decision as to whether the optional testing would be needed. A subset of the initial-phase
incineration testing was conducted at the IRF in January and February 1991.; The toxicity
characteristics of all test program samples were demonstrated to be below regulatory threshold
levels. These results led to the conclusion that several of the originally-conceivdd initial-phase
tests and the optional testing would not be necessary to meet the stated program objectives.
Results of the test program are discussed in the subsections that follow.
2.1 TEST PROGRAM
i
2.1.1 Test Facility
All tests in this program were conducted in the rotary kiln incineration system (RKS)
at the IRF. A process schematic of the RKS is shown in Figure 1. The IRF RKS consists of a
primary combustion chamber, a transition section, and a fired afterburner chamber. After exiting
the afterburner, flue gas flows through a quench section followed by a primary air pollution
control system (APCS). The primary APCS for these tests consisted of a venturi scrubber
followed by a packed-column scrubber. Downstream of the primary APCS, a backup secondary
APCS, comprised of a demister, an activated-carbon adsorber, and a high-efficiency particulate
air (HEPA) filter, is in place.
2.1.2 Test Waste Description !
The Phase III record of decision (ROD) document for the Drake Chemical site indicates
that about 252,000 yd3 of contaminated soils and sediments' will be excavated and
decontaminated onsite by a transportable rotary kiln incinerator. The ROD further indicates
that these materials are contaminated with varying levels of organic compounds and several
hazardous constituent trace metals, including arsenic, barium, eadmium, chromium, lead, and
mercury.
For the test program, seventeen 55-gal drums of the contaminated site soils were
excavated and shipped to the IRF for possible testing. Only a subset of these drums was actually
used in the test program, however. :
2.13 Test Conditions
As noted above, the objective of the proposed test program was to evaluate the
suitability of incineration as a treatment technology for the contaminated soils and sediments at
the Drake Chemical site. The rescoped test program consisted of five tests. The test numbering
of the originally conceived test program was retained, however. Of the five conditions tested,
Tests 1, 2, 3a, and 3b were designed to study the fate of the inorganic contaminants (trace
metals). Tests 1 and 2 studied the distribution of the trace metal contaminants throughout the
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QUENCH
AIR
go FAN
SINGLE-STAGE IONIZING
WETSCRUBBER
CARBON BED HEPA
ADSORBER FILTER I
MODULAR PRIMARY AIR
POLLUTION CONTROL
SYSTEM DEVICES
NATURAL
GAS.
UQUID
FEED
ROTARY KILN
INCINERATOR
REDUNDANT AIR
POLLUTION CONTROL |
SYSTEM
Figure 1. Schematic of the IRF rotary kiln incineration system.
incinerator system. These tests also provided information on the concentrations of trace metals
in the kUn ash- and flue gas flyash toxicity characteristic leaching procedure (TCLP) leachates.
Tests 3a and 3b determined the effects of kiln temperature on the trace metal concentrations
in the kiln ash and scrubber liquor streams. All of these tests were conducted with the soils in
their original, as-received, form. Tests 6 and 7 were designed to study the destruction of the
organic contaminants. Because the as-received soils contained low levels of organic
contamination, the Test 6 and Test 7 soils were spiked with naphthalene and 1,4-dichlorobenzene
at 3,000 and 130 mg/kg, respectively. The destruction of the spiked principal organic hazardous
constituents (POHCs) became the principal indicator of the effectiveness of incineration under
these test conditions.
The five tests were conducted from January 30, 1991 through February 7,1991. Tests 3a
and 3b were performed in one day, with sufficient time allowed in between subtests to achieve
steady-state operation at the target kiln exit gas temperature of 816°C (1,500°F) for Test 3a and
538°C (1,000°F) for Test 3b. Test soils were fed to the kiln via the fiberpack drum ram feeder
system. Each fiberpack contained 4.5 kg (10 Ib) of soil. One fiberpack was charged into the kiln
every 5 min, resulting in soil feedrates of nominally 55 kg/hr (120 Ib/hr).
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Table 1 compares the target and actual test operating conditions for! each test. As
shown, the average kiln exit gas temperatures were within about 15 °C (25°F!) of the target
temperatures for all of the tests. Afterburner temperatures were maintained within 3°C (5°F)
of the 1,093 °F (2,000°F) target for all tests. Both kiln exit and afterburner exit flue gas O2 levels
were somewhat higher than target levels for all tests, however, because of excessive air inleakage
into the kiln resulting from an inability to tightly secure the rotating kiln seals.; Nevertheless,
based on the IRF's past experience, the flue gas O2 levels tested likely yielded organic
contaminant destruction and contaminant trace metal distributions similar to those which would
have been measured had flue gas O2 levels been at the target conditions.
Table 2 summarizes the total amount of soil fed to the RKS for each test, and the
corresponding weight of ash collected for each test. As shown, except for Test 7, the weight of
ash discharged was generally about 70 percent of the weight of soil fed to the kiln.
2.1.4 Sampling and Analysis Procedures
Because the objectives of Tests 1, 2, 3a, and 3b were different from those of Tests 6
and 7, different sampling and analysis procedures were employed for each test grbup. However,
several procedures were performed for all tests, including:
• Obtaining a composite sample for the soil feed from each drum ^before the soil
was packaged into fiberpack containers ;
• Collecting a composite kiln ash sample
i
• Collecting a composite scrubber liquor sample
TABLE 1. TARGET VERSUS ACTUAL OPERATING CONDITIONS FOR THE
DRAKE CHEMICAL SOIL TESTS
Kiln
Afterburner
Test
no.
1
2
3a
3b
6
7
Target
temperature,
°C (°F)
816 (1,500)
816 (1,500)
816 (1,500)
538 (1,000)
816 (1,500)
538 (1,000)
Actual average
exit gas
temperature,
°C (°F)
826 (1,519)
823 (1,513)
829 (1,524)
546 (1,015)
822 (1,512)
553 (1,027)
Target O2,
%
11.0
11.0
11.0
11.0
11.0
11.0
Actual
average
02,%
13.3
13.1
13.8
17.0
12.7
15.4
Target O2,
%
7.0
7.0
7.0
7.0
7.0
7.0
; Actual
: average
; o2, %
: 8-7
9.2
: 9.2
; 11.8
9.3
: 9.9
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TABLE 2. SOIL FEED AND ASH COLLECTED
Total ash collected
Test
1 (1/30/91)
2 (2/5/91)
3a (1/31/91)
3b (1/31/91)
6 (2/6/91)
7 (2/7/91)
Test soil
M-2
M-5D
O-l
O-l
L-2
0-2
Total soil
fed, kg (Ib)
240 (529)
232 (512)
112 (246)
113 (249)
240 (529)
209 (460)
Weight,
kg (Ib)
173 (381)
177 (390)
74 (163)
83 (183)
187 (411)
183 (404)
Fraction of
soil fed, %
72
76
66
73
78
88
• Continuously measuring O-, concentrations at the kiln exit; O2, CO, CO2, and total
unburned hydrocarbons (TUHC) at the afterburner exit; O2,~CO2, arid NOX at the
scrubber exit; and CO and TUHC at the stack
• Sampling the flue gas at the stack for HC1 and particulate, using a Method 5
sampling train
The above were the only sampling procedures employed for Tests 3a and 3b. In
addition to the above, the following were performed for Tests 1 and 2:
• Sampling the flue gas at the afterburner exit (i.e., upstream of the scrubber) for
particulate load and for trace metals (excluding mercury), using a Method 17
sampling train, modified with multiple metals train impingers
• Determining the particle size distribution of the afterburner exit flue gas
particulate, using an Anderson cascade impactor train
• Sampling the flue gas upstream and downstream of the scrubber for mercury,
using a Method 101A train at each location
• Sampling the flue gas downstream of the scrubber system for particulate and trace
metals (excluding mercury), using the EPA multiple metals train
In addition to the sampling performed for all tests noted above, the flue gas downstream
of the scrubber system was sampled for semivolatile POHCs, using a Method 0010 sampling
train, in Tests 6 and 7.
In addition to analyzing flue gas sampling trains for their sampled analyte set, the
following were performed for Tests 1, 2, 3a, and 3b.
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« Analyzing the soil feed and kiln ash samples for trace metals (arsenic, barium,
cadmium, chromium, copper, mercury, nickel, lead, selenium, silver, and zinc)
• Analyzing the soil and kiln ash TCLP leachates for trace metals
• Analyzing the scrubber liquor samples for trace metals
In addition, for Tests 1 and 2, an aliquot of the afterburner exit particulate collected with the
Method 17 sampling train was extracted by the TCLP and the resulting leachate analyzed for
trace metals. For Tests 6 and 7, the analysis protocol included analyzing the soil feed, kiln ash,
and scrubber liquor samples for volatile and semivolatile organic contaminants .
22 TEST RESULTS
2.2.1 Inorganic-Contaminated-Soil Tests '•
Table 3 provides a complete summary of the trace metal analysis results for all test
samples taken for trace metal analysis. The data in Table 3 show that soil feed and resulting kiln
ash metal concentrations were generally comparable for all metals. However, afterburner exit
particulate metals concentrations were significantly greater than corresponding soil feed and kiln
ash concentrations for all metals in the two tests for which afterburner exit particulate was
collected for analysis. The afterburner exit flue gas particulate was analyzed as ap analog to the
flyash collected by dry APCSs. The data in Table 3 suggest that the flyash collected by a fabric
filter APCS, for example, will likely contain significantly higher levels of all test |program trace
metals (except mercury) than the parent soil incinerated. ;
Tests 1, 2, and 3a were performed at a kiln exit gas temperature of nominally 824°C
(1,515°C). Test 3b was performed at a lower kiln temperature of 546°C (1,0156F) to evaluate
whether variations in kiln temperature in this range affected resulting kiln ash trace metal
contents. The data in Table 3 show no significant differences in the trace metal contents of the
kiln ash from Test 3a compared to Test 3b. '
The data in Table 3 show that kiln ash TCLP leachates were quite similar in metal
content to the corresponding soil leachates, with the exception that the Test 2 leachate had a
significantly lower zinc concentration than its corresponding soil. Still, no soil, or the kiln ash
resulting from its incineration in these tests, had TCLP leachate trace metal concentrations even
approaching the TCLP regulatory levels. Thus, the kiln ashes resulting from the incineration of
site soils would not be toxicity characteristic (TC) hazardous wastes based on these test data.
In contrast, the afterburner exit flue gas particulate leachate metal concentrations were
significantly higher than corresponding soil and resulting kiln ash leachate concentrations. In
fact, the afterburner exit flue gas particulate TCLP leachate concentrations of chromium and
lead exceeded their corresponding TCLP regulatory levels for both Tests 1 and 2;; and the Test 2
particulate leachate was at or over the regulatory levels for arsenic and cadmium. Because the
afterburner exit flue gas particulate was collected as an analog for dry APCS (e.g., fabric filter)
collected flyash, the data in Table 3 suggest that the collected flyash from the incineration of soil
highly contaminated by trace metals would be a TC hazardous waste, not suitable for land
disposal without further treatment.
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The scrubber liquor trace metal data show that no scrubber liquor contained trace metal
concentrations exceeding TCLP regulatory levels. However, in two of three cases, lead
concentrations in test scrubber liquor were nearly 50 percent of the regulatory level for lead.
This suggests that the scrubber liquor discharge from a wet APCS, generated in the incineration
of "hot spot" lead-containing soils or under scrubber operation at minimum blowdown, could be
a TC hazardous waste.
The test sample concentration data from Table 3 can be combined with waste feedrate
and kiln ash discharge rates and flue flowrate data to calculate the distribution of trace metals
among the various incinerator discharges of the tests. Table 4 summarizes these trace metal
distributions among the incinerator discharge streams, expressed as fractions (in percent) of the
amount of each metal fed to the incinerator in each test. Thus, the values in the table represent
the fraction of the metal fed to the kiln accounted for by the noted discharge. The rows labeled
"Total" represent the total amount of metal fed accounted for by the sum of the discharges
analyzed. Thus, these rows represent the degree of mass balance closure achieved for each metal
for each test.
The data in Table 4 show that the kiln ash fraction contained the predominant amount
of all metals, except mercury, for both Tests 1 and 2. Scrubber exit flue gas fractions were
generally quite low for all metals except for mercury, cadmium, and possibly arsenic for both
tests. The flue gas accounted for all measured mercury for both tests. The scrubber liquor
accounted for less than about 10 percent of the amount of metal fed for all metals except
chromium, copper, and nickel in Test 1, and copper in Test 2.
The metal distribution data for Tests 3a and 3b generally support the observations from
Tests 1 and 2 discussed above. The kiln ash discharge again accounted for the predominant
fraction of each metal except mercury, which was not found in the kiln ash of either Test 3a
or 3b. Again, the scrubber liquor accounted for less than about 10 percent of the amount of
metal fed for all metals except copper. Comparing the Test 3a and Test 3b kiln ash fraction data
shows that decreasing the kiln temperature from 829°C (1,524°F) to 546°C (1,015°F) had no
effect on kiln ash metal fractions, with the possible exception of increased kiln ash zinc with
decreased temperature.
Scrubber collection efficiencies for each of the metals measured in the flue gas streams
for Tests 1 and 2 can be calculated from measured concentrations in the afterburner exit flue
gas and the scrubber exit flue gas. However, the IRF's experience has been that flue gas metal
concentrations measured at this location are generally lower than expected. Thus, calculated
scrubber collection efficiencies using measured afterburner exit flue gas concentrations are often
quite poor. Based on past experience, a better estimate of the flowrate of metals at the scrubber
inlet has been obtained by summing the flows in the two scrubber discharge streams: the
scrubber exit flue gas and the scrubber liquor. This allows an apparent scrubber collection
efficiency to be calculated as (scrubber liquor fraction)/(scrubber liquor fraction plus scrubber
exit flue gas fraction).
Table 5 summarizes the apparent scrubber collection efficiencies calculated for each
metal measured in the test program for Tests 1 and 2. The data in Table 5 show that the
venturi/packed-column scrubber system collection efficiencies were greater than about 90 percent
for barium, copper, and zinc in Tests 1 and 2; for chromium and nickel in Test 1; and greater
12
-------
TABLE 4. TRACE METAL DISTRIBUTIONS
Distribution, % of metal fed :
Sample
Test 1 (1/30/91), Soil M-2
Kiln temperature: 826°C (1,519°F)
Kiln ash
Afterburner exit flue gas
Total
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Test 2 (2/5/91), Soil M-5D
Kiln temperature: 823°C (1,513°F)
Kiln ash
Afterburner exit flue gas
Total
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Test 3a (1/31/91), Soil O-l
Kiln temperature: 829°C (1,524°F)
Kiln ash
Test 3b (1/31/91), Soil O-l
Kiln temperature: 546°C (1,015°F)
Kiln ash
Total Test 3
Kiln ash
Scrubber liquor
As
56
0.7-3
57-59
56
2-11
<6
58-73
20
6
26
20
3-5
9
32-34
(a)
(a)
(a)
(a)
Ba
90
2
92
90
<0.1
8
98
65
4
69
65
0.2-0.4
11
76
69
70
70
3
Cd
71
7
78
71
8-22
<9
79-102
65
9
74
65
12-20
9
86-94
(b)
(b)
(b)
(b)
Cr
88
11
99
88
2-4
32
122-124
61
28
89
61
1-4
13
75-78
83
69
76
7
Cu
61
0.6
62
61
1
34
96
37
2
39
37
1
26
64
75
88
82
22
Pb
66
0.6
67
66
1
6
73
38
4
42
38
4-5
14
56-57
52
68
61
3
Hg
<71
150-160
150-231
<71
350
<20
350-441
!
<25
68-71
68-96
<25
195-198
<6
195-229
<31
<35
i
<35
<6
Ni
91
12
103
91
<2
27
118-120
45
19
64
45
<2
8
53-55
129
108
118
8
Zn
55
0.9
56
55
0.2
4
59
35
2
37
35
0.6
4
40
48
81
65
3
"Arsenic present in Test 3 soil just at the PQL, not detected in any residual sample.
bCadmium not detected in Test 3 soil.
13
-------
TABLE 5. APPARENT SCRUBBER COLLECTION EFFICIENCIES
Apparent scrubber
collection efficiency, %
Metal
Arsenic
Barium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Zinc
Test 1
(1/30/91)
<36
98.8-99.6
<29
90-95
98
82-84
<5
>93
94
Test 2
(2/5/91)
64-78
97-99
31-43
76-91
94-95
76-79
<3
>76
88
than 76 percent for chromium and nickel in Test 2. Cadmium collection efficiencies were less
than 30 to 40 percent, and mercury collection efficiencies less than 5 percent for both tests.
Lead collection efficiencies were nominaiJy 80 percent for both tests. Arsenic collection
efficiencies were between 64 and 78 percent for Test 2, but less than 36 percent for Test 1.
222. Organic-Contaminated-Soil Tests
Table 6 summarizes the results of the organic analyses of the organic-contaminated test
soils. As shown in the table, fenac, a chlorinated herbicide, was present in the L-2 test soil at
70 mg/kg. Fenac was not detected in the O-2 test soil. The results in Table 6 also indicate that
both test soils contained low levels of several volatile organics, and that the O-2 soil contained
low levels of several semivolatile organics.
Because the organic test soils contained very low levels of organic contamination, they
were spiked with naphthalene and 1,4-dichlorobenzene to the 3,000 mg/kg and 130 mg/kg levels,
respectively. These two semivolatile compounds became surrogate test POHCs. Measured
naphthalene DRE was greater than 99.995 percent for both tests. No 1,4-dichlorobenzene was
detected in the scrubber exit flue gas, with a DRE corresponding to the quantitation limit for
1,4-dichlorobenzene of greater than 99.89 percent. (In retrospect, the spiking level for
1,4-dichlorobenzene should have been higher than 130 mg/kg, given the flue gas sampling and
analysis method practical quantitation limit (PQL) and the desire to demonstrate a higher DRE.)
The lower kiln temperature for Test 7, 553°C (1,027°F), compared to the Test 6 kiln
temperature of 822°C (1,512°F), did not result in a measurable decrease in DRE.
Neither fenac nor any other semivolatile organic was detected in any other organic-
contaminated soil test sample.
14
-------
TABLE 6. ORGANIC ANALYSIS RESULTS FOR FEED SAMPLES
Concentration, mg/kg
Compound
Test 6
(2/6/91)
Soil L-2
Test 7
(2/7/91)
Soil O-2
Semivolatile organics:
Benzo(a)pyrene
Fluoranthene
Indeno( 1,2,3-cd)pyrene
Phenanthrene
Pyrene
1,2,4-Trichlorobenzene
All other semivolatile organics
Volatile organics:
NDa
ND
ND
ND
ND
ND
ND
11
44
24
58
43
43
ND
2-Butanone
Chlorobenzene
Trichloroethene
Toluene
Xylenes (total)
All other volatile organics
Fenac
20
5.7
<0.63
0.69
<0.63
ND
70
20
2.9
4.5
4.7
3.0
ND
<10
aND = Not detected.
The volatile organic constituent analysis results for kiln ash and scrubber liquor are
summarized in Table 7. As shown in the table, both test's scrubber liquor contained toluene.
The Test 7 scrubber liquor also contained 2-butanone. Both tests' kiln ash contained 2-butanone
and toluene. In addition, the Test 7 kiln ash contained xylenes. Comparing the kiln ash
2-butanone, toluene, and xylene concentrations with the corresponding feed concentrations noted
in Table 6 shows that they are comparable in all cases. Evidently, incineration at both kiln
temperatures was ineffective in decontaminating the test soils of these three volatile organics.
No explanation for this observation is readily apparent.
223 Particulate and HC1 Emissions Data
Flue gas particulate load measurements were made at various sampled locations for
different tests. Afterburner exit flue gas particulate levels were in the nominal range of 100 to
15
-------
TABLE 7. VOLATILE ORGANIC CONSTITUENT CONCENTRATIONS IN KILN ASH
AND SCRUBBER LIQUOR SAMPLES
Kiln ash concentration,
mg/kg
Test: 6 7
Date: 2/6/91 2/7/91
Feed: Soil L-2 Soil O-2
Kiln temperature. °C (°F); 822 (1512) 553 (1027)
Scrubber liquor
concentration,
6 7
2/6/91 2/7/91
Soil L-2 Soil O-2
822 (1512) 553 (1027)
Volatile organics:
2-butanone
Toluene
Xylenes (total)
All other volatile organics
26
0.84
<0.62
NDa
16
8.4
0.86
ND
<100
5
<50
ND
190
6
<50
ND
RND = Not detected.
300 mg/dscm at 7 percent O0 for Tests 1, 2, 6, and 7. Scrubber exit particulate levels were
reduced to the nominal range of 10 to 20 mg/dscm at 7 percent O2 for the two tests (Tests 1
and 2) during which this location was sampled. The reduction corresponds to a scrubber
efficiency in the 90- to 95-percent range, typical for a venturi scrubber. Both scrubber exit levels
measured were below the 180 mg/dscm at 7 percent Oo hazardous waste incinerator
performance standard.
Flue gas HC1 levels were also measured at the afterburner exit and in the stack during
the test program. Afterburner exit flue gas HC1 was 13 ppm for Test 6 (L-2 soil) and 201 ppm
for Test 7 (O-2 soil). All levels were below detection limits at the stack for all tests.
Corresponding system HC1 collection efficiencies were greater than 98.5 percent for Test 6, and
greater than 99.8 percent for Test 7.
23 CONCLUSIONS
Test conclusions are as follows:
• Organic contaminants in the test soils were destroyed to greater that 99.99 percent
DRE. Naphthalene, spiked into test soils at 3,000 mg/kg for the two organic
destruction tests, was destroyed at a DRE of greater than 99.995 percent.
1,4-dichlorobenzene, spiked into the test soils at 130 mg/kg for the same two tests,
was not detected in incineration flue gas; detection limits corresponded to a DRE
of greater than 99.89 percent. These DRE levels were attained at both kiln
temperatures tested, 822°C (1,512°F) and 553°C (1,027°F), although the
afterburner was operated at 1,096 °C (2,005°F) for both tests. No native soil
semivolatile POHCs were detected in combustion flue gas.
16
-------
The treated soil (kiln ash) contained no detectable semivolatile organic soil
contaminant, indicating effective decontamination for this class of contaminants
at both kiln temperatures. However, the levels of three volatile organic soil
contaminants, 2-butanone, toluene, and xylene, in kiln ash were comparable to
parent soil concentrations at both kiln temperatures, suggesting poor
decontamination effectiveness for these constituents.
None of the soils tested, or the kiln ash resulting from their incineration, was a
TC hazardous waste based on its leachable trace metal content '
No test scrubber liquor was a TC hazardous waste based on trace metal
concentrations. However, lead concentrations in test scrubber liquors were at
levels near 50 percent of the TCLP regulatory level in some cases.: This suggests
that the scrubber liquor discharge from a wet scrubber APCS could become a TC
hazardous waste in the incineration of "hot spot" lead-containing soils, or under
scrubber operation at minimum blowdown.
The flyash collected at the afterburner exit (upstream of the wet scrubber APCS)
exceeded TC limits for leachable chromium and lead concentrations in both
metal-contaminated soils tested in the full evaluation tests, and, additionally, for
leachable arsenic and cadmium in one soil. This suggests that' the collected
paniculate from a dry APCS, such as a fabric filter, would be a TC hazardous
waste and could not be backfilled at the site without further < treatment or
stabilization. :
Particulate levels in the flue gas at the exit of the venturi/packed-column scrubber
APCS were less than 20 mg/dscrn at 7 percent O0, in compliance with the
hazardous waste incinerator performance standard of 180 mg/dscm at 7 percent
O2. HC1 emissions were not detectable downstream of the scrubber. Thus, the
hazardous waste incinerator performance standard for these constituents was met.
The kiln ash discharge accounted for the predominant fraction of all trace metals
introduced in the soil feed with the exception of mercury, which appeared to be
completely accounted for in the flue gas discharges. The scrubber exit flue gas
accounted for a minor fraction of the trace metals fed with the' exception of
mercury, cadmium, and possibly arsenic. The scrubber liquor accounted for less
than 10 percent of the trace metals fed with the exception of copper, and
chromium and nickel for one soil feed. :
Kiln ash trace metal concentrations were generally comparable to the
corresponding soil feed concentrations. Afterburner exit flue gas particulate metal
concentrations, however, were significantly greater.
Varying kiln temperature in the range of 546°C (1,012°F) to 829°C (1,524°F)
generally had little effect on contaminant metal fate or kiln ash characteristics
!
Venturi/packed-column scrubber collection efficiencies were 90 to 95 percent for
overall particulate. Apparent collection efficiencies were greater than about
17 ;
-------
90 percent for barium, copper, and zinc; about 80 percent for lead; greater than
76 percent for chromium and nickel; less than 30 to 40 percent for cadmium; and
variable, between 36 and 78 percent, for arsenic.
Test results were reported in the following report:
• King, C., J. W. Lee, and L. R. Waterland, "Pilot-Scale Incineration of
Contaminated Soils from the Drake Chemical Superfund Site," draft January 1992,
revised April 1992.
18
-------
SECTION 3
FATE OF TRACE METALS IN THE ROTARY KILN SYSTEM WITH A
CALVERT FLUX-FORCE/CONDENSATION SCRUBBER •
Risk assessments have suggested that trace metal emissions from some incinerators
treating waste streams with high levels of metals could pose unacceptable risks tq human health
and the environment. Despite their importance, available field data on the fate 'of trace metals
from hazardous waste incinerators are limited. Data describing the effects'of incinerator
operation and waste composition on trace metal fate are particularly lacking. Data to evaluate
the effectiveness of typical APCSs for collecting flue gas metals are also needed.
In response to these data needs, two extensive test programs were completed using the
RKS at the IRF in FY88 and FY89. Both test programs were performed to support regulations
development by EPA's OSW (S. Garg, R. Holloway, coordinators). These tests'quantified the
distribution of metals among the discharge streams of the RKS, and identified the effects of kiln
temperature, afterburner temperature, and waste feed chlorine content on these discharge
distributions. ;
For both test programs, kiln temperature was varied from nominally 816° to 927°C
(1,500° to 1,700°F); afterburner temperature was varied from nominally 982° to 1,204°C (1,800°
to 2,200 °F); and waste feed chlorine content was varied from 0 to nominally 8 percent. The
main difference between the two programs was the primary APCS used. A venturi/packed-
colurnn scrubber was used in the first test program (FY88); a single-stage ionizing wet scrubber
was used in the second test program (FY89). ;
i
The feed for both test programs consisted of a synthetic waste containing organics
premixed with a clay absorbent material. Toluene, tetrachloroethene, and chlorobenzene were
used as the organic compounds, and the waste feed chlorine content was altered by adjusting
their ratio in the mixture. The synthetic waste was continuously fed to the kiln by a screw
feeder. The test metals were combined in an aqueous solution and spiked bnto the solid
material as it was fed to the kiln. Five hazardous constituent metals were used: arsenic, barium,
cadmium, chromium, and lead. In addition, the nonhazardous constituent trace elements
bismuth, copper, magnesium, and strontium were also incorporated into the test feed for
comparison and to provide data to evaluate a predictive numerical model under development
in another effort within RREL. [
The results of the two completed test programs have shown the following1'2:
19
-------
• Cadmium and bismuth were relatively volatile, averaging less than 40 percent
discharged to the kiln ash. The other metals were relatively nonvolatile, averaging
greater than 75 percent discharged to the kiln ash. Lead was inconsistent,
exhibiting volatile behavior in the first test program and relatively nonvolatile
behavior in the second.
• Increased kiln temperature in the presence of feed chlorine caused increased
volatility of bismuth, cadmium, and lead. Data were not obtained to evaluate the
effects of kiln temperature in the absence of feed chlorine.
• Afterburner temperature did not affect metal partitioning among the scrubber exit
flue gas and scrubber liquor discharge streams. There was no conclusive evidence
indicating an effect on scrubber collection efficiency for metals.
• The effect of the waste feed chlorine content on the partitioning of metals was not
consistent between the two test programs. Data from the first test program
indicated increased volatility with increased chlorine for copper and lead. Data
from the second test program showed that waste feed chlorine content did not
affect metal discharge distributions within limits of data variability established by
replicate test conditions.
• Further sample analysis has shown that Method 3050 may not be sufficiently
aggressive to fully liberate the metals from the clay feed and kiln ash. Metal
recoveries achieved with sample preparation by fusion methods were about twice
the recoveries achieved by Method 3050.
• Relative metal volatilities agreed with expectations based on metal volatility
temperatures with the exception of arsenic, which was much less volatile than
expected for feeding arsenic as As9O3. Dissolving As2O3 in solution results in
AsO3= anion, which could be much less volatile than As2O3, or perhaps adsorbed
onto the clay matrix. The other spiked metals were added to the feed as soluble
nitrates dissolved as soluble cations.
The IRF trace metal research program continued in FY91 with the completion of a third
parametric test program. For the FY91 program, a Calvert Flux-Force/Condensation Scrubber
pilot plant was installed as the primary APCS. Mercury was added for a total of 10 test metals.
In addition, the particulate load and particle size distribution were measured after the quench
and at the scrubber exit in an attempt to determine fractional particulate collection efficiencies.
Scrubber pressure drop was also added as a test variable to investigate its effect on fractional
particulate collection 'efficiencies by particle size range.
As in the past trace metal test programs, the synthetic waste was a toluene-based organic
liquid mixture added to a clay absorbent material. The chlorine content of the synthetic waste
was varied by changing the relative amounts of toluene, chlorobenzene, and tetrachloroethene.
The test metals were premixed in an aqueous solution and spiked onto this solid material during
feeding to the kiln.
20
-------
The test variables for the FY91 tests were kiln temperature, waste feed chlorine content,
and scrubber pressure drop. Afterburner temperature (a test variable in past programs) was not
a test variable for these tests and was held constant. The concern over metal emissions from
incinerators has created an interest in determining whether operating the primary combustion
chamber at reduced temperature can cause greater metal retention in the kiln ash by reducing
metal volatilization and entrainment. To study this mode of operation, three low-kiln-
temperature tests were specified. Unlike the two previous trace metals test programs, three tests
were performed with the kiln temperature varied with no chlorine in the waste feed. These tests
were designed to provide data on the effects of kiln temperature in the absence :of chlorine.
Test data collected included feed material composition, incinerator process variables,
and discharge stream analysis results. The sampling and analysis protocol was specified to track
the distributions of metals among the RKS discharge streams (incinerator ash, scrubber liquor,
and flue gas). Sampling and analysis for volatile organics in the flue gas was also performed to
demonstrate that the RKS is operated at conditions suitable for organic waste destruction.
In summary, the 6-week test program performed in FY91 aimed at identifying:
• The distribution of metals among kiln ash, scrubber liquor, and flud gas discharge
streams :
• The effects of kiln temperature and waste feed chlorine content on metal fate
• The efficiency of the Calvert scrubber for collecting flue gas metals and particulate
by particle size range j
• The effects of scrubber pressure drop on metal collection efficiencies and
particulate collection efficiencies by particle size range i
The test program was completed in May through July 1991. Test sample ianalyses were
still underway at the close of FY91. Test sample analyses were completed during FY92. A
complete set of initial trace metal analysis reports was not received until late March 1992,
however. In addition, initial evaluation of-these trace metal analysis data raised several
questions concerning reported concentrations. Accordingly, in May it was decided to submit
several test program samples for reanalysis. |
Results of these repeat analyses were not reported until late September 1992. However,
relatively complete test program data were available from the late March reports to allow
evaluation of cadmium, magnesium, mercury, and strontium distributions. In addition, a partial
evaluation of bismuth, copper, and lead distributions was also possible. Results from these
evaluations, and other test data obtained are summarized in the following subsections.
3.1
TEST PROGRAM
As noted above, for this program, the RKS APCS was modified by installing a Calvert
Flux-Force/Condensation Scrubber pilot plant as the primary APCS. The skid-mounted
components of the system supplied by Calvert Environmental, were the condenser/absorber,
Calvert Collision Scrubber, entrainment separator, wet electrostatic precipitator, caustic tank and
21
-------
injection pump, and induced draft (ID) fan, as shown in the scrubber process schematic in
Figure 2. The flue gas quench, heat exchanger, and secondary APCS currently in place at the
IRF were used in place of similar components usually supplied by Calvert.
The RKS quench at the IRF was modified to create a two-stage quench. Provision for
injecting fresh water in the first stage and recirculated water in the second stage was installed.
This arrangement was designed to minimize the addition of fine particles to the flue gas by
reducing the spray dryer effect, which occurs when recirculated quench liquor containing
dissolved solids is used to quench hot flue gas. In the normal RKS quench configuration,
makeup water is added to the recirculating liquor storage tank for the quench and scrubber
systems. For these tests, however, the quench system plumbing was modified so that most of the
makeup water could be added as the fresh water supply to the first stage of the quench.
After quenching, the flue gas was directed to the Calvert scrubber. Flue gas exiting the
Calvert scrubber ID fan was directed to the secondary APCS shown in Figure 2 before being
discharged to the atmosphere.
3.1.1 Synthetic Test Mixture
The synthetic waste fired throughout the test program consisted of a mixture of organic
liquids added to a clay absorbent material. Trace metals were incorporated by spiking an
aqueous mixture of the rnetals of interest onto the organic liquid-containing solid material. The
FROM RF
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ELECTROSTATIC
PRECIPITATOR
Figure 2. Schematic of the Calvert Scrubber System.
22
-------
synthetic waste was fed to the rotary kiln via a screw feeder at a nominal rate of 63 kg/hr
(1401b/hr). ;
The base solid material was a calcined attapulgite clay sold commercially as a granular
absorbent for spill cleanup. The main components of the clay are hydrated aluminum-
magnesium silicate, free silica, dolomite, and calcite. Moisture content in the clay is about
7 percent.
The organic liquid base for the synthetic waste consisted of toluene:, with varying
amounts of tetrachloroethene and chlorobenzene added to provide a range of synthetic waste
chlorine contents. Waste chlorine content in the combined feed was varied from 0 (no
chlorinated organics added) to nominally 4 percent. The synthetic waste was prepared by adding
the premixed organic liquid to the clay absorbent material in a portable cement mixer, yielding
a homogeneous mixture containing about 22 percent (by weight) organic liquid. The clay/organic
mixture remained a,free-flowing solid, similar to the unspiked clay absorbent. After mixing, the
test mixture was poured into 55-gal drums, with lids, and stored until needed. •
All trace metals of interest, except magnesium and chromium, were introduced into the
kiln by metering an aqueous spike solution of the metals into the clay/organic liquid mixture at
the screw feeder, just prior to feed introduction. The aqueous spike solution was prepared in
glass containers, and contained the hazardous constituent trace metals arsenic, barium, cadmium,
mercury, and lead, and the nonhazardous constituent trace metals bismuth; copper, and
strontium. Previous analyses of the test clay absorbent material showed it to 'contain about
53 ppm of chromium and 2.2 percent of magnesium. Thus, chromium and magnesium were not
included in the aqueous spike solution, but were, instead, inherent in the feed because of their
presence in the clay absorbent matrix. Barium, cadmium, copper, and strontium were also
detected in the clay at concentrations of 30, 2, 35, and 40 ppm, respectively. Because these
concentrations were not considered sufficiently high to meet the test objectives, these metals
were supplemented by including them in the spike solution. ;
The spike solution was metered at a rate that produced the final nominal synthetic waste
feed concentrations noted in Table 8. A gear pump was used to continuously inject the trace
metal aqueous spike solution at a nominal flowrate of 2 L/hr. The clay/organic mixture and
metals spike solution feedrates were carefully monitored using scales. ;
3.1.2 Test Conditions
As noted above, the test variables for the program were kiln exit gas temperature,
chlorine content of the synthetic waste feed, and Calvert scrubber pressure drop. Each was
varied over three levels, as specified in Table 9. As shown, the test program consisted of 11
tests. Target kiln exit gas temperatures were 538°, 816°, and 927°C (1,000?, 1,500°, and
1,700°F). Target feed chlorine concentrations were 0, 1, and 4 percent. The scrubber pressure
drop for Tests 1 through 9 was held nominally constant, at 12.4 kPa (50 in of water column
[WC]). Test points 10 and 11 were at the same nominal conditions as test point 8, but with
scrubber pressure drops of 8.7 and 17.4 kPa (35 and 70 in WC), respectively.
Two baseline tests were also performed. These tests were conducted to determine if
there is a hysteresis effect caused by test-to-test carryover of metals. The clay/organic liquid
23
-------
TABLE 8. TARGET TRACE METAL INTEGRATED FEED CONCENTRATIONS
Synthetic solid
hazardous waste
Metal
Hazardous constituent
Arsenic
Barium
Cadmium
Chromium
Lead
Mercury
Other trace metals
Bismuth
Copper
Magnesium
Strontium
trace metals
concentration,
ppm
35
420
20
40
50
5
400
425
16,000
430
TABLE 9. TARGET TEST CONDITIONS
Kiln exit
temperature,
Test °C (°F)
1 538 (1,000)
2 816 (1,500)
3 927(1,700)
4 538 (1,000)
5 816 (1,500)
6 927 (1,700)
7 538 (1,000)
8a 816 (1,500)
9 927 (1,700)
10 816 (1,500)
11 816(1,500)
Feed mixture
chlorine content,
%
0
0
0
1
1
1
4
4
4
4
4
Calvert scrubber
pressure drop,
kPa (in WC)
12.4 (50)
12.4 (50)
12.4 (50)
12.4 (50)
12.4 (50)
12.4 (50)
12.4 (50)
12.4 (50)
12.4 (50)
8.7 (35)
17.4 (70)
aTwo baseline tests were performed at test condition 8 with
the clay/organic liquid mixture, but without the aqueous
metals spike solution.
24
-------
mixture was fed, but the aqueous metals spike solution was not. One test was conducted several
days before the test series began to establish baseline conditions for metals present in the
incinerator system. The second baseline test was performed 2 days after the test series was
completed. The two baseline tests were performed at test condition 8. '
All tests were performed at the same nominal afterburner exit flue gas O2 (9 percent),
afterburner exit gas temperature (1,093°C [2,000°F]), and synthetic waste feedrate (63.5 kg/hr
[140 lb/hr]), of which 14 kg/hr (30 Ib/hr) was the organic liquid matrix. For all tests, the kiln
rotation rate was held constant to provide a solids residence time of about 1 hour. The test
conditions reflect typical industrial hazardous waste incinerator operation. !
i
3.13 Sampling and Analysis
For each test a composite sample of the clay/organic liquid feed mixture and the
scrubber liquor, and two composite samples of the kiln ash discharge and the aqueous metal
spike solution were collected. The incinerator flue gas at the quench exit and at the exit of the
Calvert scrubber system was sampled for trace metals using the EPA multiple metals train, for
mercury using Method 101A, and for particle size distribution using an Anderson cascade
impactor train. In addition, the scrubber system exit flue gas was sampled for the volatile
POHCs using Method 0030, and the stack gas downstream of the secondary APCS was sampled
for particulate and HC1 using Method 5.
Flue gas sampling train samples were analyzed for their method-specific analytes, e.g.,
metals train samples for the test program trace metals, and Method 0030 samples for the test
program volatile POHCs. Feed clay absorbent, aqueous metal spike solution;, kiln ash, and
scrubber liquor samples were analyzed for the ten test program trace metals. The ASTM lithium
tetraborate fusion method (ASTM E-886) was used to digest solid samples for analysis. In
addition, kiln ash TCLP leachates were prepared and analyzed for the test program trace metals.
3.2
TEST RESULTS
As noted above, final analytical results for arsenic, barium, and chromium in most test
samples and bismuth, copper, and lead in many test samples were reported in late September
1992, and will be evaluated and reported in FY93. Preliminary results from initial data
evaluations are outlined in this section.
Table 10 summarizes the metals partitioning data among the RKS discharge streams
for all 11 tests in which the metals were spiked into the feed. Arsenic, barium, and chromium
distributions are not given in the table because final analytical data for these metals were under
evaluation at the end of FY92 as noted above. The first set of columns in Table 10 represents
the fraction of the metal fed accounted for by the noted discharge (e.g., kiln ash, scrubber exit
flue gas). The range (low, high) exhibited over the 11 tests performed and the averages for all
11 tests are also noted. The second set of columns in the tables represents fractions normalized
to the total amount measured in the discharge streams, closed around the scrubber discharges.
Three discharge streams were considered for closure around the scrubber discharges: the kiln
ash discharge, the scrubber liquor, and the scrubber exit flue gas. The normalized fractions.
represent discharge distributions as they would have been had mass balance closure for the metal
25
-------
TABLE 10. SUMMARY OF METAL DISCHARGE DISTRIBUTIONS IN THE KILN ASH,
QUENCH EXIT FLUE GAS, SCRUBBER EXIT FLUE GAS, AND SCRUBBER
LIQUOR
Normalized distribution, %
Distribution,
Metal
Low
% of metal fed
High Average
of total measured
Low
High
Average
Kiln ash
Bismuth
Cadmium
Copper
Lead
Magnesium
Mercury
Strontium
34
21
68
53
78
<1
54
80
79
90
99
116
<3
98
55
50
81
79
95
<1
73
86
72
95
94
99.6
<1
98.8
96
96
99.9
97
99.9
<8
99.9
91
86
98
96
99.5
<3
99.4
Quench exit flue gas
Bismuth
Cadmium
Copper
Lead
Magnesium
Mercury
Strontium
0.8
3
0.1
1
< 0.002
21
0.004
10
21
4
5
0.009
130
0.1
4
10
2
3
0.003
75
0.03
Scrubber exit Hue gas
Bismuth
Cadmium
Copper
Lead
Magnesium
Mercury
Strontium
<0.06
<0.1
0.03
<0.6
0.001
1.1
0.003
2
1
0.3
<0.6
0.02
37
0.1
0.3
0.3
0.1
<0.6
0.003
15
0.03
<0.1
<0.1
0.04
<0.6
0.001
18
0.003
0.3
1.3
0.4
<1.2
0.02
77
0.1
0.1
0.5
0.1
<0.8
0.003
33
0.04
Scrubber liquor
Bismuth
Cadmium
Copper
Lead
Magnesium
Mercury
Strontium
0.5
2
0.02
<1.2
0.1
<1.3
0.02
5
15
4
6
0.4
42
0.6
2
8
2
3
0.2
18
0.4
4
3
0.03
<2
0.1
20
0.03
14
27
5
6
0.4
80
1
9
13
2
3
0.2
37
0.6
26
-------
been 100 percent; the sum of the normalized values of each element in the three discharge
streams is, indeed, 100. '
Table 11 summarizes the mass balance closures achieved for each metaL Mass balance
closure represents the fraction of the feed metal that is accounted for in the kiln ash, scrubber
Liquor, and scrubber exit flue gas. Based on the initial data and excluding mercury, Table 11
shows that the average mass balance closure ranged from 58 percent, for cadmium, to 95 percent,
for magnesium, with an overall average of 76 percent. Excluding mercury, individual metal
closures ranged from 25 to 116 percent. [
In all tests, mercury concentrations in the kiln ash were below detections limits of
0.1 rng/kg. This is expected based on mercury's high vapor pressure. Table; 10 shows that
mercury recovery in the flue gas at the quench exit ranged from 21 to 130 percentof the mercury
fed, averaging 75 percent. It is interesting to note that, although the recovery of mercury in the
quench flue gas was good, the downstream recovery in the scrubber liquor and scrubber exit flue
gas was much lower. An explanation for this observation is provided by Figure 3, which shows
the mercury partitioning to the scrubber liquor as a function of the waste feed chlorine content.
For the three tests with no chlorine in the waste feed, mercury concentrations in the scrubber
liquor were reported below detection limits of 4 fig/L. With feed chlorine content increased to
about 0.6 percent, mercury partitioning to the scrubber liquor increased to about 7 percent of
the mercury fed. Mercury partitioning to the scrubber liquor increased to: approximately
30 percent, with a further increase in waste feed chlorine content to about 3.5 percent.
TABLE 11. SUMMARY OF METAL MASS BALANCE
CLOSURE AROUND KILN ASH AND
SCRUBBER DISCHARGES
Metal mass balance
closure, %
Metal
Bismuth
Cadmium
Copper
Lead
Magnesium
Mercury
Strontium
Low
39
25
70
56
79
<4.1
58
High
84
94
92
99
116
77
102
Average
62
58
83
82
95
35
77
27
-------
123
Waste Feed Chlorine Content (%)
Figure 3. Mercury partitioning to the scrubber liquor versus waste feed chlorine content.
In the case of no chlorine in the waste feed, mercury was likely present in the flue gas
in its elemental form or as mercuric oxide. Both forms of mercury are practically insoluble in
water, but likely would still have been scrubbed from the flue gas at the low temperatures
reached in the Calvert scrubber. However, once collected in the scrubber liquor, these insoluble
forms of mercury likely settled to the bottom of the liquor storage tank and were not collected
when the liquor sample was taken, even though the storage tank was mixed before the sample
was collected. For the tests with chlorine in the feed, mercuric chloride may have formed in the
flue gas. Mercuric chloride is soluble in water and is more likely to be collected during sampling
of the scrubber liquor. The scrubber liquor partitioning data further suggest that the conversion
to mercuric chloride was directly related to the amount of chlorine available in the flue gas.
Table 12 presents the metals partitioning data for each test as a percent of the metal
fed. Table 13 similarly presents the normalized metals data. Again, arsenic and chromium
distributions are not given in the tables because final analytical data were under evaluation at
the end of FY92. Partial barium distributions are given in Table 12; no normalized barium
distributions appear in Table 13, however.
Tests 1 through 9 provide a parametric evaluation of two of the test variables, kiln exit
temperature and waste feed chlorine content, varied over three levels. In Tests 1, 2, and 3, the
target kiln temperature was varied from 538° to 927°C (1,000° to 1,700°F), while the waste feed
chlorine content was held constant at 0. In Tests 4, 5, and 6, the kiln temperature was also
varied, while the measured waste feed chlorine content was held constant at nominally
0.6 percent. Similarly, in Tests 7, 8, and 9, the kiln exit temperature was varied, but with an
average waste feed chlorine content of 3.4 percent. To examine the effects of waste feed
chlorine content at constant kiln temperature, Tests 1, 4, and 7, Tests 2, 5, and 8, and Tests 3,
6, and 9 can be compared. Tests 8, 10, and 11 can be compared to evaluate the third test
28
-------
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variable, scrubber pressure drop. These tests were conducted at the same nominal kiln exit
temperature and waste feed chlorine content, but with scrubber pressure drop varied from 8.2
to 16.9 kPa (33 to 68 in WC). !
Full data evaluation will be completed and all test data reported in FY93.
preliminary test results outlined above were reported in the following report: •
The
Fournier, D. J., Jr., and L. R. Waterland, "Data Summary Report: The Fate of
Trace Metals in a Rotary Kiln Incinerator with a Calvert Flux-
Force/Condensation Scrubber System," draft June 1992. !
33
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SECTION 4
INCINERATION OF ARSENIC-CONTAMINATED SOILS FROM
THE CHEMICAL INSECTICIDE CORPORATION SUPERFUND SITE
The Chemical Insecticide Corporation (CIC) Superfund Site in Edison Township, New
Jersey, was formerly used to manufacture pesticide products. The results of the remedial
investigation and feasibility study (RI/FS) show that the soils at the site are highly contaminated
by organochlorine pesticides and arsenic. Dioxin (i.e., 2,3,7,8-tetrachlorodibenzo-p-dioxin) has
also been found at concentrations up to 1.8 jug/kg (ppb) in some soil samples collected during
the RI/FS. Thermal treatment has previously been demonstrated to be an effective means of
destroying pesticides, dioxin, and other organic compounds. The finding of high concentrations
of arsenic in the soils at the CIC site has raised the question of whether a thermal treatment unit
treating soil from the site, and operating under conditions capable of attaining a 99.9999-percent
destruction and removal efficiency (DRE) for dioxin and a 99.99-percent DRE for other organic
contaminants, will also yield acceptable arsenic stack emissions. To address this question, EPA
Region 2 (J. Josephs, coordinator) requested that test burns be conducted at the IRF. Region 2
was specifically interested in whether flue gas emissions of arsenic could be limited to less than
0.04 percent of the amount of arsenic in the highly arsenic-contaminated site soil fed to the
incinerator, while operating at incineration conditions sufficient to destroy dioxin and other
organic materials to the prescribed DRE.
The test program for Region 2 was designed to develop the data to support feasibility
study (FS) efforts in evaluating incineration as a possible remedial alternative. The specific
objectives of the test program were:
• To confirm the ability of conventional rotary kiln incineration to destroy
organochlorine pesticide contaminants in the soil, as measured by their absence
in the treated soil (kiln ash) discharge
• To confirm the ability of a conventional rotary kiln incinerator, with a high-
efficiency scrubber, to achieve an arsenic RE of 99.96 percent under operating
conditions associated with a 99.9999 percent dioxin DRE, where RE is defined as:
RE = 100 l -
§as emission rate
feedrate
34
-------
A series of four incineration tests was performed, using the IRF's RKS with the Calvert
Flux-Force/Condensation scrubber for air pollution control. In three of the tests, CIC soil alone
was packaged into 1.5-gal fiberpacks and fed to the RKS kiln via the system's ram'feeder. In the
fourth test, CIC soil was mixed with lime, at a blend ratio of 0.5 kg of lime pef 10 kg of soil,
before being packaged.
4.1
TEST PROGRAM
4.1.1 Test Soil Description
The CIC site was formerly used to manufacture a variety of pesticides for commercial
and military applications. The CIC product list included a wide range of insecticides, fungicides,
roderiticides, and herbicides. One specific product was 2,4,5-trichlorophenoxyacetic acid
(2,4,5-T), which might have contained dioxin as a byproduct. Pesticide manufacturing activities,
with associated propess-water storage lagoons, and poor housekeeping, led to the widespread
chemical contamination of this site.
The RI/FS for the site showed that site soils were contaminated with the pesticides p,p'-
DDT, p,p'-DDD, p,p'-DDE, a-BHC, T-BHC, and chlordane; the herbicides 2,4-D, 2,4,5-T, and
Silvex; and the trace metals arsenic, cadmium, chromium, lead, and mercury. Arsenic levels as
high as 8,000 mg/kg were found. Dioxin was found in some site soil samples at a maximum
concentration of 1.8 /ig/kg. ;
Four drums of soil were excavated from the CIC site in February 1991 for use in this
test program. Composite characterization samples were taken for pretest analysis. The results
of these analyses show that soil with an arsenic content of about 900 mg/kg was available for
testing. This same soil was also contaminated with an average of 2 mg/kg of p,p'-DDD; 3 mg/kg
of p,p'-DDE; 26 mg/kg of p.p'-DDT; and 9 mg/kg of chlordane.
Prior to testing, the test soil was packaged into 1.5-gal plastic-bag-lined fiberpack
containers for feeding to the RKS via the ram feeder in place on the system. Each fiberpack was
filled with 4.5 kg (10 Ib) of soil, its plastic bag was secured with a wire tie, then the fiberpack's
lid was secured.
4.1.2 Test Conditions
The test series was designed specifically to determine whether incineration can attain
a 99.96-percent RE for arsenic, under operating parameters associated with a 99.9999-percent
dioxin DRE. The kiln chamber, afterburner chamber, and APCS operating parameters were
held nominally constant throughout the test program. The target incinerator operating
conditions for each test are given in Table 14. Testing was completed in August 1991.
4.13 Sampling and Analysis \
The sampling effort completed during each test consisted of:
• Obtaining a composite sample of the soil feed from each drum before the soil was
packaged into the fiberpack containers :
35 :
-------
TABLE 14. TARGET INCINERATOR TEST AND OPERATING CONDITIONS
Kiln exit gas temperature 982°C (1,800°F)
Afterburner exit gas temperature 1,204°C (2,200°F)
Kiln exit O2 level 10%
Afterburner exit O2 level 7.9%
Kiln solids residence time 0.5 hr
Total waste soil feedrate 55 kg (120 Ib)
Calvert scrubber pressure drop 12.4 kPa (50 in WC)
Scrubber liquor temperature 66°C (150°F)
Scrubber liquor blowdown rate 0 to 2 L/min (0 to 0.5 gpm)
• Collecting a composite sample of the kiln ash
• Collecting a composite sample of the scrubber liquor
• Continuously measuring O0 levels in the kiln exit and afterburner exit flue gases;
O2, CO, CO-,, and NOX at "the scrubber exit; and O2, CO, and CO2 levels at the
stack
• Sampling flue gas at the scrubber system exit for organochlorine pesticides using
Method 0010, arsenic using Method 108, and particulate and HC1 using Method 5
• Sampling at the stack downstream of the secondary APCS for arsenic
(Method 108), and particulate and HC1 (Method 5)
Aliquots of the soil feed and kiln ash sample for each tests were subjected to the TCLP.
The soil feed, soil feed TCLP leachate, kiln ash, and scrubber liquor sample for each test was
analyzed for organochlorine pesticides and the trace metals arsenic, barium, cadmium, chromium,
lead, mercury, selenium, and silver. The kiln ash TCLP leachate sample for each test was
analyzed for the above trace metals. Flue gas sampling train samples were analyzed for this
sampled analyte.
4.2 TEST RESULTS
Results from the test program performed are discussed in the subsections that follow.
Test results are grouped by analyte class.
42.1 Organochlorine Pesticides Analysis Results
Table 15 summarizes the results of the organochlorine pesticide analyses of the samples
analyzed. The data in Table 15 indicate that the soil feed contained up to 17 mg/kg of
36
-------
TABLE 15. ORGANOCHLORINE PESTICIDE ANALYSIS RESULTS
Concentration
Sample Chlordane
Test 1 (8/6/91)
Soil feed, mg/kg 14
Soil feed TCLP leachate, /ig/L < 10
Kiln ash, mg/kg <0.10
Scrubber liquor, /tg/L < 1.0
Scrubber exit flue gas, /tg/dscm <0.33
Test 2 (8/8/91)
Son feed, mg/kg 17
Soil feed TCLP leachate, /tg/L < 10
Kiln ash, mg/kg <0.10
Scrubber liquor, /tg/L < 1.0
Scrubber exit flue gas, /jg/dscm <0.30
Test 3 (8/13/91)
Soil feed, mg/kg < 10
Soil feed TCLP leachate, /tg/L < 10
Kin ash, mg/kg <0.10
Scrubber liquor, /tg/L < 1.0
Scrubber exit flue gas, /tg/dscm <0.31
Test 4 (8/15/91)
Soil feed, mg/kg 13
Soil feed TCLP leachate, /tg/L < 10
Kiln ash, mg/kg <0.10
Scrubber liquor, /tg/L <1.0
Scrubber exit flue gas, /tg/dscm <0.31
TCLP regulatory level, /tg/L 30
a-BHC
<2.0
8.3
<0.02
<0.20
< 0.066
<2.0
4.4
<0.02
<0.20
< 0.060
<2.0
3.6
<0.02
<0.20
< 0.061
<2.0
<2.0
<0.02
<0.20
< 0.062
a
7-BHC
<2.0
2.3
<0.02
<0.20
< 0.066
<2.0
<2.0
<0.02
<0.20
< 0.060
<2.0
<2.0
<0.02
<0.20
< 0.061
<2.0
<2.0
<0.02
<0.20
< 0.062
400
p,p'-DDE
5.5
<2.0
<0.02
<0.20
< 0.066
6.7
<2.0
<0.02
<0.20
< 0.060
3.4
.<2.0
<0.02
<0.20
< 0.061
4.8 .
<2.0
<0.02
<0.20
< 0.062
—
p,p'-DDD I
7.3
<2.o ;
<0.02
<0.20
< 0.066
7.3 '•
2.6
-------
chlordane; between 3.4 and 6.7 mg/kg of p,p'-DDE; between 4.3 and 7.3 mg/kg of p,p'-DDD;
and between 41 and 92 mg/kg of p,p'-DDT. However, none of these soil contaminants was
found in any of the feed TCLP leachate, kiln ash, or scrubber liquor samples. Low levels of
p,p'-DDT were found in the scrubber exit flue gas in two of the four tests, although no other
pesticide analyte was found.
Table 16 summarizes the lower bound degree of pesticide decontamination achieved
corresponding to the kiln ash practical quantitation limits (PQLs). Identified in Table 16 is the
upper bound fraction of the amount of each pesticide introduced in the incinerator feed that
could have been present in the kiln ash discharge in each test. The data in Table 16 show that
no more than 0.62 percent of the chlordane, 0.44 percent of the p,p'-DDE, 0.34 percent of the
p,p'-DDD, or 0.04 percent of the p,p'-DDT fed to the incinerator could have been discharged
in the kiln ash. The decontamination effectiveness of incineration under the conditions tested
was, thus, at least 99.38 percent for chlordane; 99.56 percent for p,p'-DDE; 99.66 percent for
p,p'-DDD; and 99.96 percent for p,p'-DDT.
Table 17 summarizes the organochlorine pesticide DREs achieved for the tests as
measured at the scrubber system exit. As shown in Table 17, for the two tests in which p,p'-DDT
was detected in the scrubber exit flue gas (Tests 1 and 4), the DRE achieved was
99.9916 percent. This exceeds the 99.99-percent principal organic hazardous constituent (POHC)
DRE requirement in the hazardous waste incinerator performance standard. The lower bound
DREs achieved for p,p'-DDT in Tests 2 and 3, based on the flue gas emission stream PQL, were
also greater than 99.99 percent. Lower bound DREs based on the flue gas emission stream
measurement PQLs were greater than 99.87 percent for chlordane, 99.901 percent for p,p'-DDE,
and 99.923 percent for p,p'-DDD. The expectation is that all three of these compounds were
destroyed at greater than 99.99 percent DRE; however, method PQLs were too high to
unambiguously establish this when these compounds were present at the lower concentrations
in the soil feed. The data in Tables 16 and 17 also show that the addition of lime to the test soil
in Test 4 had no measurable impact on the effectiveness of incineration in decontaminating the
soil, or on the DREs for the organochlorine pesticide compounds.
4.2.2 Arsenic and Other Trace Metal Distributions
Table 18 summarizes the arsenic concentrations measured, and the resulting feedrates
and flue gas emission rates, for the four tests performed. As shown in the table, the arsenic RE
achieved for Test 1 at the scrubber exit, 99.89 percent, was less than the target of 99.96 percent.
This result was obtained in a quick-turnaround laboratory analysis. Based on this result, it was
decided to perform Test 4, with lime blended with the soil to evaluate whether lime addition
affected arsenic RE.
In contrast to the Test 1 experience, the arsenic REs measured at the scrubber exit in
Tests 2 and 3 were 99.990 and 99.991 percent, respectively, greater than the target 99.96 percent.
No explanation for the order of magnitude higher scrubber exit arsenic emission rate experienced
in Test 1 compared to Tests 2 and 3 is readily apparent. The 99.991-percent scrubber exit
arsenic RE in Test 4, in which lime was added to the soil, was comparable to the REs in Tests 2
and 3.
38
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TABLE 16. ORGANOCHLORINE PESTICIDE DECONTAMINATION EFFECTIVENESS
Parameter
Test 1 (8/6/91)
Soil feed
Concentration, mg/kg
Amount fed, g
Kiln ash
Concentration, mg/kg
Amount discharged, mg
Fraction of amount fed, %
Test 2 (8/8/91)
Soil feed
Concentration, mg/kg
Amount fed, g
Kiln ash
Concentration, mg/kg
Amount discharged, mg
Fraction of amount fed, %
Test 3 (8/13/91)
Soil feed
Concentration, mg/kg
Amount fed, g
Kiln ash
Concentration, mg/kg
Amount discharged, mg
Fraction of amount fed, %
Test 4 (8/15/91)
Soil feed
Concentration, mg/kg
Amount fed, g
Kiln ash
Concentration, mg/kg
Amount discharged, mg
Fraction of amount fed, %
Chlordane p,p'-DDE
14 5.5
3.03 1.17
<0.1 <0.02
<16 <3.3
<0.54 <0.28
17 6.7
3.73 1.45
<0.1 <0.02
< 17 <3.5
<0.47 <0.24
< 10 3.4
<2.1 0.71
<0.1 <0.02
— a <0.44
13 4.8
2.78 1.07
<0.1 <0.02
<17 <3.4
<0.62 <0.32
p,p'-DDD
7.3
1.55
<0.02
<3.3
<0.21
7.3
1.59
<0.02
<3.5
<0.22
4.3
0.92
<0.02
<0.34
6.4
1.42
<0.02
<3.4
<0.24
P,p'-DDT
;
{4.0
:
<0.02
<3.3
<0.02
92
19.9
<0.02
<3.5
<0.02
41
8.77
!
<0.02
•iO.04
i
46
I'O.l
<0.02
<3,4
<0.03
a— = Not applicable because not detected in the feed.
39
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TABLE 17. ORGANOCHLORINE PESTICIDE DREs
Parameter
Chlordane p,p'-DDE p,p'-DDD p,p'-DDT
Test 1 (8/6/91)
Pesticide feedrate, mg/hr
Scrubber exit flue gas emission rate, /tg/hr
DRE, %
Test 2 (8/8/91)
Pesticide feedrate, mg/hr
Scrubber exit flue gas emission rate, /ig/hr
DRE, %
Test 3 (8/13/91)
Pesticide feedrate, mg/hr
Scrubber exit flue gas emission rate, /ig/hr
DRE, %
Test 4 (8/15/91)
Pesticide feedrate, mg/hr
Scrubber exit flue gas emission rate, /*g/hr
DRE, %
791
<990
> 99.87
951
<860
>99.910
<540
<890
a
712
<880
> 99.88
305
<200
> 99.934
371
<170
> 99.954
183
<180
> 99.901
275
<180
> 99.935
405
<200
> 99.951
405
<170
> 99.958
234
<180
> 99.923
366
<180
> 99.951
3,640
306
99.9916
5,100
<170
> 99.9967
2,240
<180
> 99.9920
2,600
219
99.9916
Not applicable because not detected in the feed.
TABLE 18. ARSENIC REMOVAL EFFICIENCIES
Parameter
Test 1 Test 2 Test 3 Test 4
(8/6/91) (8/8/91) (8/13/91) (8/15/91)
Soil
Feedrate, kg/hr , 55.7
Arsenic concentration, mg/kg 1,040
Arsenic feedrate, g/hr 57.9
Scrubber exit flue gas
Flowrate, dscm/min 49.8
Arsenic concentration, /zg/dscm 22.1
Arsenic emission rate, mg/hr 66.0
55.5
1,040
57.7
47.6
2.04
5.82
54.2
794
43.0
48.6
1.38
4.02
RE, %
99.89
99.9899 99.9907
57.0
803
45.8
48.4
1.43
4.15
99.9909
40
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Table 19 summarizes the concentrations of all eight of the test metals ip the soil feed
and in each of the incinerator discharge streams analyzed. The table also notes the soil feed and
kiln ash TCLP leachate metal concentrations for each test, and the TCLP regulatory levels for
each TCLP metal determined. Comparing feed soil leachate, kiln ash leachate^ and scrubber
liquo'r metals concentrations to the TCLP regulatory levels shows that no regulatory level was
exceeded for any metal except arsenic. No feed soil would be an arsenic TC hazardous waste.
However, the Test 1 kiln ash was a TC hazardous waste for arsenic, and the Tests 2 and 3 kiln
ash leachates contained arsenic levels near the regulatory limit. The arsenic concentrations in
TCLP leachates of both the feed soil and the kiln ash for Test 4 were reduced from the levels
measured in the other three tests. This suggests that adding lime, as was done in Test 4, renders
the arsenic less leachable from both the soil and the resulting kiln ash. ]
The data in Table 19 suggest that the scrubber liquor discharge might be a1 TC hazardous
waste for arsenic based on the total sample analysis results shown. However, the scrubber liquor
metal concentrations shown in Table 19 are for bulk scrubber liquor samples, 'which contain
suspended solids. A true TCLP leachate of the full test program composite scrubber liquor was
TABLE 19. TRACE METAL ANALYSIS RESULTS
Sample
As
Ba
Cd
Cr
Pb
Hg
: Se
Ag
Test 1 (8/6/91)
Soil feed, mg/kg
Soil feed TCLP leachate, mg/L
Kiln ash, mg/kg
Kiln ash TCLP leachate, mg/L
Scrubber liquor, mg/L
Test 2 (8/8/91)
Soil feed, mg/kg
Soil feed TCLP leachate, mg/L
Kiln ash, mg/kg
Kiln ash TCLP leachate, mg/L
Scrubber liquor, mg/L
Test 3 (8/13/91)
Soil feed, mg/kg
Soil feed TCLP leachate, mg/L
Kiln ash, mg/kg
Kiln ash TCLP leachate, mg/L
Scrubber liquor, mg/L
Test 4 (8/15/91)
Soil feed, mg/kg
Soil feed TCLP leachate, mg/L
Kiln ash, mg/kg
Kiln ash TCLP leachate, mg/L
Scrubber liquor, mg/L
TCLP regulatory level, mg/L
1,040
2.2
653
5.8
8.5
56
0.89
60
0.76
0.16
1.7
0.009
0.50
0.005
0.054
16
< 0.007
9.7
< 0.007
0.15
120
0.086
74
0.28
0.23
10
< 0.002
<1.0
< 0.002
0.007
^11
0.066
<12
0.059
<0.13
<0.44
< 0.005
<0.45
< 0.005
0.01
1,040
2.2
619
3.8
12
66
0.57
60
0.70
0.23
1.1
0.012
0.42
0.005
0.023
19
< 0.007
11
< 0.007
0.089
118
0.079
58
0.088
0.27
5.8
< 0.002
<1.0
< 0.002
< 0.002
<11
6.057
16
0.065
<0.13
<0.44
< 0.005
<0.45
< 0.005
< 0.005
794
2.5
619
4.1
10
48
0.80
64
0.78
0.21
0.86
0.012
0.68
0.005
0.017
17
< 0.007
11
< 0.007
0.064
104
0.083
61
0.095
0.29
5.4
< 0.002
<1.0
< 0.002
< 0.002
<11
0.063
15
6.062
0.14
<0.43
< 0.005
<0.46
< 0.005
< 0.005
803
0.11
1,100
1.2
6.0
43
0.18
74
0.12
0.26
0.97
< 0.005
0.85
< 0.005
0.011
13
< 0.007
14
< 0.007
0.057
86
0.049
83
0.036
0.23
6.2
< 0.002
<1.0
< 0.002
< 0.002
15
6.058
<11
0.083
<0.13
<0.48
< 0.005
<0.44
< 0.005
< 0.005
5.0
100
1.0
5.0
5.0
1.0
5.0
41
-------
prepared by filtering the liquor and using the resulting filtrate as the leachate. Arsenic was not
detected in this composite scrubber liquor TCLP leachate at a PQL of 0.5 mg/L.
Table 20 summarizes the trace metal distributions among the incinerator discharge
streams, expressed as fractions (in percent) of the amount of each metal fed to the incinerator
for each test for all metals analyzed, except arsenic which will be discussed separately. The data
in Table 20 show that the kiln ash discharge accounted for most of the barium and lead fed in
all tests. The scrubber liquor contained barium and lead at concentrations about 10 percent of
those measured in the kiln ash. The kiln ash also accounted for the predominant fraction of
chromium fed in all tests, although the scrubber liquor accounted for higher relative fractions
of chromium. The behavior of cadmium was inconsistent from test to test. No mercury was
found in any kiln ash or scrubber liquor sample. The "less than" fractions noted in Table 20
correspond to sample analysis PQLs. Ostensibly, most or all of the mercury fed escaped the
incineration system via the scrubber exit flue gas.
Arsenic distributions are summarized in Table 21, with the addition of the scrubber exit
flue gas discharge stream which was sampled. The data in Table 21 show that the arsenic
distributions were quite similar in the three tests in which soil alone was fed (Tests 1 through 3).
Between 42 and 49 percent of the arsenic fed was accounted for in the kiln ash (treated soil)
discharge. About 20 percent was collected in the scrubber liquor. With lime added to the soil
TABLE 20. TRACE METAL DISTRIBUTIONS
Metal distribution, % of metal fed
Sample
Ba Cd
Cr
Pb
Hg
Test 1 (8/6/91)
Kiln ash
Scrubber liquor
Total
Test 2 (8/8/91)
Kiln ash
Scrubber liquor
Total
Test 3 (8/13/91)
Kiln ash
Scrubber liquor
Total
Test 4 (8/15/91)
Kiln ash
Scrubber liquor
Total
71
6
77
63
6
69
84
7
91
115
10
125
20
69
89
27
36
63
50
34
84
59
19
78
40
19
59
42
8
50
40
7
47
69
7
76
41
4
45
34
4
38
37
5
42
64
5
69
<7
<1
<8
42
-------
TABLE 21. ARSENIC DISTRIBUTIONS
Arsenic distribution, % of arsenic fed
Sample
Kiln ash
Scrubber liquor
Scrubber exit flue gas
Test 1
(8/6/91)
42
18
0.1
Test 2
(8/8/91)
42
19
0.01
Test 3
(8/13/91)
49
22
0.01
Test 4
(8/15/91)
91
13 :
0.01 ;
Total
60
61
71
104
(Test 4), the scrubber liquor fraction decreased to 13 percent of the amount fed, and the kiln
ash fraction increased to 91 percent of the amount fed. The scrubber exit flue gas arsenic
fraction was low, 0.1 percent or less, in all four tests.
A clearer picture of the variation in relative metal distributions with incinerator
operation is possible when the data in Table 21 are normalized by the total mass balance closure
achieved. Table 22 summarizes the test arsenic distribution data in this form. The distribution
fractions in Table 22 have been normalized to the total amount of arsenic measured in all the
discharge streams analyzed. Thus, these normalized values represent fractions that would have
resulted had mass balance closure in each test been 100 percent. Use of distribution fractions
normalized in this manner allows clearer data interpretations, because mass balance closure is
eliminated as a source of test-to-test data variability. In other words, given that variable and less
than perfect mass balance closure is experienced, the use of normalized distributions is a best
attempt to quantify metal partitioning phenomena. •
The normalized distributions in Table 22 clearly show that about 70 percent of the
arsenic accounted for was discharged in the kiln ash, or treated soil, in the three tests feeding
soil alone (Tests 1 through 3). About 30 percent of the arsenic measured was accounted for in
the scrubber system liquor. A small fraction of the arsenic measured was accounted for by the
scrubber exit flue gas. However, with lime added, in Test 4, the kiln ash arsenic fraction
increased to 88 percent and the scrubber liquor arsenic fraction decreased to about 12 percent.
The scrubber exit flue gas arsenic fraction remained negligible. The addition of lime to the soil
appears to have stabilized the arsenic, tending to keep it in the kiln ash.
The apparent arsenic scrubber collection efficiencies (defined in Section 2,2.1) for these
tests are also given in Table 22. The data show that the Calvert scrubber system achieved an
average of 99.95 percent arsenic collection in Tests 2, 3, and 4. The apparent collection
efficiency in Test 1 was lower, at 99.44 percent. However, the Test 1 result is suspected to be
an outlier.
43
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TABLE 22. NORMALIZED ARSENIC DISTRIBUTIONS
Sample
Arsenic distribution, % of arsenic measured
Test 1 Test 2 Test 3 Test 4
(8/6/91) (8/8/91) (8/13/91) (8/15/91)
Kiln ash
Scrubber liquor
Scrubber exit flue gas
70.2
29.6
0.17
68.3
31.7
0.01
69.3
30.7
0.01
87.8
12.2
0.01
Total
100
100
100
100
Apparent scrubber collection efficiency 99.44 99.953 99.963 99.937
4.2.3 Particulate and HCI Emissions
Flue gas particulate levels measured at the Calvert scrubber exit ranged from 9 to
19 mg/dscm (corrected to 7 percent O->). These levels would represent the stack emissions of
a typical incinerator equipped with a Calvert scrubber. These levels are substantially below the
180 mg/dscm (at 7 percent O9) hazardous waste incinerator performance standard. Apparent
scrubber system HCI collection efficiencies, calculated using the chlorine feedrates and measured
emission rates, were 99.95 percent, or slightly higher, in all tests. These levels are better than
the 99 percent collection efficiency required by the hazardous waste incineration performance
standards.
43 CONCLUSIONS
Test program data confirm that incineration under the conditions tested resulted in the
elimination of the soil pesticide contaminants. No pesticide was detected in any kiln ash (treated
soil) sample. Based on method PQLs, the decontamination effectiveness demonstrated was at
least 99.38 percent for chlordane, 99.56 percent for p,p'-DDE, 99.66 percent for p,p'-DDD, and
99.96 percent for p,p'-DDT. In addition, pesticide DREs of at'least 99.9916 percent were
achieved for p,p'-DDT under the conditions tested. None of the other pesticide contaminants
was detected in the scrubber exit flue gas; lower bound DREs, corresponding to method PQLs,
ranged from at least 99.87 percent for chlordane to at least 99.92 percent for p,p'-DDD.
Arsenic REs of 99.99 percent were achieved with the Calvert scrubber under the
conditions tested feeding soil alone. Adding lime to the soil did not measurably improve arsenic
RE.
Trace metal concentrations in TCLP leachates of both untreated soil and kiln ash
(treated soil) were significantly below corresponding TC regulatory levels for all metals except
arsenic. Soil leachate arsenic concentrations were 40 to 50 percent of the regulatory level. Kiln
44
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ash leachate arsenic concentrations were near or above arsenic's TC regulatory level, suggesting
that treated soil could or would be a TC hazardous waste. Adding lime to the spU significantly
lowered leachate arsenic concentrations in both the soil and resulting incineration kiln ash.
Nominally 70 percent of the arsenic measured in the incinerator discharge was in the
kiln ash of all tests in which soil alone was fed; about 30 percent was accounted for in the
scrubber liquor. A negligible fraction was accounted for in the scrubber exit flue gas. In the test
in which lime was added to the soil, the kiln ash arsenic fraction increased to about 90 percent;
about 10 percent of the arsenic measured was in the scrubber liquor of this test; Scrubber exit
flue gas continued to account for a negligible fraction of the arsenic discharged. The Calvert
scrubber apparent arsenic collection efficiency was approximately 99.95 percent, and was not
affected by lime addition. Paniculate levels at the Calvert scrubber exit were nominally 10 to
20 mg/dscm at 7 percent O-,, well below the hazardous waste incinerator performance standard
of 180 mg/dscm at 7 percent Cv Calvert scrubber apparent HC1 collection efficiencies were
99.95 percent or greater, above the hazardous waste incinerator performance standard of
99 percent. j
In summary, test results suggest that conventional rotary kiln incineration in a unit
equipped with a high-efficiency scrubber system, such as the Calvert system tested, would be an
appropriate treatment. Elimination of contaminant organochlorine pesticides from the soil, and
destruction of the contaminant at a DRE of 99.99 percent, was achieved. Arsenic;REs of greater
than 99.96 percent were achieved in the system with the Calvert scrubber in normal operation.
The hazardous waste incinerator particulate and HC1 performance standards were easily
achieved. :
Incineration treatment of soils with arsenic concentrations in the! range of the
concentrations of the soil tested may result in the treated soil being a TC hazardous wastes.
However, adding lime to soil prior to incineration can significantly reduce the lea'chability of the
kiln ash arsenic in the TCLP test. :
Test results were reported in the test report: ;
• Siag, A., D. J. Fournier, Jr., and L. R. Waterland, "Pilot-Scale Incineration of
Contaminated Soil from the Chemical Insecticide Corporation Superfund Site,"
draft April 1992, revised September 1992.
45
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SECTION 5
INCINERATION OF CONTAMINATED SLUDGES FROM
THE BOFORS-NOBEL SUPERFUND SITE
The Bofors-Nobel Superfund Site in Muskegon, Michigan, was included on the National
Priority List in March 1989. Several former lagoons at the site contain sludges contaminated
with several volatile and semivolatile organic contaminants, chiefly methylene chloride,
chloroform, benzene, toluene, azobenzene, benzidine, and 3,3'-dichlorobenzidine. The sludges
are also contaminated with several trace' metal contaminants, chiefly barium, cadmium,
chromium, and lead. EPA Region 5 and USAGE (H. Ellison, Region 5, L. Janis, USAGE,
coordinators) requested that the IRF conduct test burns to support evaluations of incineration
as a treatment technology for the contaminated sludges. The purpose of the test program was
to evaluate the incinerability of selected site sludges in terms of the destruction of organic
contaminants and the fate of contaminant trace metals. The specific test objectives addressed
the following questions:
• Can incineration effectively destroy the sludges' POHCs to the required DRE of
99.99 percent?
• Are treated sludges (kiln ash) free of organic contamination?
• What are the nature and concentrations of any organic contaminants in the
discharge from a wet scrubber APCS?
• What is the distribution of the contaminant trace metals among the incineration
system discharge streams?
• What is the effectiveness of the IRF APCS in collecting particulate and trace
metals?
This test program investigated the treatability of sludges from two of the site lagoons.
Three incineration tests, under similar incinerator operating conditions, were performed for each
of the two sludges. All of the tests were conducted in the IRF's pilot-scale RKS, which was
equipped with a venturi scrubber/packed-column scrubber APCS.
Results of the test program are discussed in the subsections that follow.
46
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5.1
TEST PROGRAM
5.1.1 Test Waste Description \
The ROD for the Bofors site identifies five lagoon sludges as candidates for incineration
treatment. The sludges in these five lagoons are contaminated to varying degrees by several
volatile and semivolatile organic compounds. From the baseline risk assessment, the ROD
identified six principal organic contaminants of concern: methylene chloride, benzene,
3,3'-dichlorobenzidine, aniline, azobenzene, and benzidine. Hazardous metal contaminants were
also present. Among these, cadmium and lead were present at maximum concentrations of 22
and 887 mg/kg, respectively, in some lagoon sludge samples. :
Two of the five incineration candidate sludges, the Lagoon 3 and Lagoon 8j sludges, were
selected for testing at the IRF based on the results of the bench-scale thermal treatability studies
and on other physical/chemical properties of the sludges.
5.12 Test Conditions
Three tests were performed at similar incinerator operating conditions for each lagoon
sludge selected (six tests total). For each test, test sludges were fed to the kiln via the fiberpack-
drum ram feeder system. Each fiberpack drum was packaged to contain nominally4.6 kg (10 Ib)
of sludge. During each test, one fiberpack was charged into the kiln every 5 min, resulting in
target sludge feedrates of nominally 55 kg/hr (120 Ib/hr). Kiln rotation rate was set to result
in solids residence time in the kiln of 45 to 60 min.
Table 23 compares the target and actual test operating conditions for each test. As
shown, average kiln exit gas temperatures were within 25°C (44°F) of target temperatures for
all tests. Kiln exit flue gas O9 levels were within 2 percent of target levels. ' Afterburner
temperature was within 4°C (7°F) of target for all tests. ;
5.13 Sampling and Analysis
In addition to obtaining sludge feed, kiln ash, and scrubber liquor samples^ the sampling
protocol for all tests included sampling the flue gas at the afterburner exit and at the scrubber
system exit: EPA Method 0010 for semivolatile organic constituents; EPA Method 0030 for
volatile organic constituents; and an Anderson cascade impactor train for particulate size
distribution. In addition, the EPA multiple metals sampling train sampled : the flue gas
downstream of the scrubber system for trace metals. Finally, EPA Method 5 was used to sample
the flue gas at the afterburner exit, the scrubber system exit, and the stack downstream of the
secondary APCS for particulate and HC1.
In addition to analyzing flue gas sampling trains for their sampled analyte set, the sludge
feed sample for each test and each of the kiln ash and scrubber liquor samples were analyzed
for semivolatile and volatile organic hazardous constituents and trace metals. Also, the sludge
feed and the kiln ash for each test were subjected to TCLP extraction, and;the resulting
leachates were analyzed for trace metals.
47
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TABLE 23. TARGET VERSUS ACTUAL OPERATING CONDITIONS
Kiln
Exit temperature, °C (°F)
Test
1
2
3
4
5
6
Target
982
982
982
982
982
982
(1,800)
(1,800)
(1,800)
(1,800)
(1,800)
(1,800)
Actual
average
1,007
986
996
988
976
979
(1,844)
(1,806)
(1.825)
(1,811)
(1,788)
(1,794)
Afterburner
Flue gas O2, %
Target
10
10
10
10
10
10
Actual
average
10.3
9.4
8.1
8.1
9.5
9.3
Exit temperature, °C (°F)
Target
1,204
1,204
1,204
1,204
1,204
1,204
(2,200)
(2,200)
(2,200)
(2,200)
(2,200)
(2,200)
Actual
average
1,208
1,208
1,208
1,208
1,208
1,208
(2,207)
(2,207)
(2,207)
(2,207)
(2,207)
(2,207)
Flue gas O2, %
Target
7
7
7
7
7
7
Actual
average
4.7
11.2a
5.7
5.9
6.0
6.1
"Afterburner O2 sampling probe clogged.
5.2 TEST RESULTS
5.2.1 Volatile Organic Constituents
Table 24 summarizes the volatile organic constituent concentrations measured in each
Lagoon 3 test sample. A compound is noted in Table 24 if it was found in any test program
sample in Tests 1 through 3. The major volatile organic contaminants in the Lagoon 3 sludge
samples were benzene, toluene, methylene chloride, and chloroform. These compounds were
generally not found in the incineration residuals streams (kiln ash and scrubber liquor) or in the
incinerator flue gas at the two locations sampled.
The Lagoon 3 sludge samples were analyzed using the high-level sediment/soil
procedure documented in Method 8240. This method gives the PQLs of 0.625 to 1.25 mg/kg for
all volatile organic analytes except acetone with a 12.5 mg/kg PQL. The Test 1 sample was the
first of the Lagoon 3 sludge samples analyzed. In this initial analysis, the volatile organic
concentrations in the undiluted methanol extract prepared in the high-level sediment/soil
procedure were sufficiently high that the mass spectrometer detector was saturated over much
of the chromatogram. However, it was possible to quantitate the levels of bromomethane,
1,1,1-trichloroethane, chlorobenzene, ethyl benzene, and total xylenes noted in Table 24. The
methanol extract was subsequently diluted 100-fold and reanalyzed. This second analysis allowed
quantitation of the major sludge components noted in Table 24: methylene chloride, chloroform,
benzene, and toluene. Diluted methanol extracts were used in all subsequent Lagoon 3 sludge
sample analyses. This dilution resulted in the higher PQLs for the minor components for the
Test 2 and 3 sludge samples noted in Table 24.
Incineration effectively decontaminated the Lagoon 3 sludge of its major volatile organic
constituents. Using the sludge-feed and ash-collected weights from each test, and the
composition data in Table 24, the following decontamination efficiencies were calculated: at
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least 99.995 percent for methylene chloride; greater than 99.9991 percent for chloroform; and
at least 99.99994 percent for benzene and toluene.
Table 25 summarizes the volatile organic constituent concentrations measured in each
Lagoon 8 sludge incineration test sample. Again, a compound is noted in Table 25 if it was
found in any test sample from Tests 4 through 6. As shown in Table 25, toluene was the only
volatile organic contaminant found in the Lagoon 8 sludge; it was present at only 3 mg/kg.
Toluene was found in all three kiln ash samples at levels of 36 to 38 Mg/kg. The amount of
toluene discharged in the kiln ash was about 0.5 percent of the amount fed. Thus, incineration
achieved a decontamination efficiency for toluene from the Lagoon 8 sludge of about
99.5 percent.
Benzene, ethyl benzene, and xylenes were found in all kiln ash samples at about 40, 10,
and 10 fig/kg, respectively. No toluene, benzene, ethyl benzene, or xylenes were found in the
scrubber liquor or the flue gas at either of the two locations sampled.
522 Semivolatile Organic Constituents
Of the list of analytes sought in the semivolatile organic analyses, only azobenzene and
3,3'-dichlorobenzidine were found in the Lagoon 3 sludge and only 3,3'-dichlorobenzidine was
found in the Lagoon 8 sludge. The Lagoon 3 sludge contained an average of 5,110 mg/kg of
azobenzene and 4,390 mg/kg of 3,3'-dichlorobenzidine. The Lagoon 8 sludge contained
710 mg/kg of 3,3'-dichlorobenzidine.
No semivolatile organic constituents were found at concentrations above the method
PQL in any test program incineration residuals (kiln ash and scrubber liquor) or flue gas
(measured at both the afterburner and scrubber exits) samples. Using the sludge feed and ash
collected weights from each test, the sludge feed organic contaminant concentrations noted
above, and the ash contaminant PQLs, the following decontamination efficiencies were
calculated: greater than 99.990 to 99.993 percent for azobenzene from the Lagoon 3 sludge;
greater than 99.989 to 99.992 percent for 3,3'-dichlorobenzidine from the Lagoon 3 sludge; and
greater than 99.89 percent for 3,3'-dichlorobenzidine from the Lagoon 8 sludge.
523 POHC DREs
Based on POHC selection criteria specified in the hazardous waste incinerator
regulations, the POHCs in the Lagoon 3 sludge would be benzene, toluene, and
3,3'-dichlorobenzidine; in Lagoon 8 sludge the POHC would be 3,3'-dichlorobenzidine. Table 26
summarizes the DREs measured for these POHCs in the tests performed.
As discussed above, no POHCs were detected in any flue gas sample analyzed, with the
exception of benzene in the Lagoon 3 sludge Test 1 afterburner exit flue gas. Therefore, except
for this one instance, only a minimum POHC DRE, based on the flue gas analysis method PQL,
can be established. Most of the entries in Table 26, as a result, indicate that POHC DRE was
greater than this lower bound.
The test results summarized in Table 26 show that a greater than 99.99 percent DRE
was clearly achieved in the Lagoon 3 sludge tests for toluene and 3,3'-dichlorobenzidine in
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TABLE 26. DESTRUCTION AND REMOVAL EFFICIENCIES (PERCENT) FOR THE
PRINCIPAL ORGANIC HAZARDOUS CONSTITUENTS
Measured at the afterburner exit
Measured at the scrubber exit
POHC
Testl
Test 2
Test3
Test 1
Test 2
Test 3
Lagoon 3 sludge
Benzene 99.961 > 99.989 > 99.9922
Toluene > 99.9917 > 99.984 > 99.9959
3,3'-Dichlorobenzidine > 99.9958 > 99.9950 > 99.9942
> 99.974 > 99.9930 > 99.9914
> 99.9953 > 99.9913 > 99.9970
> 99.9959 > 99.9949 > 99.9946
Test 4
Tests
Test 6
Test 4
Tests
Test 6
Lagoon 8 sludge
3,3'-Dichlorobenzidine > 99.971 > 99.972 > 99.971
> 99.975 > 99.975 > 99.974
Test I, 3,3'-dichlorobenzidine in Test 2, and benzene, toluene, and 3,3'-dichlorobenzidine in
Test 3, as measured both at the afterburner exit and the scrubber exit. In addition, benzene and
toluene DREs, as measured at the scrubber exit, were clearly greater than 99.99 percent in
Test 2. The afterburner exit flue gas benzene level measured in Test 1 corresponded to a
99.96 percent DRE. No benzene was found in the scrubber exit flue gas, corresponding to a
benzene DRE of greater than 99.97 percent. Clear compliance with the 99.99 percent DRE
standard at the scrubber exit was shown for all three Lagoon 3 sludge POHCs, with this one
detection limit exception.
For the Lagoon 8 sludge tests, methods PQLs, combined with the low feed POHC
concentrations, corresponded to lower bound DREs for 3,3'-dichlorobenzidine of 99.971 percent
to 99.972 percent, as measured in the afterburner exit flue gas, and 99.974 percent to
99.975 percent, as measured in the scrubber exit flue gas.
5.2.4 Trace Metals
Table 27 summarizes the trace metal concentrations measured in each Lagoon 3 sludge
incineration test sample. The five metals found in Lagoon 3 sludge samples are listed in the first
five columns of Table 27; the five metals not found in any Lagoon 3 sludge sample are listed in
the last five columns. The data in Table 27 show that the metals absent in Lagoon 3 sludge
samples were not found in any other test program sample. Metals found in the Lagoon 3 sludge
samples were distributed among all other incineration residuals and flue gas samples, with the
exception of arsenic, which was not found in the scrubber exit flue gas in Tests 2 and 3.
The data in Table 27 show that the concentrations of the five metals detected in the
Lagoon 3 sludge were comparable from test to test in the incinerator discharge streams with the
exception of arsenic, barium, cadmium, and chromium in the scrubber liquor. Scrubber liquor
concentrations for these four metals were unexplainably lower for Test 3 than for Tests 1 and 2.
The data in Table 27 show that arsenic, barium, and chromium levels in the flue gas were
52
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generally less than 50 /zg/dscm. Cadmium and lead levels, however, were significantly higher at
153 to 206 jug/dscm for cadmium, and 4,420 to 6,180 /ig/dscm for lead.
All test kiln ash samples were subjected to the TCLP, and resulting leachates were
analyzed. These results are shown in Table 27. The TCLP regulatory level is also noted in the
table. As shown, neither the Lagoon 3 sludge nor the kiln ash resulting from its incineration had
leachate metal concentrations that would make them TC hazardous wastes. The lead
concentrations in the bulk, unfiltered, scrubber liquor samples from all three tests exceeded the
TCLP regulatory level. However, the three-test composite scrubber liquor sample was filtered
to yield a TCLP leachate sample. Metals concentrations in this composite scrubber liquor TCLP
leachate are also given in Table 27. As shown the composite scrubber liquor TCLP leachate had
a lead concentration below the TCLP regulatory level.
Table 28 summarizes the trace metal analysis results for all Lagoon 8 sludge incineration
test samples. As was the case for the Lagoon 3 sludge tests, no Lagoon 8 sludge sample
contained detectable antimony, beryllium, mercury, selenium, or silver. Levels of arsenic,
barium, and chromium in the Lagoon 8 sludge were in the same range as in the Lagoon 3 sludge.
No cadmium was found in the Lagoon 8 sludge. Also, Lagoon 8 sludge lead levels were much
lower than those in the Lagoon 3 sludge.
The data in Table 28 show that the metals absent in the Lagoon 8 sludge were not found
in any other test program sample, with the exception of cadmium, which was found at low levels
in the scrubber exit flue gases of all three tests and in the scrubber liquors of two of the three
tests. Metals found in the Lagoon 8 sludge were distributed among all other incineration
residuals and flue gas samples, with the possible exception of lead, which was found in the
Tests 5 and 6 kiln ash samples at just greater than the method detection limit (MDL), and not
found above the MDL in the Test 4 kiln ash samples. Incinerator discharge stream
concentrations of the four metals detected in the Lagoon 8 sludge were comparable from test
to test with the exception of the scrubber liquor arsenic and lead concentrations and the scrubber
exit flue gas lead concentrations, all of which steadily decreased from Test 4 through Test 6. The
much higher lead concentration in the Test 4 scrubber exit flue gas, compared with the Tests 5
and 6 flue gases, is suspected to be the result of some residual Lagoon 3 sludge material from
Test 3 left on the afterburner walls as slag.
The data in Table 28 further show that neither the Lagoon 8 sludge feed sample nor any
of the test kiln ash samples would be TC hazardous wastes based on the trace metal
concentrations in their TCLP leachates. In addition, the trace metal concentrations measured
in scrubber liquor samples were sufficiently low that no test's scrubber liquor discharge would
be a TC hazardous waste, with the possible exception of the Test 4 unfiltered scrubber liquor.
Table 29 summarizes the test trace metal distributions among the three incineration
system discharges: kiln ash, scrubber liquor, and scrubber exit flue gas. The distribution
fractions in Table 29 have been normalized to the total amount of each metal measured in all
the discharge streams analyzed. Achieved mass balance closure levels ranged from 42 percent
to 107 percent if the lead mass balance closure for Test 4 (over 600-percent) is excluded. As
noted above, the high Test 4 scrubber exit flue gas lead concentration measured is suspected to
have been affected by some residual Lagoon 3 sludge material, from Test 3, left in the
afterburner.
54
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TABLE 29. NORMALIZED TRACE METAL DISTRIBUTIONS—PERCENT OF
METAL MEASURED
Lagoon 3 sludge
Lagoon 8 sludge
Trace metal
Barium
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Cadmium
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Chromium
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Lead
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Testl
(10/24/91)
84-86
2-4
12
100
6
58
36
100
86
5
9
100
3
63
34
100
Test 2
(10/29/91)
89-91
2-4
7
100
6
63
31
100
87
3
10
100
2
49
49
100
Test3
(10/31/91)
93-96
4
<3
100
6
92
2
100
97
3
1
100
3
82
15
100
Test 4
(11/5/91)
98-99
<1
1
100
(a)
(a)
(a)
(a)
93
3
4
100
<5
11
84-89
100
TestS
(11/6/91)
98-99
1
<1
100
(a)
(a)
(a)
(a)
96
2
2
100
41-63
1-8
33-55
100
Test 6
(11/7/91)
96
1
3
100
(a)
(a)
(a)
(a)
96
1
3
100
40-69
19-39
<38
100
'Cadmium not found in feed sample.
The distribution data in Table 29 show that barium and chromium exhibited relatively
nonvolatile behavior in all of the tests. Between 84 percent and 96 percent of the barium
discharged was accounted for by the kiln ash in the Lagoon 3 sludge tests; even more,
96 percent to 99 percent, was accounted for by the kiln ash in the Lagoon 8 sludge tests.
Similarly, between 86 percent and 97 percent of the chromium discharged was accounted for by
the kiln ash discharges in all of the tests. The scrubber exit flue gas accounted for 1 percent to
5 percent of the chromium measured; the remaining 1 percent to 10 percent was found in the
scrubber liquor.
In contrast, cadmium and lead were quite volatile in the Lagoon 3 sludge tests. Only
6 percent of the cadmium discharged and 2 percent to 3 percent of the lead discharged were
found in the kiln ash. Further, the major fraction of the cadmium and lead that escaped the kiln
exited the scrubber system. About 60 percent of the cadmium discharged in Tests 1 and 2 and
92 percent in Test 3 were measured in the scrubber exit flue gas. Similarly, between 49 percent
56
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and 82 percent of the lead discharged in the Lagoon 3 sludge tests was measured in the scrubber
exit flue gas.
Lead was much less volatile in the Lagoon 8 sludge tests. For Tests 5 and 6, as much
as 40 percent to 69 percent of the lead discharged was measured in the kiln ash.' Interestingly,
the Lagoon 8 sludge contained no measurable chlorine (<0.1 percent, dry basis). The Lagoon 3
sludge contained 3.5 percent chlorine on a dry basis. The chlorine present in'the Lagoon 3
sludge would allow the formation of lead chlorides, which are much more volatile than lead metal
or lead oxides. This most likely explains the significantly increased lead volatility (decreased kiln
ash fraction) in the Lagoon 3 sludge tests. Similar chlorine effects on lead volatility have been
seen in past IRF tests1.
5.2.5 Particulate and HCi
Particulate levels at the scrubber exit were quite high, at 195 and ;266 mg/dscm,
corrected to 7 percent O0, in Tests 1 and 2 with the Lagoon 3 sludge. These levels exceed the
hazardous waste incinerator performance standard of 180 mg/dscm. Particulate emission levels
as high as those measured in Tests 1 and 2 would cause a hazardous waste incinerator to fail a
trial burn. Scrubber exit particulate levels for Test 3 were lower, at 44 mg/dscm at 7 percent O2-
Scrubber exit flue gas particulate levels were also low, in the 11 to 25 mg/dscm range, for the
three Lagoon 8 sludge tests. These levels easily meet the hazardous waste incinerator
performance standard. ;
Scrubber exit HCI levels ranged from 0.2 to 2.8 ppm for the Lagoon 3 sludge tests, and
were nondetectable at a PQL of 30 ppb for all three Lagoon 8 sludge tests. Corresponding HCI
discharge rates were 0.5 to 7.2 g/hr for the Lagoon 3 sludge tests and less than 80: mg/hr for the
Lagoon 8 sludge tests. As the hazardous waste incinerator performance standard minimum is
a 1.8 kg/hr emission rate, all results were within the standard limits.
5.3 CONCLUSIONS
Test conclusions in terms of the objectives stated in the introductory'paragraphs of
Section 5 are as follows:
• Greater than 99.99 percent DRE of the POHCs in the Lagoon 3 sludge was
achieved under the incineration conditions tested. This was clearly shown for two
of the three Lagoon 3 sludge POHCs (toluene and 3,3'-dichlorobenzidine) in all
three tests; and for the third POHC (benzene) in two of the three tests. Method
PQL limitations allowed establishing only that the benzene DRE was greater than
99.974 percent in the third test. .
• The Lagoon 8 sludge POHC, 3,3'-dichlorobenzidine, was not detected in the flue
gas; however, method PQL limitations, combined with low sludge POHC
concentrations, only allowed firmly establishing that greater than 99.974 percent
to 99.975 percent DRE was achieved. ;
• For the Lagoon 3 sludge, the organic compound decontamination effectiveness,
based on treated sludge contaminant concentrations, ranged from at least
57
-------
99.989 percent, for 3,3'-dichlorobenzidine, to 99.99994 percent, for benzene and
toluene.
• For the Lagoon 8 sludge, the organic compound decontamination effectiveness
was 99.5 percent for toluene (present at 3 mg/kg in the sludge) and greater than
99.89 percent for 3,3'-dichlorobenzidine (present at 710 mg/kg in the sludge).
• Of the contaminant trace metals, barium and chromium were relatively
nonvolatile. The kiln ash discharge accounted for nominally 85 percent to
95 percent, or greater, of the measured discharge amounts of these metals for
both sludges tested.
• Of the contaminant trace metals, cadmium and lead exhibited relatively volatile
behavior. The kiln ash discharge accounted for only 2 percent to 3 percent of the
lead, and 6 percent of the cadmium, in the measured discharge amounts of these
metals in the Lagoon 3 sludge tests. The kiln ash discharge accounted for
nominally 40 percent to 70 percent of the lead measured in discharges for the
Lagoon 8 sludge tests; cadmium was not present in the Lagoon 8 sludge. The
increased lead volatility in the Lagoon 3 sludge tests may be attributable to
different sludge chlorine contents; the Lagoon 3 sludge contained chlorine whereas
the Lagoon 8 sludge did not. Significantly increased lead volatility in the presence
of chlorine during incineration, as observed here, has been documented in past
work1.
• Neither of the sludges tested, nor the kiln ash resulting from their incineration,
would be classified as TC hazardous waste based on leachable metals
concentrations.
• Unfiltered scrubber liquor metal concentrations were generally below TCLP limits.
However, the unfiltered scrubber liquor from each Lagoon 3 sludge test and from
the first Lagoon 8 test, however, had lead concentrations above TCLP limits. The
TCLP leachate of a composite Lagoon 3 sludge test scrubber liquor (i.e., filtered
scrubber liquor) had a lead concentration below its TCLP limit.
• Scrubber exit particulate levels were low for the Lagoon 8 sludge tests at
25 mg/dscm at 7 percent O2, or less. Scrubber exit particulate levels were
significantly higher in the Lagoon 3 sludge tests—195 and 266 mg/dscm at
7 percent O2 for two of the Lagoon 3 sludge tests. These values exceed the
hazardous waste incinerator performance standard of 180 mg/dscm at 7 percent
02.
• Scrubber exit HC1 emission rates were acceptable during every test.
The test results suggest that incineration under the conditions tested represents an
effective treatment option for the Lagoon 8 sludge. Substantial removal of organics from the
sludge was achieved; the POHC was not detected in the flue gas; and particulate and HC1
emissions were low and in compliance with performance standards.
58
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Incineration also appears to be an effective treatment option for the Lagpon 3 sludge;
substantial organic decontamination was achieved, and the POHC DRE standard was met. A
wet scrubber APCS of the type tested may not, however, be an appropriate choice for air
pollution control. While HC1 emissions were acceptable, particulate emissions were greater than
those allowed by the incinerator performance standards. In addition, scrubber exit cadmium
emission levels were in the 153 to 206 /xg/dscm range, and lead emission levels were in the 4,420
to 6,180 ^g/dscm range. Furthermore, the unfiltered scrubber liquor discharge exceeded the
TCLP limit for lead; however, scrubber liquor filtrate concentrations may be below these limits.
If a wet scrubber APCS is used, incineration at a kiln temperature lower than the 982°C
(1,800 °F) temperature tested might be warranted. A lower kiln temperature would, likely reduce
the amount of cadmium and lead volatilized and carried out of the kiln in the combustion gas.
Test results were reported in the test report:
• King,, C, and L. R. Waterland, "Pilot-Scale Incineration of Contaminated Sludge
from'the Bofors-Nobel Superfund Site," draft July 1992, revised October 1992.
59
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SECTION 6
INCINERATION OF PCB-CONTAMINATED SOILS FROM
THE SCIENTIFIC CHEMICAL PROCESSING SUPERFUND SITE
The Scientific Chemical Processing (SCP) site in Carlstadt, New Jersey, was operated
by SCP in the 1970's for the handling, treatment, and disposal of a wide variety of chemical
wastes. Due to these, and perhaps former, activities at the 5.9-acre site, the soil and underlying
groundwater have been contaminated with a wide variety of contaminants, including volatile and
semivolatUe hazardous organic constituents, PCBs, organochlorine pesticides, trace metals, and
petroleum hydrocarbons.
One possible permanent remedy for the contaminated soils at the site is incineration.
However, specific data need to be developed before incineration can be selected and defended
as the permanent remedy. Accordingly, EPA Region 2 (P. Evangelista, Region 2, R. Koustas,
RREL/Edison, coordinators) requested that a pilot-scale incineration treatability study be
performed at the IRF using actual site soils. The purpose of this study was to evaluate whether
incineration can effectively destroy the organic contaminants in the site soils, and whether the
leachable trace metal content of the treated soils (ash) would be sufficiently low that the treated
soil could be landfilled as a solid waste instead of managed as a toxicity characteristic (TC)
hazardous waste. Specific test program objectives were as follows:
• Confirm that conventional incineration can achieve the required 99.9999 percent
DRE for the contaminant PCBs and the 99.99 percent DRE for the other organic
contaminants, and result in an ash discharge that is not PCB-contaminated and
is free of other soil organic contaminants
• Determine the distribution of the contaminant trace metals among the incinerator
discharge streams, including the metals' leachability from the kiln ash
• Determine the effects of incineration temperature on organic contaminant
destruction and metal distributions, including the metals' leachability from the kiln
ash
• Measure the effectiveness of a conventional APCS of the type available at the IRF
for collecting particulate and trace metals
• Determine if the kiln ash from the incinerator can be disposed of as nonhazardous
solid waste by virtue of the ash not being a TC hazardous waste
60
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To address these objectives, a series of three tests was performed in the RKS at the IRF during
January and February 1992. Results of the test program are discussed in subsections that follow.
6.1
TEST PROGRAM
6.1.2 Test Waste Description
Three 55-gallon drums of contaminated soil were excavated from what has been termed
the hot layer of the SCP site. A characterization sample representing each drum! excavated was
shipped to the IRF for pretest analyses. These analyses showed that the average total PCB
concentration of the three drums was 1,290 mg/kg, as received. The level required in an RKS
feed to be able to just establish 99.9999 percent DRE at a typical 55 kg/hr (120 Ib/hr) feedrate
is 6,400 mg/kg, five times higher than the average excavated drum characterization sample level.
Consequently, it was decided to spike the soils to higher PCB concentrations to provide a margin
in the ability to establish 99.9999 percent DRE. The material used to spike the soils was an
Askarel transformer fluid comprised of roughly 70 percent Aroclor 1242 a:nd 30 percent
Aroclor 1254. :
One drum's characterization sample was also subjected to ash fusion temperature
determination. Results of these analyses showed that the test soil had a relatively low ash fusion
temperatures under both oxidizing and reducing conditions. Initial fusion temperatures were
1,060°C (1,940°F), with fluid temperatures in the 1,170° to 1,108°C (2,140° to 2,160°F) range.
These temperatures are below the afterburner temperature tested (see below) suggesting that
any soil carried into the afterburner entrained in the combustion gas would become molten in
the afterburner.
i
For the test program, all three drums of soil were shipped to the IRF, where they
combined to form one test feed material. Prior to testing, the combined sediments were
repackaged into 1.5-gallon fiberpack containers for feeding the RKS via the ram feeder. About
110 kg (240 Ib) of the mixed raw soils was packaged without the PCB spiking material added,
while the remainder was spiked with the PCB material during packaging. Each spiked fiberpack
drum was contained 4.5 kg (10 Ib) of combined soils and 0.18 kg (0.4 Ib) of spike PCB liquid.
6.1.2 Test Conditions '•
Three tests were performed as noted above. Plans were to vary kiln exit gas
temperature at 816°C (1,500°F) to 982°C (1,800°F) and kiln exit flue gas O2 at 6 percent and
10 percent. Afterburner exit gas temperature was to be held constant at 1,204°C (2,200°F). The
high kiln temperature, low O2 test, Test 2, was to have included a period of operation feeding
both native (unspiked) and spiked soil. The period of operation with unspiked soil was denoted
Test 2a, the period with spiked soil Test 2b. :
For all tests, both the average kiln and afterburner exit gas temperatures were within
5°C (8°F) of the target temperatures. The actual O-, levels in the kiln were generally higher
than the target concentrations, however. The higher 62 levels again resulted from the inability
to tightly secure the kiln rotating seal. The minimum average O2 achievable for the high kiln
temperature test condition was 7.4 percent at the kiln exit. The maximum O2 tested was
61
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8 percent. As a practical matter, these two levels present comparable combustion environments.
Consequently, it was not possible to test kiln excess air as a variable.
Significant slag formation (molten ash buildup) was experienced in the afterburner for
all tests. This is understandable given that the ash fusion temperature of the soil tested was
below the afterburner gas temperature of 1,208° to 1,209°C (2,207° to 2,208°F) employed in the
tests.
6.13 Sampling and Analysis
In addition to obtaining soil feed, kiln ash, and pre- and post-test scrubber liquor
samples, the sampling protocol for all tests included sampling the flue gas at the afterburner exit
and at the scrubber system exit for trace metals using the EPA multiple metals train and for
mercury using Method 101A. The scrubber exit flue gas was sampled for PCBs and semivolatile
organic constituents using Method 0010 and for volatile organic constituents using Method 0030.
Particle size distribution measurements were made at the afterburner exit using an Anderson
cascade impactor train. Finally, the flue gas at the scrubber system exit, and the stack
downstream of the secondary APCS was sampled for particulate and HC1, using Method 5.
In addition to analyzing flue gas sampling trains for their sampled analyte set, the soil
feed sample for each test and each of the kiln ash and scrubber liquor samples were analyzed
for PCBs, semivolatile and volatile organic hazardous constituents, and trace metals. Also, the
soil feed and the kiln ash for each test were subjected to TCLP extraction, and the resulting
leachates analyzed for trace metals.
62 TEST RESULTS
6.2.1 PCB Analysis Results and DREs
Table 30 summarizes the PCB concentrations of each incineration test sample. As
shown in Table 30, the spiked soil contained about 4 percent PCB compared to the native soil
content of 0.12 percent. The kiln ash from the high kiln temperature tests, Tests 2a, 2b, and 3,
contained no detectable PCB at a PQL of 0.33 mg/kg. However, the kiln ash from the low kiln
temperature test, Test 1, contained 56 mg/kg PCB. This suggests that, at 1 hr solids residence
time, a kiln temperature of 816°C (1,500°F) is not sufficient for complete decontamination of
the soil PCB and that kiln temperatures as high as 982°C (1800°F) may be required. No
scrubber liquor sample contained detectable PCB at a PQL of 3.3 jig/L.
Table 31 summarizes the degree of PCB decontamination achieved in each test in terms
of the fraction of the amount of PCB introduced in the incinerator feed accounted for by the
resulting kiln ash. As shown in the table, less than 0.0003 percent of the amount of PCBs fed
in the spiked soil for the high kiln temperature tests was discharged in the kiln ash. The
decontamination effectiveness achieved was thus greater than 99.9997 percent. For the unspiked
soil incinerated at the high kiln temperature, less than 0.0093 percent of the PCB fed was
discharged in the kiln ash, for a decontamination effectiveness of greater than 99.9907 percent.
In contrast, 0.039 percent of the PCB in the spiked soil incinerated at the low kiln temperature
was present in the kiln ash discharge, for a decreased decontamination effectiveness of
99.961 percent.
62
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TABLE 30. PCB ANALYSIS RESULTS
Parameter
Average kiln exit gas
temperature,
°c
,(°F)
PCB concentration
Soil feed, %
Kiln ash, mg/kg
Posttest scrubber liquor, /ig/L
Scrubber exit flue gas, /ig/dscm
a— = Sample not collected.
Test 1
(1/28/92)
818
(1,504)
4.07
56
<3.3
<0.28
Test 2a
(1/30/92)
986
(1,807)
0.12
<0.33
a
—
Test 2b
(1/30/92)
987
(1,808)
4.01
<0.33
<3.3
<0.14
;Test 3
(2/4/92)
:
:983
1(1,802)
i
4.24
<0.33
<3.3
;<0.14
1
TABLE 31. PCB DECONTAMINATION EFFECTIVENESS '
Parameter
Average kiln exit gas temperature
°c
(°F)
Soil feed:
PCB concentration, %
Total amount of PCB fed, kg
Kiln ash:
PCB concentration, mg/kg
Total amount of PCB discharged, g
Fraction of amount fed, %
Test 1
(1/28/92)
818
(1,504)
4.07
9.90
56
3,850
0.039
Test 2a
(1/30/92)
986
(1,807)
0.12
0.13
<0.33
<12
< 0.0093
Test 2b
(1/30/92)
987
(1,808)
4.01
9.90
<0.33
<28
< 0.0003
, Test3
: (2/4/92)
1 983
; (1,802)
; 4.74
9.88
!
; <0.33
; <23
, < 0.0002
63
-------
Table 32 takes the scrubber exit flue gas maximum concentration noted in Table 31
(based on method PQL) and combines them with the soil feedrate data and flue gas flowrate
data to give the lower bound PCB DREs achieved for the tests. As shown in the table, greater
the 99.99998 percent PCB DRE was achieved for all three tests for which it was measured. This
exceeds the required level of 99.9999 percent. Good PCB DRE was even achieved for the low
kiln temperature Test 1, despite the kiln ash still being PCB-contaminated for this test.
6.2.2 Volatile Organic Constituent Analysis Results and Contaminant DREs
The composite soil tested contained an average of 170 mg/kg chlorobenzene, 500 mg/kg
ethyl benzene, 3,300 mg/kg tetrachloroethene, 2,700 mg/kg toluene, 3,700 mg/kg trichloroethene,
and 2,800 mg/kg total xylenes. No test kiln ash sample contained detectable levels of volatile
organic constituents. Thus, both the low and high kiln temperature conditions tested resulted
in essentially complete soil volatile organic constituent decontamination. The maximum fractions
of the contaminant volatile organics in the soil feed for each test that could have been discharged
in the treated soil kiln ash discharge, based on the ash PQLs, ranged from at most 0.016 percent
of the soil toluene to at most 0.30 percent of the soil chlorobenzene. Soil decontamination
effectiveness was, thus, at least 99.70 percent for chlorobenzene to at least 99.984 percent for
toluene. No pre- or post-test scrubber liquor sample contained detectable levels of volatile
organic constituents.
Scrubber exit flue gas contained detectable levels of the soil volatile organic
contaminants in the low-kiln-temperature test, Test 1, as shown in Table 33. No volatile organic
contaminants were found in the scrubber exit flue gas for the two high-kiln-temperature tests,
Tests 2b and 3, at the PQLs noted in Table 33. Table 33 also notes the volatile organic
contaminant DREs achieved. As shown in the table, greater than 99.99 percent DREs were
achieved only for ethylbenzene and total xylenes in Test 1. Tetrachloroethene, toluene, and
TABLE 32. PCB DREs
Parameter
Test 1
(1/28/92)
Test 2b
(1/30/92)
Test3
(2/4/92)
Average kiln exit gas temperature,
°C
(°F)
Soil feed:
Soil feedrate, kg/hr
PCB feedrate, g/hr
Scrubber exit Hue gas:
PCB concentration, jig/dscm
PCB emission rate, /ig/hr
818
(1,504)
57
2,320
<0.28
<450
987
(1,808)
57
2,290
<0.14
<230
983
(1,802)
57
2,420
<0.14
<240
PCB DRE, %
> 99.999981 > 99.999990 > 99.999990
64
-------
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trichloroethene DREs were only about 99.98 percent, and the chlorobenzene DRE was only
99.97 percent for this test. That less than 99.99 percent DREs were measured for several volatile
organic constituents under conditions which gave greater than 99.9999 percent PCB DRE likely
lies in the relative feed concentration of the constituents. The soil feed was spiked with PCBs
to give feed PCB concentrations of 4 percent or. more. The volatile organic constituents
measured were present in the soil feeds at levels 'of less than 0.4 percent (4,000 ppm). Past
observations have been that constituent DREs decrease as feed concentrations decrease. In
addition, the volatile organics present in the feed soil are also commonly measured products of
incomplete combustion (PICs). It is possible that the flue gas levels measured in Test 1 arose
from PIC production with incomplete destruction at the low kiln gas temperature of Test 1, even
when combined with the higher temperature afterburner.
In contrast to Test 1, the minimum DREs for Tests 2b and 3, based on the scrubber exit
flue gas method PQLs, were uniformly greater than 99.99 percent for all soil volatile organic
contaminants with the exception of chlorobenzene. The flue gas chlorobenzene PQL combined
with its low soil concentration permitted showing only that greater than 99.975 percent DREs
were achieved in Tests 2b and 3.
Test data show that, although the low kiln gas temperature of nominally 816°C (1,500°F)
was sufficient to effectively decontaminate the SCP test soil with 1 hour sqlids residence time,
volatile organic contaminant destruction was apparently not complete, even with a downstream
afterburner operating at a gas temperature of nominally 1,204°C (2,200°F). Higher kiln gas
temperatures, up to 982°C (1,800°F), were required, in combination with the downstream
afterburner, to ensure contaminant DREs greater than 99.99 percent.
6.23 Semivolatile Organic Constituent Analysis Results
The composite test soil contained an average of 424 mg/kg bis(2-ethylhexyl)phthalate,
40 mg/kg 2-chloronaphthalene, 53 mg/kg 1,2-dichlorobenzene, 71 mg/kg naphthalene, 45 mg/kg
nitrobenzene, and 73 mg/kg phenol. None of the semivolatile organic soil contaminants was
found in any test kiln ash, pre- or post-test scrubber liquor, or scrubber exit flue gas samples at
PQLs of 2 mg/kg in kiln ash, 20 /ig/L in scrubber liquor, and 61 /zg/dscm (Test 1) to 66 /xg/dscm
(Test 3) in scrubber exit flue gas. Minimum soil decontamination effectiveness based on the kiln
ash PQL ranged from greater than 98.4 percent for 2-chloronaphthalene to greater than
99.85 percent for bis(2-ethyhexyl)phthalate. Minimum semivolatile organic contaminant DREs
based on the scrubber exit flue gas PQLs ranged from greater than 99.8 percent for
2-chloronaphthalene to greater than 99.985 percent for bis(2-ethylhexyl)phthalate.
6.2.4 Trace Metal Analysis Results and Discharge Distributions
Table 34 summarizes the metal concentrations in soil feed samples and in each of the
incinerator discharge streams. The table also notes the composite soil feed and kiln ash TCLP
leachate metal concentrations for each test, and the TCLP regulatory levels for each TCLP metal
determined. No soil feed or kiln ash would be a TC hazardous waste for any of the TCLP
metals. However, Test 2b and Test 3 posttest scrubber liquor had cadmium concentrations above
the cadmium TCLP regulatory level; the posttest scrubber liquor lead concentrations exceeded
the lead TCLP regulatory level for all three tests; and the mercury concentration in the Test 3
posttest scrubber liquor was at the mercury TCLP regulatory level. However, the scrubber liquor
66
-------
TABLE 34. TRACE METAL ANALYSIS RESULTS
Sample
Sb
As
Ba
Be
Cd
Cr
Cu
Soil feed, mg/kg
Composite 1
Composite 2
Analysis
Duplicate analysis
Average
Soil feed TCLP leachate, mg/L
Composite 1
Composite 2
5.6
4.9
3.2
4.6
0.058
18
12
19
16
0.049
410
300
290
330
0.37
<0.3
<0.3
<0.3
<0.3
97
29
33
53
< 0.003 0.096
270
'210
1190
!220
[0.34
11,100
6,500
13,000
10,200
7.15
Analysis
Duplicate analysis
Average
Test 1 (1/28/92), Kiln temperature: 818°C (1,504°F)
Kiln ash, mg/kg
Kiln ash TCLP leachate, mg/L
Afterburner exit flue gas, /ng/dscm
Scrubber exit flue gas. ^ig/dscm
Pretest scrubber liquor, mg/L
Posttest scrubber liquor. mg/L
Test 2a (1/30/92), Kiln temperature: 986°C
(1,807°F)
Kiln ash, mg/kg
Kiln ash TCLP leachate, mg/L
Test ?.b (1/30/92), Kiln temperature: 987°C
(1,808° F)
Kiln ash, mg/kg
Kiln ash TCLP leachate, mg/L
Afterburner exit flue gas, jug/dscm
Scrubber exit flue gas, ^tg/dscm
Pretest scrubber liquor, mg/L
Posttest scrubber liquor, mg/L
Test 3 (2/4/92), Kiln temperature: 983°C (1,802'F)
Kiln ash, mg/kg
Kiln ash TCLP leachate, mg/L
Afterburner exit flue gas, ^g/dscm
Scrubber exit flue gas, /jg/dscm
Pretest scrubber liquor, mg/L
Posttest scrubber liquor, mg/L
TCLP regulatory level, mg/L
0.058
0.058
0.058
5.0
0.048
33
4-13
< 0.022
0.15
<2.1
< 0.022
<2.0
< 0.022
37-41
15-23
0.052
0.18
2.3
< 0.022
26
21-26
< 0.022
0.14
a
0.043
0.048
0.047
31
< 0.027
65
16-28
0.055
0.18
11
< 0.027
7.7
< 0.027
140
58-66
0.12
0.41
3.2
< 0.027
73-78
66-73
0.043
0.27
5.0
0.36
0.36
0.36
570
0.14
35
6.0
0.14
0.30
300
0.096
100
0.18
49
9.0
0.15
0.029
460
0.16
13
8.0
0.27
0.085
100
< 0.003
< 0.003
< 0.003
0.76
< 0.003
0.3-1.0
0.1-1.4
< 0.003
< 0.003
0.45
< 0.003
0.3-0.5
< 0.003
0.1-0.7
<1.0
< 0.003
< 0.003
<0.3
< 0.003
<0.6
<0.8
< 0.003
< 0.003
—
0.044
0.043
0.061
48
0.46
730
240
0.007
0.48
1.9
< 0.005
26
< 0.005
1,020
380
0.22
1.7
2.8
0.006
580
490
0.08
1.3
1.0
'0.32
'0.32
0.33
250
:< 0.007
270
|3.6
jO.036
10.32
;76
iO.040
32
•0.21
410
4.4
!o.079
10.28
!89
10.26
66
28
0.089
10.31
5.0
6.42
6.25
6.61
11,900
0.33
20,000
5,530
0.44
32
6,670
13.3
2,550
4.2
. 37,300
10,500
3.9
47
11,100
22
21,200
14,300
2.2
41
-
a_ = Not a TCLP metal
(continued)
67
-------
TABLE 34. (continued)
Sample
Pb
Hg
Ni
Se
Ag
Tl
Average
Soil feed TCLP leachate, mg/L
Composite 1
Composite 2
Analysis
Duplicate analysis
Average
Test 1 (1/28/92), Kiln temperature: 818°C
(l,504eF)
830
0.025
0.025
0.025
0.025
8.6
0.018
0.033
0.033
0.026
14
0.062
0.067
0.065
0.064
<4.3
0.075
0.070
0.069
0.072
4.4
0.018 0.016
0.014
0.006
0.015
0.015
0.014 0.015
Zn
Soil feed, mg/kg
Composite 1
Composite 2
Analysis
Duplicate analysis
1,220
640
640
8.3
8.8
8.9
12
15
14
<4.3
<4.2
<4.1
3.5 <
4.7 <
4.9 <
1.4 1,220
1.4 1,230
1.4 1,160
1,200
1.87
1.05
1.02
1.45
Kiln ash, mg/kg
Kiln ash TCLP leachate, mg/L
Afterburner exit flue gas, /ig/dscm
Scrubber exit flue gas, pg/dscm
Pretest scrubber liquor. mg/L
Posttest scrubber liquor. mg/L
Test 2n (1/30/92), Kiln temperature: 986°C
(1,807'F)
Kiln ash, mg/kg
Kiln ash TCLP leachate. mg/L
Test 2b (1/30/92), Kiln temperature: 987°C
(l.SQST)
Kiln ash, mg/kg
Kiln ash TCLP leaehate, mg/L
Afterburner exit flue gas, ^g/dscm
Scrubber exit flue gas, /ig/dscm
Pretest scrubber liquor, mg/L
Posucsi scrubber liquor, mg/L
Test 3 (2/4/92), Kiln temperature: 983°C (1,802°F)
Kiln ash, mg/kg
Kiln ash TCLP leachate. mg/L
Afterburner exit flue gas, f(g/dscni
Scrubber exit flue gas, pg/dscm
Pretest scrubber liquor, mg/L
Posttest scrubber liquor, mg/L
TCLP regulatory level, mg/L
580
0.052
5,750
2,600
0.59
15
110
0.069
33
0.066
9.570
3.100
3.1
9
140
0.060
5,570
4,220
1.5
11
5.0
< 0.012
< 0.0006
78
79
< 0.0001
0.0023
< 0.012
• < 0.0006
< 0.012
1 < 0.0006
240
_b
, 0.0005
0.051
< 0.060
< 0.0006
_b
_b
0.0003
0.20
0.2
33
0.024
140
14-18
<0.010
0.053
14
0.014
2.5
•s 0.010
230
41-44
< 0.010
0.10
' 21
0.017
31-33
4-7
0.025
0.095
a
<4.6
0.056
46
4-20
< 0.048
0.10
<4.5
0.078
<4.4
0.052
36
4-13
0.052
0.13
5.5
0.069
27
15
0.059
0.15
1.0
6.9
0.012
17
14
0.017
0.04
2.7
0.012
1.2
0.011
37
18
0.044
0.11
4.9
0.014
19
20
0.23
0.097
5.0
<1.4
< 0.015
5-9
2-9
< 0.015
< 0.015
<1.4
< 0.015
<1.4
< 0.015
11-14
2-6
< 0.015
< 0.015
<1.5
< 0.015
8-10
5-8
< 0.015
< 0.015
a
3,170
1.2
11,680
4,850
20
36
1,630
9.4
830
8
11,690
3,750
11
30
1,450
7.2
5,090
3,960
12
23
a
"— » Not a TCLP metal
"The Method 101 train at the scrubber exit failed to function properly during Test 2. Test 3 Method 101A impinger samples
were not analyzed due to a laboratory sample tracking error.
68
-------
rnetal concentrations noted in Table 34 are for bulk scrubber liquor samples, 'which contain
suspended solids. A TCLP leachate of the full test program composite scrubber liquor was
prepared by filtering the liquor. Cadmium, lead, and mercury concentrations in this test program
composite scrubber liquor TCLP leachate were all below TCLP regulatory levels.
i
Table 35 summarizes the test trace metal distributions among the three incineration
system discharges, the kiln ash, scrubber liquor and scrubber exit flue gas. The distribution
fractions in Table 35 have been normalized to the total amount of each metal measured in all
the discharge streams analyzed. Actual mass balance closures achieved ranged from 5 percent
to 96 percent, with an average of 40 percent and a median of 41 percent. Two of the three
poorest closures experienced were for chromium. The fact that metals mass balance closures
achieved were less than 100 percent, is likely a consequence of the significant slag formation
experienced in the afterburner for all tests owing to the low test soil ash fusion temperature.
Because of this slag formation, some fraction of the ash carried out of the kiln and into the
afterburner would be deposited on the afterburner wall as molten slag and remain in the
afterburner.
The data in Table 35 show that barium and chromium exhibited relatively nonvolatile
behavior in all tests. Greater than 99 percent of the barium measured in the discharge streams
and greater than 91 percent of the chromium was accounted for in the kiln ash discharge.
Further, the barium and chromium distributions were not affected by kiln temperature in the
range tested. In contrast, mercury was quite volatile at the low kiln temperature tested. No
measurable mercury was discharged in the kiln ash, and a small fraction was collected in the
scrubber system for this one test for which a scrubber exit flue gas sample was successfully taken
and analyzed.
Cadmium and lead were moderately volatile at the low kiln temperature tested, about
60 percent of the discharged amount of each was accounted for in the kiln ash. However, both
were significantly more volatile at the high kiln temperature; the kiln ash fractions decreased to
between 9 and 18 percent. Arsenic and silver were relatively nonvolatile at! the low kiln
temperature, becoming significantly more volatile, and depleted in the kiln ash, at the high kiln
temperature.. Increased volatility with increased kiln temperature was also seen for antimony
and zinc. Copper and nickel were also nonvolatile and accounted for largely in the kiln ash at
the low kiln temperature. However, their behavior differed between Test 2b and 3 at high kiln
temperature.
6.2.5 Particulate and HC1 Emissions Data !
Table 36 summarizes the flue gas particulate levels measured at the afterburner and
scrubber exit locations. The data in Table 36 show that afterburner exit particulate levels were
in the 238 to 408 mg/dscm at 7 percent O2 range for the three spiked soil tests. The scrubber
exit level for Test 1 at low kiln temperature was a reduced 88 mg/dscm, corresponding to a
calculated scrubber collection efficiency of 63 percent. This level is atypically low for the RKS
venturi/packed column scrubber. Scrubber exit particulate levels were significantly higher for
Test 2b and 3, the high kiln temperature tests, and in fact were only marginally reduced from
the scrubber inlet levels. Calculated scrubber particulate collection efficiencies were only
24 percent and 33 percent for Tests 2b and 3. Evidently the particulate generated by the high
kiln temperature test condition was quite difficult to collect, even more so than the low kiln
69
-------
TABLE 35. NORMALIZED TRACE METAL DISTRIBUTIONS
Distribution, % of metal measured in discharges
Test 1 (1/28/92), Kiln temperature:
818°C (1,504°)
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Test 2b (1/30/92), Kiln
temperature: 987°C (1,808°F)
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Test 3 (2/4/92), Kiln temperature:
983"C ( 1,802" F)
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Sb
60-69
5-17
23-26
100
<37
36-47
27-53
100
29-31
29-34
37-40
100
As
88-91
5-8
4
100
47-49
30-33
21
100
20
45-47
33-35
100
Ba
99.6
0.1
0.3
100
99.3
0.7
<0.01
100
99.8
0.2
< 0.005
100
Cd
61
32
7
100
5
61
34 '
100
3
63
34
100
Cr
98.5
0.1
1.3
100
92
1
7
100
91
3
6
100
Cu
93
4
3
100
66
22
12
100
83
11
6
100
Pb Hg
56 <0.1
26 99.6
18 0.4
100 100
9 _«
72 —
19 -
100 —
18 -
54 -
28 -
100 —
Ni
93
5
2
100
35
49
16
100
89
3
8
100
Ag
79
17
4
100
35
44
21
100
55
24
21
100
Zn
82
13
5
100
61
23
16
100
65
19
16
100
scrubber exit flue gas Method 101A sampling train failed to function properly during Test 2.
Test 3 Method 101A impinger samples were not analyzed due to a laboratory sample tracking error.
TABLE 36. FLUE GAS PARTICULATE LEVELS
Test
Test
Test
a ,
1 (1/28/92)
2b (1/30/92)
3 (2/4/92)
= Not measured.
Flue gas paniculate,
7%O2
Afterburner exit
238
408
355
mg/dscm at
Scrubber exit
88
310
237
Scrubber
collection
efficiency, %
63
24
33
temperature test paniculate. The levels measured for Tests 2b and 3 exceed the hazardous waste
incinerator performance standard of 180 mg/dscm at 7 percent O2.
Table 37 summarizes the scrubber exit flue gas HC1 levels measured. Also shown in the
table are the corresponding chlorine feedrates based on the chlorine content of the
corresponding test feed. The data in Table 37 show that scrubber exit flue gas HC1 levels were
comparable for the two high kiln temperature tests, Tests 2b and 3. Apparent scrubber HC1
collection efficiencies, based on the assumption that all the chlorine fed was converted to HC1
70
-------
TABLE 37. FLUE GAS HC1 LEVELS
Parameter
Test 1 Test 2b Test 3
(1/28/92) (1/30/92) (2/4/92)
Cl feedrate, g/hr
Scrubber exit
Flue gas HC1 concentration,
Flue gas emission rate,
Apparent scrubber collection
mg/dscm
ppm
g/hr
efficiency, %
2,200
23
15
36
98.4
2,480
1.3
0.88
2.1
99.91
2,280
2.2
1.5
3.8
99183
= Not sampled for.
and carried to the scrubber inlet, were 99.8 percent to 99.9 percent. This level of control
efficiency meets the hazardous waste incinerator performance standard of 99 percent HC1
removal. Scrubber exit HC1 levels were about a factor of 10 higher for Test 1. Tftis observation
has no apparent explanation.
6.3
CONCLUSIONS
Test conclusions in terms of the objectives stated in the introductory .paragraphs of
Section 6 are as follows. Greater than 99.9999 percent PCB DRE was achieved at both kiln
temperatures with the RKS afterburner operating at nominally 1,204°F (2,200 °F). Despite this
high PCB DRE at both kiln temperatures, volatile organic contaminant DREs were less than the
required 99.99 percent at the low kiln temperature for four of the six soil volatile organic
contaminants. DREs achieved for chlorobenzene, tetrachloroethene, 'toluene, and
trichloroethene were only 99.97 to 99.98 percent at the low kiln temperature tested. Greater
than 99.99 percent volatile organic contaminant DREs were uniformly achieved at the high kiln
temperature tested. |
Both kiln temperatures tested resulted in complete soil decontamination of its volatile
and semivolatile organic contaminants, with soil kiln residence time of about 1 hr. However,
complete soil PCB decontamination was achieved only at the high kiln temperature tested. Kiln
ash from the incineration of the hot layer soil, spiked with Askarel transformer fluid to raise its
PCB content to about 4 percent, still contained 56 mg/kg PCB at the low kiln temperature
tested.
Of the soil contaminant trace metals, barium and chromium exhibited nonvolatile
behavior and were retained in the kiln ash discharge at both incineration temperatures. Greater
than 99 percent of the barium and greater than 91 percent of the chromium measured in the
incinerator discharge stream was accounted for in the kiln ash discharge. In contrast, mercury
was quite volatile at even the low kiln temperature. No measurable mercury was discharged in
the kiln ash, and only a small fraction was collected in the scrubber system for the one test for
which a scrubber exit flue gas sample was successfully taken and analyzed.
71
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Cadmium and lead were moderately volatile at the low kiln temperature tested, about
60 percent of the discharged amount of each was accounted for in the kiln ash. However, both
were significantly more volatile at the high kiln temperature. The kiln ash fractions decreased
to 9 percent to 18 percent. Arsenic and silver were relatively nonvolatile at the low kiln
temperature, becoming significantly more volatile, and depleted in the kiln ash, at the high kiln
temperature. Increased volatility with increased kiln temperature was also seen for antimony
and zinc. Copper and nickel were also nonvolatile and accounted for largely in the kiln ash at
the low kiln temperature. However, their behavior was inconsistent at high kiln temperature.
These metals distribution observations are consistent with metals partitioning data from past IRF
tests1 >2»3.
The venturi/packed-column scrubber system was only about 63 percent efficient in
collecting the flue gas particulate resulting from the low kiln temperature incineration treatment
of the site soil. Scrubber exit flue gas particulate levels, at 88 mg/dscm at 7 percent O2, were
below the 180 mg/dscm hazardous waste incinerator performance standard. The efficiency of
the scrubber in collecting the flue gas particulate resulting from the high temperature
incineration treatment of the site soil was significantly lower, at 24 percent to 33 percent.
Scrubber exit flue gas particulate levels for the high kiln temperature tests, at 237 and
310 mg/dscm at 7 percent O2, exceeded the hazardous waste incinerator performance standard.
Neither the site soil tested, nor the kiln ash discharge from its incineration treatment
at either kiln temperature tested, was TC hazardous due to teachable trace metal content.
Other test program conclusions include:
• The ash fusion temperature of the site soil test was quite low, in the 1,100°C
(2,000°F) range, such that significant slag formation in the RKS afterburner was
experienced for all tests
• Apparent scrubber HC1 collection efficiencies, at 99.8 to 99.9 percent, met the
hazardous waste incinerator performance standard of 99 percent for the high kiln
temperature tests. Unexplainably, apparent HC1 collection efficiency was
decreased, at 98.4 percent, for the low kiln temperature test.
Test results suggest that incineration under the high kiln temperature conditions tested
would be an effective treatment option for the SCP site "hot-layer" soil. With kiln exit gas
temperature of nominally 982°C (1,800°), kiln solids residence time of nominally 1 hr, and
afterburner gas temperature of nominally 1,204 °C (2,200 °F), complete decontamination of PCBs
and volatile and semivolatile organic contaminants was achieved, PCB DREs were greater than
the required 99.9999 percent, and volatile organic contaminant DREs were greater than the
required 99.99 percent. The kiln ash (treated soil) discharge was not be a TC hazardous waste
and the hazardous waste incinerator HC1 removal efficiency standard was met with the
conventional wet scrubber APCS in place at the IRF.
Incineration at lower temperatures might be similarly effective. However, with a kiln
gas temperature of nominally 816°C (1,500°F), the kiln ash from the treatment of soil spiked
with PCBs to about 4 percent concentration still contained 56 mg/kg PCB, and the DREs
achieved for four of six volatile organic contaminants were less than 99.99 percent.
72
-------
Operating problems will likely be encountered in a conventional incinerator system
under the operating conditions tested. The soil's ash fusion temperature is low, at ^bout 1,100°C
(2,000°F). Thus, significant slag formation will likely occur in a 1,204°C (2,200°F^) afterburner,
with possible attendant operating difficulties.
In addition, the paniculate control capabilities of a wet scrubber APCS of the design in
place at the IRF may not be sufficient to meet the hazardous waste incineratpr paniculate
emission standard. Further, increased flue gas emissions of the volatile contaminant trace
metals, particularly cadmium and lead, at the higher kiln temperature may pose some concern.
Test results were reported in the test report: i
• Siag, A. and L. R. Waterland, "Pilot-Scale Incineration of Contaminated Soil from
the Scientific Chemical Processing Superfund Site," draft September 1992.
73
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SECTION 7
BENCH-SCALE TREATABILITY TESTING OF CONTAMINATED SOIL
FROM TWO WOOD PRESERVING PLANT SUPERFUND SITES
The PopiJe Superfund site, in El Dorado, Arkansas, and the American Creosote
Superfund site, in Winnfield, Louisiana, are abandoned wood preserving plants that treated wood
by using creosote and pentachlorophenol. Soils and sediments at both sites are contaminated
with pentachlorophenol and several polynuclear aromatic hydrocarbon (PAH) compounds
including naphthalene, acenaphthalene, benzo(a)pyrene, and fluorene. Incineration is being
considered for the remediation of both sites. EPA Region 6 (R. Griswold, P. Sieminski,
coordinators) requested that bench-scale treatability testing of waste samples from both sites be
performed under the Risk Reduction Engineering Laboratory's (RREL's) Superfund Technical
Assistance Response Team (START) program (E. Harris, E. Bates, RREL coordinators) to
provide remedy screening information on incineration as a treatment option for both sites.
Accordingly, treatability tests were conducted using the bench-scale Thermal Treatment Unit
(TTU) at the 1RF.
The test program included four tests: two for the contaminated soil from each site.
Results of the test program are discussed in the following subsections.
7.1
TEST PROGRAM
7.1.1 Test Facility Description
The IRF TTU is a small commercial pathological incinerator that has been modified to
allow for continuous test-material feed and treated-material (e.g., ash) removal. It has also been
modified for variable thermal treatment temperature control, for expanded process operation
monitoring, and for combustion flue gas sampling.
The TTU is illustrated in Figure 4 and it consists of three combustion chambers: the
charge, retention, and breeching chambers. The charge chamber is designed to accept and
thermally treat the waste feed material and corresponds to the primary combustion chamber, or
kiln portion, of a waste incinerator. Its inner cross-section is 66 cm (2-ft 2-in) square, 1.9 m
(6-ft 2-in) high, and its chamber volume is 0.82 m3 (29 ft3).
The retention chamber, directly above the charge chamber, is designed to effect
complete destruction of organic constituents in the charge chamber flue gas. It corresponds to
the secondary combustion chamber, or afterburner portion, of a waste incinerator. The chamber
74
-------
r
TO MOV-2 f-
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Figure 4. The IRF TTU.
75
-------
inner cross-section is also 66 cm (2-ft 2-in) square, 1.5 m (5-ft) high, and its chamber volume is
0.66 m3 (23.5 ft3).
The breeching chamber serves as a second-stage afterburner. This cylindrical inner
chamber is 41 cm (1-ft 2-in) in diameter, 76 cm (2-ft 6-in) high, and its chamber volume is
0.10 m2 (3.5 ft3). Ail three chambers are lined with 13-cm (5-in) thick refractory.
The three chambers were designed to be fired with natural gas. The burners installed
in the charge and retention chambers are identical and each is rated at 350 kW (1.2 MBtu/hr)
heat input with a 5-to-l turndown capability. Independent modulating burner controls vary the
firing rates to control temperatures and air-to-fuel ratios in the chambers. The breeching
chamber has a manually adjustable 220 kW (750 kBtu/hr) burner. Temperatures in the charge
and retention chambers may be controlled between 260° and 1,090°C (500° and 2,000°F).
Contaminated test material is introduced into the charge chamber via a variable-speed
tray/conveyor feed system. Up to 0.9 kg (2 Ib) of test material can be put in a quartz tray 20 cm
(8-in) long, 10 cm (4-in) wide, and 5 cm (2-in) deep. The variable-speed chain-drive conveyor
produces material treatment residence times in the charge chamber from 20 min to 2 hr.
Multiple trays can be fed sequentially to simulate semibatch continuous feed.
7.1.2 Feed Preparation and Sample Collection
The IRF received two 5-gal containers of soils from each site on March 11, 1992. The
contents in both 5-gal containers from each site were placed in a 25-gal galvanized container and
mixed to produce a homogeneous soil mixture. Three samples were taken from the soil mixture
to fill three 1-L jars. A 0.45 kg (1 Ib) quantity of the mixed soil was placed in each of seven
quartz trays, and these were introduced to the TTU. The unused soil portions were returned
to Region 6 in the original shipping containers.
After completion of each test, the contents of the seven trays were weighed, mixed with
a small shovel in a 2.5-gal container and then transferred into four 1-L jars. These samples were
then submitted for analyses.
7.13 Test Conditions
Two thermal treatment tests were performed using each site's soil. For each soil, two
treatment temperatures at two solid treatment durations were tested. For each test, 3.2 kg (7 Ib)
of soil, in seven sequentially fed quartz trays, were subjected to thermal treatment.
During the first test, the TTU charge chamber temperature was held at an average of
nominally 982°C (1,800°F) and the solid treatment duration was about 60 min. During the
second test, the temperature was 871 °C (1,600°F) and solid treatment time was 20 min.
Throughout the tests, the retention chamber temperature was held at an average of 1,093°C
(2,000°F). Table 38 shows the target conditions versus actual conditions met for all four tests.
7.2 TEST RESULTS
Results from the test program are discussed in this section by the analyte group.
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7.2.1 Proximate and Elemental Composition '
Results of proximate and elemental composition analyses of soil samples are presented
in Table 39. Both soils had similar characteristics with respect to moisture, ash content, and
heating value. As received, the soils were moist but did not contain free liquids. The low
heating value (less than 300 Btu/lb) is not sufficient to render the soils flammable. The
laboratory-measured fusion temperatures of 2,600°F (and higher) suggests that the soils are not
likely to form slag in an incinerator operating at typical temperatures.
A comparison of the proximate ash analyses and the fraction of ash recovered during
the tests is shown in Table 40. The table compares the cumulative weight of soil fed for each
test with the total weight of ash collected. The results indicate that 82 percent of the Popile soil
and 76 to 77 percent of the American Creosote soil were collected as ash. These fractions
correspond to the expected ash weights for the two soils from the proximate analysis results.
7.2.2 Semivolatile Organic Constituents
Table 41 summarizes the results of the semivolatile organic compounds analyses. Only
compounds that were detected in the soil feed or treated soil samples are listed. As shown in
Table 41, ten target semivolatile organic compounds were found to be present in the Popile soil
at low concentrations. The contaminant concentration levels ranged from not detected
(
-------
TABLE 39. SOIL PROXIMATE AND ELEMENTAL COMPOSITION ANALYSIS RESULTS
Parameter
Proximate analyses (as received)3
Moisture, %
Ash, %
Volatile matter, %
Fixed carbon, %
Higher heating value, kJ/kg
(Btu/lb)
Elemental Composition, %a
C
H
0
N
S
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Popile site American Creosote site
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81.8
3.3
0.2
476
(205)
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0.6
<0.5
0.05
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17.1 ;
78.9 :
3.9 :
0.1 ;
666 ;
(287) ;
!
2.0 i
<0.5
0.7 :
<0.5 ;
0.14 :
<0.1 :
aAverage of two analyses reported.
TABLE 40. SOIL FED AND ASH COLLECTED
Test
Popile site
1 High temperature,
long residence time
2 Low temperature,
short residence time
American Creosote Site
1 High temperature,
long residence time
2 Low temperature,
Total soil fed,
kg (Ib)
3.2 (7.0)
3.2 (7.0)
3.2 (7.0)
3.2 (7.0)
Ash
Weight,
kg (Ib)
2.6 (5.7)
2.6 (5.7)
2.4 (5.3)
2.5 (5.4)
collected
Fraction of
amount fed,
% j
82 ,
82 !
76 ,
77
short residence time
79
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of 99.82 and 99.928 percent.
i
The treated soil samples were subjected to TCLP extraction and the extracts analyzed
for semivolatile organic constituents. No TCLP leachate contained any semivblatile organic
constituent at the method PQL of 10
123 Organochlorine Pesticides j
Table 42 summarizes the concentrations of the organochlorine pesticides found in the
soil feed and treated soil samples for the tests. Five pesticide compounds were found at or
above their detection limit: /3-BHC, dieldrin, endosulfan I, endosulfan II, endrin aldehyde.
These were present in both soil samples at generally comparable concentrations of 74 /xg/kg or
lower. None was found in any of the treated soil samples from the test program at the detection
limit noted in Table 42. Corresponding decontamination effectiveness was at least 92.9 to
99.01 percent.
TCLP leachate samples of all treated soil were also analyzed for lindane (y-BHC)
endrin, methoxychlor, heptachlor, heptachlor epoxide, chlordane, and toxaphene. None was
found in any treated soil leachate sample at detection limits ranging from 1 to 200 jig/L. AH
detection limits were at least a factor of 2 below corresponding pesticide constituent TCLP
regulatory levels. i
7.2.4 Volatile Organic Constituents
The concentrations of volatile organic compounds in the test samples Were analyzed
using EPA Method 8240, a GC/MS technique. No volatile organic constituent was found in any
Popiie site soil or treated soil sample. In contrast, the American Creosote soil samples contained
measurable levels of acetone, 2-butanone, toluene, ethyl benzene, styrene and total xylenes at
concentrations ranging from 170 to 3,200 /*g/kg, as shown in Table 43. The treated American
Creosote site soil at both test conditions contained no detectable volatile organic constituents
at the PQLs noted in Table 43. Corresponding decontamination effectiveness was at least
91.1 percent for acetone to at least 99.76 percent for total xylenes. j
TCLP leachate samples of all treated soil were also analyzed for the volatile organic
constituents noted in Table 44. None was found in any leachate sample at a PQL of 10 /ig/L.
7.2.5 Trace Metals
All test soil feed, treated soil, and treated soil TCLP leachate samples were analyzed for
the 14 trace metals listed in Table 45. Of the 14 trace metal analytes, only barium and copper
were found in any test program sample. Results are summarized in Table 46. As shown in
Table 46, the Popiie site soil contained 140 mg/kg of barium and 17 mg/kg of copper.
Corresponding levels in the American Creosote site soil were 17 and 18 mg/kg, respectively.
Roughly comparable levels of barium were found in the treated soil for both jtests with the
American Creosote site soil and for Test 2 with the Popiie site soil. Copper concentrations in
treated soil were uniformly reduced for both soils at both test conditions. Treated soil TCLP
leachate concentrations were less than the detection limit in all leachates.
81
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TABLE 42. ORGANOCHLORINE PESTICIDE ANALYSIS RESULTS AND
DECONTAMINATION EFFECTIVENESS
Parameter
Popiie site
Soil concentration, /ig/kg
Amount fed, /ig
Test 1: High temperature,
Treated soil:
Concentration, /ig/kg
Amount discharged /tg
Fraction of amount fed,
Test 2: Low temperature,
Treated soil:
Concentration, /tg/kg
Amount discharged /ig
Fraction of amount fed,
American Creosote site
Soil concentration, /ig/kg
Amount fed, /ig
/3-BHC Dieldrin
13
41
long residence
<0.3
<0.8
% < 1.9
short residence
<0.3
<0.8
<2
<6
27
86
time
<0.3
<0.8
<0.91
time
<0.3
<0.8
<0.91
19
60
Endo- Endo-
sulfan I sulfan II
8 74
25 240
<0.7 <0.7
<7.1 <0.77
<0.7 <0.7
<7.1 <0.77
8 42
25 130
Endrin
aldehyde
<2
<6
<0.7
a
<0.7
16
51
Test 1: High temperature, long residence time
Treated soil:
Concentration, /tg/kg
Amount discharged /ig
Fraction of amount fed,
Test 2: Low temperature,
Treated soil:
Concentration, /ig/kg
Amount discharged /ig
Fraction of amount fed,
<0.3
<0.7
short residence
<0.3
<0.7
<0.3
<0.7
time
<0.3
<0.7
<0.7 <0.7
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<0.7 <0.7
<6.7 <1.3
<0.7
<3.3
<0.7
<3.4
a_ = Constituent not detected in the soil feed.
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83
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TABLE 44. VOLATILE ORGANIC CONSTITUENTS ANALYZED
IN TCLP LEACHATE SAMPLES
Vinyl chloride
1,1-Dichloroethene
Chloroform
1,2-Dichloroethane
2-Butanone
Carbon tetrachloride
Trichloroethene
Benzene
Tetrachloroethene
Chlorobenzene
TABLE 45. TRACE METALS ANALYZED IN
TEST PROGRAM SAMPLES
Antimony
Arsenic
Barium
Beryllium
Cadmium
Chromium
Copper
Lead
Nickel
Selenium
Silver
Thallium
Zinc
Vanadium
84
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TABLE 46. TRACE METAL ANALYSIS RESULTS
Sample
Concentration
Barium Copper
Popile site ;
SoH, mg/kg 140 17 '
Test 1 ;
Treated soil, mg/kg 52 < 10
Treated soil TCLP leachate, mg/L <2 <0.02 ;
Test 2 :
Treated soil, mg/kg 140 < 10
Treated soil TCLP leachate, mg/L <2 <0.02
American Creosote site
Soil, mg/kg 660 18 ;
Test 1 ;
Treated soil, mg/kg 900 6 '
Treated soil TCLP leachate, mg/L <2 <0.02 ;
Test 2 :
Treated soil, mg/kg 640 5 '
Treated soil TCLP leachate, mg/L <2 <0.02 !
TCLP regulatory level,-mg/L 100 —a
a— = Has no TCLP regulatory level. ;
TEST CONCLUSIONS ;
Test conclusions are as follows: :
• Bench-scale incineration treatment at 982°C (1,800°F) and 1-hr solid treatment
test resulted in effective removal of semivolatile compounds from both site soils,
as confirmed by the absence of detectable semivolatile compounds Jn the treated
soil residues
• Bench-scale incineration treatment at 871 °C (1,600°F) and 20-min treatment time
resulted in effective removal of the semivolatile compounds from the Popile soil.
However, that condition allowed up to about 0.2 percent of the semivolatile
compounds to remain in the American Creosote treated soil (ash):
85
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• Bench-scale incineration treatment under both conditions tested resulted in the
elimination of the soil organochlorine pesticides and volatile organic contaminants.
No pesticides or volatile organic constituents were detected in any treated soil
sample in any test performed. The Popile site soil had no volatile organic
contamination, however.
• Both site soils are contaminated with barium and copper. Roughly comparable
levels of barium, though uniformly reduced levels of copper were found in both
site's treated soil residues for both test conditions. TCLP leachates of all treated
soils contained no detectable barium or copper.
Test results were documented in the brief report:
• Siag, A., and J. W. Lee, "Evaluating the Thermal Treatability of Contaminated
Soils from the Popile and American Creosote Superfund Sites: START Program
Screening Tests," draft May 1992.
86
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SECTIONS
EVALUATION OF THE IMPACTS OF REPEATED WASTE FEED CUTOFFS
In July 1990, the EPA and the Occupational Safety and Health Administration (OSHA)
established a joint Task Force to review safety and health issues at hazardous waste incineration
facilities nationwide'. The Task Force inspected 29 facilities. In addition to noting a number of
violations of OSHA and EPA regulations and hazardous waste management permit conditions,
EPA noted a significant number of waste feed cutoff (WFCO) episodes at about half the
incinerators inspected.
In accordance with EPA hazardous waste incinerator regulations, incinerator
management permits require that an incinerator have a WFCO control system that automatically
stops waste feed to the incinerator whenever one or more of several permit operating conditions
is exceeded. The intent of the WFCO provisions is to establish a fail-safe measure. Thus, if an
established permit condition, based on acceptable operation as demonstrated during the facility
trial burn, was exceeded, then waste feed would be terminated in an attempt to minimize the
adverse environmental impacts of the out-of-permit-condition operation. The expectation was
that WFCOs would be quite infrequent because good operating practice would hate an adequate
margin of safety between routine operation and a permit limit.
The facility review, however, showed that, at some facilities, the incinerator was being
routinely operated at conditions sufficiently close to permit limits that small upsets associated
with nonsteady state operations caused routine WFCOs. This has caused some concern because
the premise has been that operation outside of permit conditions has unacceptable
environmental impacts. Thus, if incinerator operation routinely drifts into conditions causing
WFCO, the question arises as to what adverse emissions impacts, if any, occur due to this
temporary excursion or the interruption of steady operation associated with the WFCO event.
The purpose of this test program, performed in support of OSW and the EPA permit
writers group (R. Holloway, S. Sasseville, coordinators), was to address this question.
Specifically, the test program was designed to evaluate whether increases in hazardous
constituent trace metals, hazardous constituent organics, and HC1 emissions occur with repeated
WFCO episodes. Tests were conducted to evaluate the incremental emission impact of
triggering WFCOs by two modes of APCS failure (exceeding a permit condition) and by two
modes of exceeding the incinerator CO emission limit. The APCS failure test objective was to
determine whether incremental emissions of trace metals and HC1 occur with WFCOs triggered
by APCS failure. The elevated-CO-emissions test objective was to determine whether
incremental POHC emissions occur with WFCOs triggered by operation with high flue gas CO
levels.
87
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The test program consisted of a series of seven tests performed in the IRF RKS.
Results of the test program are discussed in the subsections that follow.
8.1
TEST PROGRAM
8.1.1 Test Waste Description
The waste fired throughout the test program was composed of a mixture of organic
liquids (POHCs) and a hazardous constituent trace metals solution added to a clay absorbent
material. The synthetic waste was packaged into plastic-bag-lined fiberpack drums and fed to
the rotary kiln via the fiberpack drum ram feed system. The same mixture of organic liquids was
also co-fired through the kiln burner via a liquid nozzle in the burner.
The organic liquid was a mixture of 76 percent toluene by weight and 12 percent each
of chlorobenzene and tetrachlorethene. The POHC mixture was made by mixing the proper
weights of each component in a steel drum. This mixture was used to co-fire the kiln burner and
to mix with the clay absorbent and trace metals solution.
All hazardous constituent trace metals were added to the synthetic waste via a
concentrated aqueous solution. The aqueous metals solution was prepared in glass containers
and contained five test program hazardous constituent trace metals. When added to the
clay/organic liquid mixture, the resulting synthetic solid waste contained arsenic at 31 mg/kg,
barium at 310 mg/kg, cadmium at 16 mg/kg, and chromium and lead at 39 mg/kg.
8.1.2 Test Conditions
The WFCOs planned for testing were venturi scrubber pressure drop upsets, scrubber
liquor flow upsets, and excessive CO emissions upsets. One test was performed for each of the
scrubber upsets. Two test conditions resulting in excessive CO emissions were tested. The first
test condition used a reduced combustion air flow to produce excessive CO and the second used
an elevated charge size to produce excessive CO. Duplicate baseline condition tests, with no
WFCOs, were also completed. Alow feedrate baseline test was added to the test program near
the conclusion of the program. This test was at a decreased feedrate more consistent with the
lower overall feedrates associated with significant periods of no waste feed during the scrubber
failure tests.
The baseline tests, conducted in duplicate (Tests la and Ib), were performed to establish
the emission levels of HC1 and the test trace metals, as well as the baseline POHC DREs
achieved during routine operation. The test conditions selected represent typical operation for
a well-operated incinerator in full compliance with the hazardous waste incinerator performance
standards. For this test, the target kiln exit gas temperature was 871 °C (1,600 °F), with flue gas
O2 at nominally 10 percent and the target afterburner exit gas temperature was 1,093 °C
(2,000 °F), with flue gas O2 at nominally 8 percent. In addition to Tests la and Ib, Test 5 was
added to the test program as a low feedrate baseline test. All other conditions for Test 5 were
to be the same as those for Tests la and Ib with the exception that the synthetic waste per
charge and corresponding solid waste feedrate were reduced.
88
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Test 2 evaluated the incremental HC1 and trace metal emissions resulting from WFCO
triggered by low venturi scrubber pressure drop. For this test, an automatic WFCO interlock,
which stopped waste feed when the venturi scrubber pressure drop fell below 4.5 kPa (18 in
WC), was programmed into the RKS process control system. The RKS was set to steady
operation at the conditions of the baseline test. After 20 minutes of normal operation and just
after a fiberpack charge entered the kiln, the venturi scrubber pressure drop was rapidly
decreased by shutting off the scrubber system induced draft fan. This caused the venturi
scrubber pressure drop to fall below the interlock setpoint of 4.5 kPa (18 in WC) and the process
control system halted waste feed by preventing further drum charging and interrupting liquid
waste feed to the kiln burner. After 20 minutes, venturi scrubber pressure drop was returned
to 6.2 kPa (25 in WC) by restarting the induced draft fan. As soon as the waste feed permissive
signal occurred, liquid and solid waste feed were restarted. The cycle was repeated after about
40 minutes of returned operation at baseline conditions. The full cycle was repeated four times
so that flue gas samples over four WFCO events could be collected during the test.
i
Test 3 evaluated the incremental HC1 and trace metal emissions associated with WFCO
triggered by low scrubber system scrubber liquor flow. Scrubber liquor for both the venturi and
packed-column scrubbers is supplied via a common delivery system. In this test, an automatic
WFCO interlock, which stopped waste feed when the scrubber liquor inlet flowrate to the venturi
scrubber or to the packed-column scrubber dropped below preset limits, was programmed into
the RKS process control system. This test proceeded exactly as Test 2 except that, instead of
reducing venturi scrubber pressure drop, scrubber liquor recirculation to both the venturi
scrubber and the packed-column scrubber was stopped. Scrubber liquor flow to both scrubbers
remained off for 20 minutes, and then was restarted and set to routine operation! levels. Waste
feed was restarted as soon as a feed permissive signal occurred. After about a 40-minute time
interval at returned baseline operation, the WFCO cycle was repeated. Four cycles were tested
over the test day. :
Tests 4a and 4b evaluated the incremental emissions associated with WFCO triggered
by elevated CO emissions. For these tests an automatic WFCO interlock, which prevented both
liquid and solid waste feed when instantaneous scrubber exit flue gas CO levels exceeded
100 ppm was programmed. Thus, if scrubber exit CO levels spiked at above 100 ppm after a
solid waste batch charge, the WFCO interlock terminated liquid waste feed through the kiln
burner and prevented further solid waste charging. After scrubber exit CO levels fell below
100 ppm, liquid and solid waste feed was restarted and continued until a solid waste batch charge
caused another scrubber exit CO spike.
Current EPA guidance for hazardous waste incinerator permits is to require WFCO
when 1-hr rolling average stack gas CO levels exceed 100 ppm corrected to 7 percent O2. This
is a more flexible condition to comply with than a 100 ppm instantaneous limit. However, some
incinerators with older permits require WFCO if CO emissions exceed 100 ppm on an
instantaneous basis. In addition, some incinerator operators with rolling average permit
conditions use an interlock which terminates waste feed if instantaneous CO emissions exceed
100 ppm because the instantaneous interlock is simpler to implement and guarantees compliance
with a rolling average permit condition. Thus, the operating mode tested represented a valid test
of repeated WFCOs for the set of incinerators operating with instantaneous CO interlocks.
However, test results could have limited applicability to incinerators experiencing repeated
WFCOs triggered by exceeding a 1-hr rolling average 100 ppm CO limit.
89
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Two different excessive CO tests were performed. For Test 4a the baseline waste feed
regimen was used. However, air flow to both the kiln and the afterburner was reduced to a rate
that resulted in the average availability of excess air over a charge cycle, but at a rate that was
insufficient to satisfy the peak oxygen demand following a solid waste batch charge. A CO spike
of about 1-minute duration resulted. For Test 4b, air flows to both the kiln and afterburner were
set to levels closer to, through still below those used in the baseline tests. However, the solid
waste feed charge size and corresponding feedrate was greater than that used in the other tests,
and the solid waste formulation contained more POHC mixture than that used for the other
tests.
Routine scrubber exit CO spikes were indeed experienced during the high CO tests, as
desired. Twenty-two spikes were experienced during the volatile organic emissions sampling
period during Test 4a, seven of which drove the scrubber exit CO monitor to a full-scale reading
of 650 ppm (the 100 ppm 1-hr rolling average CO emission Emit was not exceeded, however).
Less frequent CO spikes were experienced for Test 4b. Eleven scrubber exit spikes occurred
over the volatile organic emissions sampling period during this test. Only two of these drove the
scrubber exit CO monitor to full scale. The other spikes were about 200 ppm or less.
8.13 Sampling and Analysis
In addition to obtaining synthetic solid and liquid waste feed, kiln ash, and pre- and
post-test scrubber liquor samples, the sampling protocol for all tests included sampling the flue
gas at the afterburner exit and at the scrubber system exit for trace metals, using the EPA
multiple metals train, and particulate and HC1, using Method 5. In addition, the scrubber exit
flue gas was sampled for the volatile POHCs, using Method 0030. The stack downstream of the
secondary APCS was also sampled for particulate and HC1, using Method 5.
The Method 0030 samples were analyzed for the volatile POHCs, and the multiple
metals train samples were analyzed for the five test trace metals. In addition, the synthetic solid
waste feed, kiln ash, and pre- and post-test scrubber liquor samples were analyzed for the test
POHCs and trace metals.
8.2 TEST RESULTS
8.2.1 POHC Analysis Results and DREs
Table 47 summarizes the measured scrubber exit flue gas concentrations and
corresponding emission rates and POHC DREs for each of the tests. As shown in the table, the
overall feedrates for the tests with scrubber-failure-induced WFCOs were lower than the overall
feedrates for the baseline tests. This resulted from the periods of interrupted feed associated
with the WFCOs. Test 5 was performed at lower overall feedrate to allow accounting for this
overall feedrate decrease with WFCOs.
The data in Table 47 show that toluene concentrations in the scrubber exit flue gas
ranged from 12 to 88 /xg/dscm, tetrachloroethene concentrations ranged from 1.5 to 14 jug/dscm,
and chlorobenzene concentrations ranged from 1.5 to 9.8 /ig/dscm. The highest concentrations
for all three POHCs were measured in the repeat baseline test, Test Ib. The lowest toluene
concentration was measured in the high CO from reduced air flow test, Test 4a. The lowest
90
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TABLE 47. SCRUBBER EXIT FLUE GAS POHC CONCENTRATIONS AND POHC DREs
Parameter
Test la: Baseline
Scrubber exit gas
Concentration, /ig/dscm
Emission rate, mg/hr
Feedrate, kg/hr
Solid feed
Liquid feed
Total feed
DRE, %
Test Ib: Repeat baseline
Scrubber exit gas
Concentration, /*g/dscm
Emission rate, mg/hr
Feedrate, kg/hr
Solid feed
Liquid feed
Total feed
DRE, %
Test 2: Scrubber fan failure
Scrubber exit flue gas
Concentration, /ig/dscm
Emission rate, mg/hr
Feedrate, kg/hr
Solid feed
Liquid feed
Total feed
DRE, %
Test 3: Scrubber liquor flow failure
Scrubber exit flue gas
Concentration, /jg/dscm
Emission rate, mg/hr
Feedrate, kg/hr
Solid feed
Liquid feed
Total feed
DRE, %
Toluene
32
70
3.90
4.86
8.76
99.99920
88
170
4.07
5.26
9.33
99.9982
40
67
2.47
2.50
4.97
99.9987
14
27
2.73
2.80
5.53
99.99951
91
Tetrachloroethene
3.7
8.0
0.86
0.83
1.69
99.99952
14
26
1.18
0.73
1.91
99.9986
7.0
12
0.70
0.38
1.08
99.9989
1.5
3.0
0.49
0.44
0.93
99.99967
Chlorobenzene
i
3.0
6.5
^0.77
1076
!1.53
199.99957
1
19.8
19
0.83
0.90
1.73
;99.9989
3.6
.6.0
'0.48
0.43
;o.9i
99.99933
'•-
1.5
3.0
:0.53
10.47
1.00
99.99970
(continued)
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TABLE 47. (continued)
Parameter
Toluene Tetrachloroethene Chlorobenzene
Test 4a: High CO, reduced air flow
Scrubber exit flue gas
Concentration, /ig/dscm 12 1.7 1.7
Emission rate, mg/hr 15 2.1 2.1
Feedrate, kg/hr
Solid feed 3.35 0.59 0.60
Liquid feed 3.28 0.54 0.53
Total feed 6.63 1.13 1.13
DRE, % 99.99977 99.99981 99.99981
Test 4b: High CO, increased charge
mass
Scrubber exit flue gas
Concentration, /ig/dscm 33 4.1 3.8
Emission rate, mg/hr 61 7.5 7.0
Feedrate, kg/hr
Solid feed 8.52 2.07 1.49
Liquid feed 3.30 1.97 1.27
Total feed 11.82 4.04 2.76
DRE, % 99.99948 99.99981 99.99974
Test 5: Low feedrate baseline
Scrubber exit flue gas
Concentration, /ig/dscm 22 4.6 1.9
Emission rate, mg/hr 32 6.7 2.8
Feedrate, kg/hr
Solid feed 1.58 0.28 0.28
Liquid feed 2.69 0.46 0.46
Total feed 4.27 0.74 0.74
DRE, % 99.99925 99.99909 99.99962
tetrachloroethene and chlorobenzene concentrations were measured in Test 3, the scrubber
liquor flow failure test. Flue gas concentrations for these two POHCs, however, were
comparably low in Test 4a. Flue gas POHC concentrations for all three POHC in the other high
CO test, Test 4b, were comparable to those measured in the baseline test, Test la.
Corresponding DREs as measured at the scrubber exit ranged from 99.9982 percent to
99.99977 percent for toluene, from 99.9986 percent to 99.99981 percent for tetrachloroethene,
and 99.9989 percent to 99.99981 percent for chlorobenzene. Again, the lowest DREs for all
three POHCs occurred in the repeat baseline test (Ib). The highest DREs for all three POHCs
92
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occurred in the high CO, reduced air flow test (4a). POHC DREs for the high CO, increased
charge mass test (4b) were comparable to, though uniformly greater than, those measured in
Test la, the baseline test. ;
The data in Table 47 clearly show that repeatedly exceeding an instantaneous 100 ppm
CO limit at the exit of the APCS via the two mechanisms tested did not cause increased POHC
flue gas concentrations or emission rates, nor decreased POHC DRE. As noted in Section 8.1.2,
however, these results may not be applicable to incinerators experiencing repeated WFCOs
triggered by exceeding a 100 ppm 1-hr rolling average CO limit.
Original plans were to continuously monitor scrubber exit flue gas total unburned
hydrocarbon (TUHC) levels during the tests. This was not done, however, due, to instrument
calibration problems. As a consequence, it is not known whether increases in flue gas TUHC
accompanied the increased CO levels in the high CO tests, or the WFCOs tested in the scrubber
failure tests. |
No POHC was detected in any test kiln ash or scrubber liquor sample.
$22 Trace Metal Analysis Results
Table 48 summarizes the trace metal concentrations in each test program sample
analyzed. Metal concentration data for the scrubber exit flue gas stream noted in the table often
appear as ranges. This arises from the fact that two samples from the metals sampling train
were analyzed to yield the flue gas stream concentration, a particulate probe Wash plus filter
sample, and an impinger solution sample. In some cases, the metal was not detected in the
impinger sample. In these cases the flue gas concentrations are shown as ranges. The lower
bound of the range assumes metals not detected in the impinger solution sample were not
present (zero concentration); the upper bound of a range assumes metals not detected in the
impinger solution sample were present at the detection limit.
i
The data in Table 48 show that measurable concentrations of barium, cadmium,
chromium, and lead were found in each of the pretest scrubber liquor samples. Arsenic was not
detected in any pretest scrubber liquor sample. Each of the test metals was found in each of the
kiln ash, posttest scrubber liquor, and flue gas samples as well. The data in Table 48 also show
no significant test-to-test variations in scrubber exit flue gas metal concentrations for any of the
test rnetals. Thus, within the metals concentration variability range of the duplicate baseline
tests, it appears that none of the tested WFCO operating modes significantly affected the
concentration of metals in the scrubber exit flue gas. Similarly, metals emissions rates were
apparently not significantly different for the WFCO tests when compared with the baseline tests.
Table 49 summarizes the test metal distributions among the three incineration system
discharges: the kiln ash, scrubber liquor, and scrubber exit flue gas. The distribution fractions
in Table 49 have been normalized to the total amount of each metal measured in all the
discharge streams analyzed. Actual achieved metal mass balance closures ranged from 35 to
146 percent and averaged 62 percent. These levels are in the range typically achieved at the
IRF.
93
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TABLE 48. TRACE METAL ANALYSIS RESULTS
Sample
Unspiked clay absorbent
Aqueous metals spiking solution, g/L
Test la (6/4/92), Baseline
Solid waste feed, mg/kg
Kiln ash, mg/kg
Afterburner exit flue gas, /tg/dscm
Scrubber exit flue gas, /jg/dscm
Pretest scrubber liquor, mg/L
Posttest scrubber liquor, mg/L
Test Ib (6/19/92), Repeat baseline
Solid waste feed, mg/kg
Kiln ash, mg/kg
Afterburner exit flue gas, /ig/dscm
Scrubber exit flue gas, pg/dscm.
Pretest scrubber liquor, mg/L
Posttest scrubber liquor, mg/L
Test 2 (6/9/92), Scrubber fan failure
Solid waste feed, mg/kg
Kfln ash, mg/kg
Afterburner exit flue gas, pg/dscm
Scrubber exit flue gas, pg/dscm
Pretest scrubber liquor, mg/L
Posttest scrubber liquor, mg/L
Test 3 (6/11/92), Scrubber liquor flow failure
Solid waste feed, mg/kg
Kiln ash, mg/kg
Afterburner exit flue gas, ^g/dscm
Scrubber exit flue gas, /ig/dscm
Pretest scrubber liquor, mg/L
Posttest scrubber liquor, mg/L
Test 4a (6/23/92), High CO, reduced air flow
Solid waste feed, mg/kg
Kiln ash, mg/kg
Afterburner exit flue gas, /ig/dscm
Scrubber exit flue gas, ^g/dscm
Pretest scrubber liquor, mg/L
Posttest scrubber liquor, mg/L
Test 4b (4/29/92), High CO, increased charge mass
Solid waste feed, mg/kg
Kiln ash, mg/kg
Afterburner exit flue gas, pg/dscm
Scrubber exit flue gas, /tg/dscm
Pretest scrubber liquor, mg/L
Posttest scrubber liquor, mg/L
Test 5 (6/25/92), Low feedrate baseline
Solid waste feed, mg/kg
Kiln ash, mg/kg
Afterburner exit flue gas, /ig/dscm
Scrubber exit flue gas, /ig/dscm
Pretest scrubber liquor, mg/L
Posttest scrubber liquor, mg/L
Arsenic
<3
1-3
29
24
52-62
14-32
<0.05
0.20
29
21
69-79
12-31
<0.05
0.53
36
26
43-52
8-25
<0.05
0.29
37
24
64-73
6-28
<0.05
0.16
24
20
175-185
23-34
<0.05
0.21
33
35
140-150
21-38
<0.10
0.21
31
18
61-71
8-28
<0.05
0.26
Barium
125
15
454
465
20
4
0.28
0.47
503
498
30
9
0.22
13
433
503
17
6
0.19
0.71
479
503
58
9
0.14
036
408
510
30
10
0.23
0.26
515
783
75
18
0.21
0.63
450
510
12
9
0.22
0.44
Cadmium
2.5
0.61
15
1.7
190
115
0.03
0.14
16
11
210
63
0.05
0.53
16
10
97
56
0.03
0.16
17
10
130
42
0.02
0.07
13
1.7
47
130
0.04
0.10
16
10
240
96
0.03
0.21
15
12
96
53
0.02
0.12
Chromium
220
1.2
215 '
330
240
18
0.07
1.0
250
373
215
13-17
0.11
1.1
192
603
120
14
0.07
0.82
380
340
140
14-17
0.03
0.26
207
225
190
18
0.12
0.25
192
524
620
37
0.03
0.79
330
400
41
16
0.05
0.42
Lead
58
1.7
77
76
90-98
155-170
0.43
0.29
106
103
86-94
160
0.26
2.7
91
107
56-64
41-54
0.10
0.54
98
104
58-79
18-36
0.14
0.17
59
67
145-155
40-67
0.19
0.15
76
111
420
94-110
0.49
1.5
110
100
52-60
17-33
0.14
0.32
94
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TABLE 49. NORMALIZED TRACE METAL DISTRIBUTIONS
Distribution, % of metal measured
Test la (6/4/92), Baseline
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Test Ib (6/19/92), Repeat baseline
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Test 2 (6/9/92), Scrubber fan failure
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Test 3 (6/11/92), Scrubber liquor flow failure
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Test 4a (6/23/92), High CO, reduced air flow
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Test 4b (4/29/92), High CO, increased charge mass
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Test 5 (6/25/92), Low feedrate baseline
Kiln ash
Scrubber exit flue gas
Scrubber liquor
Total
Arsenic
87-91
3-7
6
100
84-88
3-7
9
100
79-85
3-10
11-12
100
77-85
3-13
10-12
100
81-83
5-7
12
100
82-86
6-10
8
100
65-72
5-14
21-23
100
Barium
99.5
0.1
0.4
100
99.0
0.1
0.9
100
98.4
0.2
1.4
100
98.8
0.2
1.0
100
99.7
0.1
0.2
100
98.8
0.3
0.9
100
98.7
0.3
1.0
100
Cadmium
19
71
10
100
66
22
12
100
54
37
9
100
60
34
6
100
18
71
11
100
43
44
13
100
56
34
10
100
Chromium
97.4
0.3
2.3
100
,
98.6
0.3
1.1
100
98.1
0.3
1.6
100 .
98.0
0.6
1.4
100
i
98.6
0.4
1.0
100
97.0
0.7
2.3
100
97.4
0.5
2.1
ioo
Lead
88-90
10-11
<1
100
84
8
8
100
90
5
5
100
95-97
2-4
1
100
94-97
3-5
<1
100
80-81
7-8
12 .
100
92-94
2-4
4
100
95
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The data in Table 49 show that barium and chromium were relatively nonvolatile in all
of the tests. Greater than 98 percent of the barium in the discharges and 96 percent of the
chromium in the discharges was accounted for by the kiln ash. Less than 1 percent of the
barium and chromium was measured in the scrubber exit flue gas, with about 1 percent of the
barium and 1 to 2 percent of the chromium measured in the scrubber liquor. Arsenic and lead
were more volatile in the tests, though still predominantly nonvolatile. Nominally 80 to
90 percent of the arsenic was measured in the kiln ash discharge for all tests except the low
feedrate baseline test, Test 5, where it was 65 and 72 percent for no readily apparent reason.
Between about 3 and 14 percent of the arsenic was measured in the scrubber exit flue gas for
all tests. Comparable, to slightly larger, fractions of arsenic were measured in the scrubber
liquor. Nominally 80 to 95 percent of the lead was measured in the kiln ash discharge for all
tests. About 3 to 10 percent of the lead was measured in the scrubber exit flue gas, and 1 to
12 percent in the scrubber liquor. Cadmium exhibited even more volatile behavior than arsenic
and lead in all tests. Nominally 20 to 66 percent of the cadmium was accounted for in the kiln
ash discharge. Comparable amounts, 20 to 70 percent, were accounted for in the scrubber exit
flue gas. Only 13 percent or less of the cadmium was accounted for in the scrubber liquor.
The data in Table 49 show no repeatedly significant difference in metals distributions
from test to test for any of the metals, within the degree of data variability exhibited in the two
baseline tests, within the precision of the measurements, or both. This suggests that metals
partitioning among the incinerator discharges was relatively unaffected by the different tested
operating conditions leading to repeated WFCOs.
Table 50 summarizes the apparent scrubber collection efficiencies for the metals.
Apparent scrubber collection efficiencies are calculated by assuming that the sum of the amount
of metal measured in the two scrubber discharges (the scrubber liquor and the scrubber exit flue
gas) was the amount of metal in the scrubber inlet flue gas. The data in Table 50 show that the
venturi/packed column scrubber system was nominally 70 to 90 percent efficient in collecting
barium and chromium. Arsenic apparent collection efficiencies were perhaps as low as 45 to
64 percent. Cadmium apparent collection efficiencies were lower, in the 13 to 35 percent range.
Lead apparent collection efficiencies were highly variable. Within the range of variability in the
data, however, no test-to-test differences in collection efficiencies are apparent. This suggest that
none of the repeated WFCOs tested affected scrubber metals collection efficiencies.
8.23 Particulate and HC1 Emission Data
Table 51 summarizes the particulate levels measured at the afterburner exit (scrubber
inlet) and scrubber exit. The data in the table show that afterburner exit particulate levels
ranged from 48 to 98 mg/dscm, corrected to 7 percent O2, for the two baseline, the two scrubber
failure, and the low feedrate baseline tests, Tests la, Ib, 2,3, and 5. Afterburner exit particulate
levels were increased, ranging from 133 to 148 mg/dscm, for the two high CO WFCO tests. This
is probably because of a combination of increased kiln ash entrainment into the combustion gas,
as well as some flue gas soot formed during the high CO tests. Significant soot formation was
evident during both high CO tests in visual observations of the kiln combustion gas and the
substantial darkening of the scrubber liquor with collected soot.
Scrubber exit particulate levels were reduced to the 8 to 15 mg/dscm at 7 percent O2
for Tests la, Ib, 2, 3, and 5. Scrubber exit particulate levels were essentially the same for the
96
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two scrubber failure tests as for the two baseline and the low feedrate baseline tests. Thus, the
two scrubber failure modes tested with WFCO resulted in no apparent increased particulate
emissions. ;
Scrubber exit particulate emissions for the two high CO WFCO tests were somewhat
higher, at 17 and 26 mg/dscm at 7 percent O2. These are probably because of the higher
scrubber inlet loadings for the two tests. Table 51 also notes the particulate removal efficiencies
of the scrubber system, calculated based on the scrubber inlet (afterburner exit) and exit levels
measured. Removal efficiencies were not significantly different from test to test; ranging from
77 to 89 percent.
Table 52 summarizes the HC1 levels measured in the flue gas at the three locations
sampled. As shown in the table, afterburner exit HC1 levels ranged from 325 to 1,130 ppm with
the test-to-test variations in chlorine feedrate as determined by waste feedrate and chlorine
content. Scrubber exit HC1 levels were reduced to 0.5 to 1.6 ppm. Relatively constant scrubber
HC1 collection efficiencies, at 99.8 to 99.9 percent, were measured. The two scrubber failure
modes tested, with attendant WFCO, apparently did not result in measurably increased HC1
emissions or decreased scrubber HC1 collection efficiency.
8.3
CONCLUSIONS
Test program results show that none of the incinerator operating modes tested, which
resulted in repeated WFCOs, caused measurably increased POHC, hazardous constituent trace
metal, or HC1 emissions. The DREs for the three test POHCs (toluene, tetrachloroethene, and
chlorobenzene) ranged from 99.9982 to 99.99981 percent over the test program. The lowest
DREs were measured in one of the two baseline tests (Test Ib). The highest DREs were
measured in the repeated CO spike test in which CO spikes were produced by reducing the
combustion air flowrate to the incinerator from the baseline test levels. The other CO spike test,
in which CO spikes were produced by increasing the mass and heat content of each batch charge
of solid waste to an overcharge situation, had POHC DREs comparable to the other baseline
test (Test la). POHC DREs for the two scrubber system failure tests, one in which venturi
scrubber pressure drop was repeatedly reduced by shutting off the scrubber induced draft fan
(fan failure) and the other in which scrubber liquor flow was stopped by shutting off the scrubber
system recirculation pump, were also comparable to those measured in the baseline tests.
The high CO operating modes tested, however, interrupted waste feed whenever
instantaneous scrubber exit flue gas CO levels exceeded 100 ppm. Current permitting guidance
allows more flexibility by requiring WFCO when 1-hr rolling average stack gas CO levels exceed
100 ppm corrected to 7 percent O2. The test result that repeated WFCOs due to high flue gas
CO did not apparently lead to decreased POHC DRE may not be applicable to incinerators with
WFCO interlocks based on a 100 ppm 1-hr rolling average CO limit. In addition, flue gas
TUHC levels were not measured in the tests, so no information was obtained on whether
increased TUHC levels accompanied the CO spikes.
Within the variability in the test-to-test trace metal data, none of the repeated WFCO
operating modes tested resulted in significant increased flue gas metals emissions. Scrubber exit
flue gas concentrations and emissions rates of arsenic, barium, cadmium, chromium, and lead
for the two scrubber failure and two high CO WFCO tests were not significantly different than
97
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TABLE 50. APPARENT SCRUBBER TRACE METAL COLLECTION EFFICIENCIES
Apparent scrubber collection efficiency3, %
Test la (6/4/92), Baseline
Test Ib (6/19/92), Repeat
baseline
Test 2 (6/9/92), Scrubber
fan failure
Test 3 (6/11/92), Scrubber
liquor flow failure
Test 4a (6/23/92), High
CO, reduced air flow
Test 4b (4/29/92), High
CO, increased charge mass
Test 5 (6/25/92), Low
feedrate baseline
As
48-68
54-76
54-79
46-81
64-73
45-60
61-84
Ba
88
89
90
80
69
78
81
Cd
13
35
20
16
14
22
23
Cr
89
80-84
85
67-71
72
76
79
Pb
<3
51
46-54
15-26
<15
59-63
49-65
"(Scrubber liquor fraction)/(scrubber liquor fraction + scrubber exit flue gas fraction).
TABLE 51. FLUE GAS PARTTCULATE LEVELS
Flue gas particulate,
mg/dscm at 7% O2
Afterburner
la:
Ib:
2:
3:
4a:
4b:
5:
Test
Baseline
Repeat baseline
Scrubber fan failure
Scrubber liquor flow failure
High CO, reduced airflow
High CO, increased charge mass
Low feedrate baseline
Date
6/4/92
6/19/92
6/9/92
6/11/92
6/23/92
4/29/92
6/25/92
exit
98
52
81
67
148
133
48
Scrubber
exit
15
12
10
9
17
26
8
— Scrubber
removal
efficiency, %
85
77
88
87
89
80
83
98
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TABLE 52. FLUE GAS HC1 LEVELS
Afterburner exit
Scrubber exit
Test
HCI
concentration,
HCI
emission
HCI
concentration,
HCI
emission,
Scrubber
mg/dscm ppm rate, g/hr mg/dscm ppm rate, g/hr efficiency, %
Test la (6/4/92), Baseline
Test Ib (6/19/92), Repeat
baseline
Test 2 (6/9/92), Scrubber
fan failure
Test 3 (6/11/92), Scrubber
liquor flow failure
Test 4a (6/23/92), High
CO, reduced airflow
Test 4b (4/29/92), High
CO, increased charge mass
Test 5 (6/25/92), Low
feedrate baseline
1,100
1,090
545
494
1,640
1,710
638
724
718
359
325
1,080
1,130
420
1,980
1,950
990
916
2,250
2,850
1,110
1.6
2.2
0.8
0.9
2.3
2.4
1.2
1.1
1.4
0.5
0.6
1.5
1.6
0.8
3.4 99.8
4.2 ! 99.8
!
1.3 ! 99.9
1.7 • 99.8
2.9 99.9
4.5 : 99.8
i
1.8
those for the baseline tests. Trace metal distributions among the three inciner
streams (kiln ash, scrubber liquor, and scrubber exit flue gas) and scrubber trace m
efficiencies were not significantly different from baseline to WFCO tests, ag£
test-to-test data variability and the precision of the metals analysis methods.
99.8
itor discharge
etal collection
tin within the
Flue gas HCI concentrations and emission rates at the scrubber exit varied only with the
feedrate of chlorine in the wastes fed to the incinerator. Scrubber HCI collection efficiencies
were 99.8 to 99.9 percent for all tests and were not reduced with any scrubber failure or high CO
operating mode tested.
Flue gas particulate levels at the scrubber exit were in the 8 to 15 mg/dscm at 7 percent
O2 range for all tests except the two high CO WFCO tests. Flue gas particulate levels at the
scrubber exit for the two scrubber failure WFCO tests were lower than levels measured in the
two baseline tests. Scrubber exit particulate levels were somewhat higher, at 17 and 26 mg/dscm,
for the two high CO WFCO tests. These increases were the result of increased scrubber inlet
particulate levels for these two tests. Scrubber particulate collection efficiency was relatively
constant at 77 to 89 percent from test to test.
The higher inlet particulate levels for the high CO WFCO tests probably resulted from
a combination of increased entrainment of solids from the kiln into the kiln exit combustion gas
and soot formed during the incomplete combustion environment resulting in the CO spikes. The
99
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increased entrainment results from the high intensity puff of incompletely combusted organics
associated with kiln overcharging used to produce the high CO.
Overall, test results suggest that the permit requirement to terminate waste feed
whenever a permit-specified operating limit is exceeded apparently prevents signifiant increased
incinerator emissions of POHCs, trace metals, and HC1. Only particulate emissions increases,
to up to double the baseline, routine operation levels, were measured in these tests. These
increases were not associated with APCS failures, but with increased APCS inlet particulate
levels arising from combustion conditions associated with repeated CO spikes.
Barium and chromium exhibited nonvolatile behavior in all the tests performed. Greater
than 98 percent of the barium and 96 percent of the chromium measured in incinerator
discharges was accounted for in the kiln ash. Arsenic and lead exhibited more volatile behavior.
The kiln ash discharge accounted for 80 to 90 percent of the arsenic measured in the discharges
for all tests except the low feedrate baseline test, Test 5, which was 65 to 72 percent. Nominally
80 to 95 percent of the lead measured in the incinerator discharges was in the kiln ash.
Cadmium was even more volatile in all tests; 18 to 66 percent of the cadmium in the discharges
was accounted for in the kiln ash. These observations are consistent with past IRF metal
partitioning experience1'2'3.
Test results were reported in the preliminary draft test report:
• Whitworth, W. E., Jr., and L. R. Waterland, "Evaluation of the Impacts of
Incinerator Waste Feed Cutoffs," preliminary draft August 1992.
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SECTION 9
THIRD-PARTY TESTING
The Federal Technology Transfer Act allows for the use of government facilities and
equipment in joint projects with private-sector third parties. The IRF represents a unique facility
with capabilities unavailable anywhere else in the United States. Furthermore, the hazardous
waste incineration research and testing arena is quite active. Thus, the demand for such third-
party joint projects is expected to become significant. >
The RREL policy established during FY89 was to encourage, and even; solicit, third-
party use of the IRF. In fact, the IRF operations and research contract specifically provides for
this type of usage, and efforts to identify appropriate joint third-party projects have proceeded.
FY92 saw the initiation of the first two third-party use projects at the IRF. These two projects
are discussed in the following subsections.
9.1 BENCH-SCALE TREATABILITY TESTING OF CONTAMINATED NEW YORK
HARBOR SEDIMENTS
In this initial third-party use project, the USAGE Waterways Experiment Station (WES)
(D. Averett, coordinator) requested that a series of bench-scale treatability tests be performed
in the IRF TTU to evaluate the effectiveness of incineration in destroying organic contaminants
in sediments from the New York Harbor. The New York Harbor sediments are (contaminated
with petroleum hydrocarbons, polynuclear aromatic hydrocarbon (PAH) compounds, and dioxin.
Based on previous data obtained by WES, total petroleum hydrocarbon levels in sediment
samples ranged from 260 to 8,100 mg/kg, and dioxin levels ranged from < 1.2 to 450 ng/kg.
A 10-gal sample of dredged sediments was delivered to the IRF in July, 1992. These
sediments were tested in a five-test program incorporating two incineration temperatures and
two incineration residence times, as summarized in Table 53. A description of the ITU is given
in Section 7.1.1. For the tests, feed material, contained in quartz trays, was fed to the TTU, with
each quartz tray charged with nominally 0.45 kg (1 Ib) of test material. For all tests, the 'ITU
retention chamber was operated at a temperature of 1,093°C (2,000°F) and the breeching
chamber was continuously fired, with resulting temperatures of nominally 1,093°C (2,000°F).
The test plan, prepared in July 1992, specified analyzing one composite sediment sample,
and the treated sediment samples of all tests for PAH compounds, PCBs, and pblychlorinated
dibenzo-p-dioxins (PCDDs) and polychlorinated dibenzofurans (PCDFs). For Tests 4 and 5, the
TTU flue gas was also sampled for PAHs, PCBs, and PCDDs/PCDFs. ,
101
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TABLE 53. TEST CONDITIONS
Charge chamber
gas temperature,
Test °C (°F)
Charge chamber
solids residence time,
hr
1
2
3
4
5
816 (1,500)
816 (1,500)
982 (1,800)
982 (1,800)
Repeat Test 4
0.5
1.0
0.5
1.0
The tests were completed at the close of FY92 in September 1992. Sample analyses,
data reduction, and reporting will be completed during early FY93.
9.2 ROTARY KILN INCINERATION TESTING OF SIMULATED LOW-LEVEL MIXED
WASTE
This project was initiated during FY91 with an IRF response to a request from the
Westinghouse Savannah River Company (WSRC) (D. Burns, H. Burns, M. Looper, coordinators)
to propose a series of tests to generate ash and measure the combustor exit particle size
distributions from the incineration of simulated low-level mixed waste under a variety of
conditions. WSRC operates the Department of Energy's (DOE's) Savannah River Plant (SRP)
in Aiken, South Carolina. The initial work recommendation for a test program was submitted
in July 1991. In response to the initial proposal, WSRC modified the desired scope of work and
requested a further response. A revised proposal was prepared and submitted at the beginning
of FY92, in October 1991. Agreement was reached with WSRC (in early September 1992) to
perform the third-party test project.
Current plans are to complete a 22 test program in which three simulated low-level
mixed wastes will be incinerated in the IRF RKS. The three simulated wastes will be the design
waste mix for the Consolidated Incineration Facility (GIF) planned for installation at the SRP,
a high-ash waste, and a spiked design waste mix. The design waste mix will be a mixture of
paper, polyvinyl chloride (PVC) bags, polyethylene (PE) bags, and latex gloves. The high-ash
waste will be paper alone. The spiked design waste mix will be the paper/P VC/PE/latex mixture
spiked with hazardous constituent organics and trace metals. Seventeen tests with the design mix
waste are planned. Test variables will be incineration temperatures, waste feedrate, kiln solids
residence time, and waste density. Two tests with the high-ash waste at two solids residence
times are planned. Three tests with the spiked design waste mix at different combinations of
incineration temperatures, solids residence time, and waste density are planned.
The objectives of all tests will be to collect kiln bottom ash and scrubber liquor for
stabilization properties characterization, to collect gram-sized quantities of afterburner exit
particulate for characterization, and to measure afterburner exit particle size distributions.
102
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Additional objectives of the spiked design waste mix tests will be to measure the organic
constituent DRE for each condition and to determine the fate of the trace metals spiked.
Current plans are to complete the testing in the second quarter of FY93, with test
program results reported by the end of FY93.
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SECTION 10
EXTERNAL COMMUNICATIONS
During FY92,11 test reports were prepared and submitted, and 7 technical papers were
presented or published. These are listed in Table 54. This level of external communication and
technology transfer is comparable to levels experienced over the preceding 5 years, and testifies
to the high level of important research being supported at the IRF.
Table 55 lists some of the visitors to the IRF during FY92. The length of the list attests
to the visibility of the work being performed at the IRF to the incineration research community.
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TABLE 54. IRF PROGRAM REPORTS AND PRESENTATIONS IN FY92
Reports
» Waterland, L. R., "Operations and Research at the U.S. EPA Incineration Research
Facility, Annual Report for FY91," draft October 1991, revised December 1991,
published EPA/600/R-92/051, March 1992 ;
«> .Whitworth, W. E., and L. R. Waterland, "Pilot-Scale Incineration of PCB- :
Contaminated Sediments from the New Bedford Harbor Superfund Site," draft
November 1991, revised January 1992, final April 1992, published EPA/60p/R-92/068,
September 1992
» Lee, J. W., W. E. Whitworth, and L. R. Waterland, "Pilot-Scale Evaluation of the
Thermal Stability POHC Incinerability Ranking," revised January 1992, published as
EPA/600/R-92/065, May 1992
« King, C, J. W. Lee, and L. R. Waterland, "Pilot-Scale Incineration of Contaminated
Soils from the Drake Chemical Superfund Site," draft January 1992, revised April
1992
• Whitworth, W. E., J. W. Lee, and L. R. Waterland, "Pilot-Scale Incineration Tests of
Spent Potliners from the Primary Reduction of Aluminum (K088)," revised February
1992, final June 1992 :
» Saig, A., D. J. Fournier, Jr., and L. R. Waterland, "Pilot-Scale Incineration of
Contaminated Soil from the Chemical Insecticide Corporation Superfund Site," draft
April 1992, revised September 1992
• Saig, A., and J. W. Lee, "Evaluating the Thermal Treatability of Contaminated Soils
from the Popile and American Creosote Superfund Sites: START Program Screening
Tests," draft May 1992. '•
• Fournier, D. J., Jr., and L. R. Waterland, "Data Summary Report: The Fate of Trace
Metals in a Rotary Kiln Incinerator with a Calvert Flux-Force/Condensation Scrubber
System," draft June 1992
• King, C., and L. R. Waterland, "Pilot-Scale Incineration of Contaminated Sludges
from the Bofors-Nobel Superfund Site," draft July 1992, revised October 1992
« Whitworth, W. E., Jr., and L. R. Waterland, "Evaluation of the Impact of Incinerator
Waste Feed Cutoffs," preliminary draft August 1992 :
• Saig, A., and L. R. Waterland, "Pilot-Scale Incineration of Contaminated Soils from
the Scientific Chemical Processing Superfund Site," draft September 1992
I (continued)
105
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TABLE 54. (continued)
Papers and Presentations
• Carroll, G. J., and J. W. Lee, "Assessment of Relative POHC Destruction at EPA's
Incineration Research Facility," presented at the Eighteenth Annual Risk Reduction
Engineering Laboratory Research Symposium, Cincinnati, Ohio, April 1992
• Richards, M. K, and D. J. Founder, Jr., "Metals Partitioning Resulting from Rotary
Kiln Incineration of Hazardous Waste," presented at the Eighteenth Annual Risk
Reduction Engineering Laboratory Research Symposium, Cincinnati, Ohio, April 1992
• Turner, R. J., "Rotary Kiln Incineration of Spent Potliner from the Manufacture of
Aluminum," presented at the Eighteenth Annual Risk Reduction Engineering
Laboratory Research Symposium, Cincinnati, Ohio, April 1992
• Waterland, L. R., W. E. Whitworth, and M. K. Richards," Pilot-Scale Incineration of
PCB-Contaminated Sediments from the Hot Spot of the New Bedford Harbor
Superfund Site," presented at the 1992 Incineration Conference, Albuquerque, New
Mexico, May 1992
• Waterland, L. R., "Incineration Data on Arsenic and Lead Emissions," presented at
the Air & Waste Management Association Specialty Conference on New RCRA
Regulations for Industrial Boilers, Furnaces, and Incinerators, Orlando, Florida,
March 1992
• Thurnau, R. C, and D. J. Fournier, Jr., "The Behavior of Arsenic in a Rotary Kiln
Incinerator," J. Air Waste Manage. Assoc., 42:179 (1992)
• Carroll, G. J., R. C. Thurnau, J. W. Lee, L. R. Waterland, B. Dellinger, and P. H.
Taylor, "Pilot-Scale Evaluation of an Incinerability Ranking System for Hazardous
Organic Compounds," accepted for publication, J. Air Waste Manage. Assoc., 1992
106
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TABLE 55. VISITORS TO THE IRF
Person
R. Skipman
S. Schultz
J. Piriion
J. Pinion
J. Pinion
H. Ellison
E. DeCresie
J. Silva
L. Janis
J. Beran
H. Ellison
R. Pryzbyoz
G. Carroll
S. Schultz
J. Pinion
M. Nawar
M. Boyd
R. Mournighan
W. Thurber
B. Blackburn
S. Schulberg
D. Brown
A. Dorobati
E. Fleming
F. Hosseim
A. Robertson
P. Sieminski
E. Frarike
R. Giiswold
P. Sieminski
R. Griswold
C. McWilk
D. Hobby
C. Wright
T. McKee
G. Brunk
Affiliation
C-E O&MS
Donahoe Associates
Cross/Tessitore Associates
Cross/Tessitore Associates
Cross/Tessitore Associates
EPA Region 5
Cross/Tessitore Associates
SAIC
USAGE
USAGE
EPA Region 5
Michigan Department of National Resources
EPA/RREL
Donahue Associates
Cross/Tessitore Associates
EPA/ORP
EPA/ORP
EPA/RREL
Sanford Cohen & Associates
S-Cubed
SRA
ADPC&E
ADPC&E
ADPCE
University of Arkansas, Little Rock
University of Arkansas, Pine Bluff
EPA Region 6
EPA Region 6
EPA Region 6
EPA Region 6
EPA Region 6
ADPC&E
ADPC&E
J&C Environmental Technologies
CCM Company
CCM Company '
Date
9/30/91
10/21/91
10/23/91
10/24/91
10/29/91
10/30/91
10/31/91
11/5/91
11/6/91
11/7/91
11/18/91
12/16/91
12/17/91
1/21/92
1/29/92
1/30/92
1/31/92
1/30/92
2/18/92
3/3/92
3/11/92
4/6/92
5/26/92
Purpose of visit
Facility tour
Witness Bofors scoping
tests
Witness Bofors tests
Witness Bofors tests
Witness Bofors tests
i
Facility tour
Bofors preliminary data
review meeting
Facility tour, MSO test
feasibility discussions
Quality Assurance
Technical Systems Review
6-month compliance review
i
Facility tour
Facility tour
i
Facility tour, deliver Popile
and American Creosote
site soils
Discuss preliminary Popile
and American Creosote
test findings1
Facility tour;
(continued)
107
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TABLE 55. (continued)
Person
Affiliation
Date
Purpose of visit
D. Brown ADPC&E
A. Dorobati ADPC&E
J. Hedgecock NCTR
G. Tapp NCTR
G. Carroll EPA/RREL
S. Tituskin IT Corporation
M. Nawar EPA/ORP
M. Eagle EPA/ORP
M. Halper EPA/ORP
G. Carroll EPA/RREL
L. Taylor DOE
T. Carlson Chem Nuclear Geotech
R. Gay Rockwell/ETEC
C. Newman RockweU/ETEC
M. Bohn National Renewable Energy Laboratory
J. Vavruska Equinox, Ltd.
F. Hetzler Consultant
D. Moore Arkansas Department of Labor
P. Wilson ADPC&E
R. Thurnau EPA/RREL
D. Burns WSRC
H. Bums WSRC
M. Looper WSRC
6/19/92
7/2/92
7/7/92
7/8/92
7/9/92
7/16/92
7/17/92
7/30/92
9/17/92
RCRA Facility Inspection
Work Plan follow-up site
inspection
Tank storage system design
planning
RCRA Facility Inspection
Work Plan Revision data
gathering
MSO Task Group planning
meeting and facility tour
Perform personnel
exposure monitoring
Review staff training
records
WSRC third party test
program kickoff meeting
R. Wade
USACE/WES
9/29/92
9/30/92
10/1/92
Witness New York Harbor
TTU testing
108
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SECTION 11
PLANNED EFFORTS FOR FY93
One test program was completed in the fourth quarter of FY91 for which reporting
efforts were still not complete at the close of FY92. This was the Calvert scrubber trace metal
tests discussed in Section 3. As noted in Section 3, final sample trace metal analysis were fully
completed and reported in late September 1992. Thus, final data evaluation and reporting will
extend into FY93. The current schedule calls for submittal of a complete draft report in
December 1992.
Li addition, two test programs were performed in FY92 for which reporting efforts were
not fully completed. The complete draft report to replace the preliminary draft report for the
WFCO tests discussed in Section 8 is scheduled for submittal in November 1992. Revision of
this draft and the draft report for the SCP soils treatability test program (discussed in Section 6)
will occur in FY93. Finally, test sample analyses, data evaluation, and test reporting efforts for
the New York Harbor sediments bench-scale treatability tests discussed in Section 9.1 will be
completed in early FY93. The current schedule has draft report completion in November 1992.
The initial test program planned for completion in FY93 is scheduled to begin in early
December 1992. This test program will investigate the effectiveness of the treatment of
contaminated soil in the RKS with the kiln operated at the low to moderate temperatures
associated with thermal desorption processes. The specific test objectives are to evaluate the
effects on solids bed temperature, solids residue time, solids bed depth, soil moisture content,
and bed agitation on soil decontamination of organic constituents with a range of, boiling points,
and on the distribution of trace metals among the incinerator discharges. :
A series of 12 tests under 11 test conditions (one test in duplicate) are planned. Target
solids bed temperatures are in the 120° to 430°C (250° to 800°F) range with target treatment
times in the 10 to 60 min range. Tests with two soil moisture contents, 10 and 30 percent, are
planned.
The contaminated soil will be prepared at the IRF by mixing contaminant organics and
trace metals with a locally procured topsoil. The selected organic contaminants are benzene,
n-heptane, toluene, tetrachloroethene, n-octane, chlorobenzene, naphthalene, phenanthrene, and
pyrene. These compounds are common soil contaminants (benzene, n-heptane, and n-octane
represent gasoline) and exhibit a boiling point range from 80° to 404°C (176° tp 759°F). The
volatile organic constituents, those other than the three PAHs will be spiked into the soil at
levels in the 2,200 to 4,800 mg/kg range. The three PAHs will be spiked at 200 ;to 400 mg/kg.
109
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The trace metal contaminants will be arsenic, barium, cadmium, chromium, lead, and
mercury. All will be spiked in aqueous solution into the soil at levels in the 10 to 40 mg/kg
range except barium which will be spiked at 200 mg/kg.
A series of scoping tests will be performed in the TTU at the IRF prior to the RKS
testing. The scoping tests will confirm that a range of decontamination effectiveness can be
achieved within the bed temperature/residue time envelope planned for testing. The scoping
tests will also supply data to correlate TTU performance with RKS performance.
In the RKS testing, bed temperature will be measured continuously at four axial
locations in the kiln using a specially fabricated probe. This probe was fabricated, installed, and
checked out in September, and functions as intended. During each test, soil bed samples will be
taken at the four monitored axial locations so that each test will give samples representing four
combinations of bed temperature and treatment time.
As noted above, a series of 12 tests is planned, scheduled to begin in early December.
Completing these tests will require most of the first quarter of FY93.
The second series of tests planned for completion in FY93 is the WSRC third party tests
discussed in Section 9.2. As noted in Section 9.2, the objective of these tests is to generate
incineration residue samples, combustor exit particle size distribution data, and some DRE and
trace metal fate data in the incineration of simulated low-level mixed waste. Current plans are
to begin this test program in January 1993. This 22-test program will require most of the second
quarter of FY93 to complete.
The third major test program currently planned for FY93 will be a parametric study of
the effects of additives on trace metal fate during incineration. Test planning efforts will be
initiated during the first quarter of FY93, with testing likely during the third quarter.
Plans for other FY93 testing will be firmed as the year progresses. One current high
probability candidate is the possibility of the IRF program providing support to the DOE Waste
Management and Environmental Restoration program, by performing evaluation testing of a
pilot-scale molten salt oxidation (MSO) unit. A possible test program was initially discussed
during a visit to the IRF by representatives of EPA's Office of Radiation Programs (ORP) in
January 1992. Following this visit, a test plan outline was submitted in June. This outline
suggested that a pilot-scale MSO unit, fabricated by the process developer, be brought to the IRF
and tested as an APCS for application to mixed waste incinerators.
MSO is being viewed as a potential technology for treating mixed wastes stored and
continuing to be generated within the DOE nuclear weapons complex. Two possible applications
of MSO are under consideration: as a direct treatment for oxidizing radionuclide-contaminated
solvent wastes, and as a secondary oxidation and flue gas cleanup process to be applied to the
effluent combustion gas from the primary chamber (i.e., kiln) of a rotary kiln incinerator.
DOE has developed a 5-year implementation plan ultimately aimed toward having actual
process units in operation at several national laboratories by FY97. Testing of a pilot-scale
APCS at the IRF is currently viewed as an integral part of the implementation plan. A test
program is currently envisioned in which a pilot-scale MSO cocurrent contacting scrubber system
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would be brought to the IRF and installed to treat a slipstream of kiln exit flue gas. Once
installed, an extended test program is planned in which simulated mixed wastes would be
incinerated under a range of simulated waste types, feedrates, kiln operating conditions, and
MSO scrubber operating conditions.
Current scheduling suggests the actual test program may not occur until FY94, although
an accelerated schedule may require some FY93 efforts.
Other candidate programs being considered for late FY93 include:
• Treatability testing of contaminated materials from the M.W. Manufacturing
Superfund Site in Region 3
• Demonstration testing of an acoustically-enhanced burner system under the
Superfund Innovative Technology Evaluation (SITE) program
• Testing to define the composition of the TUHC emissions from Ian incinerator
under various operating regimes, and an attempt to achieve a better TUHC mass
balance
• Another third-party test program to be identified during the year
• Testing of the fate of trace metals in the RKS using a spray dryer/baghouse
combination for air pollution control. A test matrix similar to that employed in
the Calvert scrubber tests discussed in Section 3 is contemplated if an appropriate
spray dryer/baghouse system can be rented or fabricated at acceptable cost.
• A parametric test series to evaluate the effect of feed metal form ;on trace metal
fate in the RKS. Alternative feed metal forms other than the aqueous solution
co-fed with the clay-based hazardous waste analog include an aqueous metal
solution atomized into the kiln burner flame, and mixed powder compounds fed
in suspension with the clay-based hazardous waste analog.
• A parametric field test series to evaluate a POHC surrogate soup for possible trial
burn applications
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