EPA/600/R-93/241
January 1994
ABSTRACTS OF PHASE I AND PHASE II AWARDS
Small Business Innovation Research Program
(SBIR)
FISCAL YEAR 1993
Office of Research and Development
Office of Exploratory Research
U.S. Environmental Protection Agency
Printed on Recycled Paper
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DISCLAIMER
This brochure has been reviewed and approved for publication in accordance
with the U.S. Environmental Protection Agency policy. Any mention of trade
names or commercial products hi the brochure does not in any manner constitute
endorsement or recommendation for its use.
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TABLE OF CONTENTS
INTRODUCTION 1
1993 PHASE I ABSTRACTS ...... 3
TOPIC A: DRINKING WATER TREATMENT 4
1. Membrane Dissolution of Hydrogen Gas for Nitrate 4
Removal From Drinking Water and Brines
Membran Corporation -
Minneapolis, MN 55414
2. Drinking Water Treatment by Directional Freeze ......;........... 4
Crystallization
Polar Spring Corporation
Menlo Park, CA 94025
TOPIC B: MUNICIPAL AND INDUSTRIAL WASTE WATER ........... 5
TREATMENT AND POLLUTION CONTROL
3. A Novel Process for Heavy Metal Removal From .................. 5
Industrial Waste Water
LSR Technologies, Inc.
Acton, MA 01720
4. Emulsion Liquid Membrane Extraction of Selenium from Refinery ....... 5
Waste Waters
TDA Research, Inc. ,
Wheat Ridge, CO 80033
TOPIC C: PREVENTION AND CONTROL OF NOX, VOC'S, AND 6
TOXIC AIR EMISSIONS
5. Removal of Automotive Pollutants Using New Metal-Supported 6
Metal Catalyst
ACCEL Catalysis, Inc.
Iowa City, IA 52242
6. Low NOX Multiple Flame Burner Concept 6
Altex Technologies Corporation
Santa Clara, CA 95054
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7. Reducing Diesel NOX and Soot Emissions Via Particle-Free Exhaust 6
Gas Recirculation
CeraMem Corporation
Waltham, MA 02154
8. Removal of Volatile Organic Compounds From Gaseous Effluent Streams . . 7
by Novel Perfluoromembranes
Compact Membrane Systems, Inc.
Wilmington, DE 19802
9. NOX Stripping from Spark Ignition Automotive Engine Exhaust 7
Energy and Environmental Research Corporation
Irvine, CA 92718
10. Ultra Low NOX Gas Fired Domestic Appliances 8
Energy and Environmental Research Corporation
Whitehouse, NJ 08888
11. In-Duct Selective Catalytic Reduction of NOX 8
KSE, Inc.
Amherst, MA 01004
12. Improved Method for Heating Catalytic Converters of Vehicles to Attain ... 9
Ultra-Low Emissions
Lynntech, Inc.
Bryan, TX 77803
13. Recycle and Reuse of VOCs from Fugitive Emissions and Small Vent 9
Streams
Membrane Technology and Research, Inc.
Menlo Park, CA 94025
14. Plasma Ignition Retard for NO, Reduction 10
Plasmachines, Inc.
Natick, MA 01760
15. Catalysts for the Control of Automotive Cold Start Emissions 10
TDA Research, Inc.
Wheat Ridge, CO 80033
16. Catalysts for the Oxidation of Chlorinated Hydrocarbons 10
TDA Research, Inc.
Wheat Ridge, CO 80033
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17. Selective Catalytic Reduction of NOX with Methane 11
TDA Research, Inc.
Wheat Ridge, CO 80033
TOPIC D: SOLID AND HAZARDOUS WASTE DISPOSAL . . 11
18. Silo Summation Reactor for Waste Plastic and Rubber for Inclusion in .... 11
High Performance Concrete
Coalition Technologies, Ltd.
Midland, MI 48641-1391
19. An Innovative Technology for the Destruction of Chlorinated Compounds . . 12
in the Vapor Phase
Eckenfelder, Inc.
Nashville, TN 37228
20. Fixation of Lead and Select Organic Compounds Using a Cold Mix 12
Asphalt Process
Eckenfelder, Inc.
Nashville, TN 37228
21. Utilization of Scrap Prepreg Wastes as a Reinforcement in a Wholly 13
Recycled Plastic
Foster-Miller, Inc.
Waltham, MA 02154-1196
22. Scrap Tire Pyrolysis ~ Production of Highly Enhanced Marketable 13
Products
HiChem Corporation
Chicago, IL 60657
23. Application of Artificial Intelligence to Automated Waste Recycling ....... 14
National Recovery Technologies, Inc.
Nashville, TN 37228-1223
24. A Process for Increasing the Amount and Quality of Recycled Plastics .... 14
Resins
National Recovery Technologies, Inc.
Nashville, TN 37228-1223
25. Separation of Post-Consumer PET and PVC Plastics in the Regrind 14
Flake Form
National Recovery Technologies, Inc.
Nashville, TN 37228-1223
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26. Development of a New Lead Fixation Technology 15
Wamax, Inc.
Bellevue, WA 98006
TOPIC G: POLLUTION PREVENTION 15
27. Extraction of Copper and Zinc From Mixed-Metal Cyanide Solution 15
Using Solid Phase Extraction
ChromatoChem, Inc.
Missoula, MT 59801-7407
28. Selective Elimination of Waste in a Metal Finishing Operation 16
lonEdge Corporation
Fort Collins, CO 80526
29. A New Membrane Process for Air Pollution Minimization hi 16
Chlor-Alkali Plants
Membrane Technology and Research, Inc.
Menlo Park, CA 94025
30. In-Process Recycling of Acetic Acid From Dilute Aqueous Waste Streams
Membrane Technology and Research, Inc.
Menlo Park, CA 94025
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31. Development of Ink Recycling Process Technology 17
Resource Recycling & Remediation, Inc.
Pittsburgh, PA 15212
32. Unique, On-Site Destruction of Transformer Askarels Using a Low- 17
Temperature, Mild Chemical Method
Veritay Technology, Inc.
East Amherst, NY 14051
TOPIC H: CONTINUOUS MONITORING OF PROCESSES FOR 18
COMPLIANCE AND CONTROL EFFECTIVITY DETERMINATION
33. Continuous Emission Monitor for Halogenated Compounds . 18
ADA Technologies, Inc.
Englewood, CO 80112
34. Catalytic Bridge, Chemical Monitor 19
Envirochem, Inc
Lexington, MA 02173
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1993 PHASE H ABSTRACTS 21
TOPIC B: MUNICIPAL AND INDUSTRIAL WASTEWATER TREATMENT . . 22
AND POLLUTION CONTROL
35. A Low Life-Cycle Cost UV Source and Reactor to Oxidize Aqueous 22
Phase Organics
Energy & Environmental Engineering, Inc.
East Cambridge, MA 02141
TOPIC D: SOLID AND HAZARDOUS WASTE DISPOSAL 22
36. Photo-Thermal Conversion of CFCs and Halons to Valuable and ........ 22
Environmental Safe Materials
M.L. Energia, Inc.
Princeton, NJ 08542
37. A Low Cost Automated Process for Recovery of Recyclable Plastic and .... 23
Glass Containers from Solid Waste
National Recovery Technologies, Inc.
Nashville, TN 37228-1223
38. Method for Opening and Emptying the Contents of Plastic Bags ........ 23
Entering Recycling Facilities
National Recovery Technologies, Inc.
Nashville, TN 37228-1223
39. Conversion of Waste Stream Plastics Into Polymer Matrix Composite 24
Materials
Robert Morgan & Company, Inc.
Battle Creek, MI 49015
TOPIC G: CONTROL OF ACID RAIN PRECURSORS 24
40. ENOX Process for NOX and Unburned Hydrocarbon Emissions from 24
Combustion Sources
Plasmachines, Inc.
Natick, MA 01760
41. Direct Sulfur Recovery 24
Sorbent Technologies Corporation (formerly Sanitech, Inc.)
Twinsburg, OH 44087
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42. Bifunctional Catalysts for the Decomposition of Nitric Oxide 25
TDA Research, Inc.
Wheat Ridge, CO 80033
TOPIC I: AIR POLLUTION CONTROL 25
43. A Novel Membrane System for Recovering Volatile Organic Contaminants . . 25
from Air
Bend Research, Inc.
Bend, OR 97701-8599
44. A Low Cost Catalytic Filter for Simultaneous VOC and Particulate 26
Removal
CeraMem Corporation
Waltham, MA 02154
45. A New Vapor Recovery Nozzle for Air Pollution Control 26
H&R Technology, Inc.
Newton, MA 02159
46. Carbon Adsorption/Membrane Regeneration Hybrid System 27
Membrane Technology and Research, Inc.
Menlo Park, CA 94025
47. Novel High Efficiency Catalytic Converter for Utility and Other Engines ... 27
Precision Combustion, Inc.
New Haven, CT 06511
48. Novel Catalysts for the Low Temperature Oxidation of Volatile Organic ... 28
Compounds
TDA Research, Inc.
Wheat Ridge, CO 80033
TOPIC J: WASTE REDUCTION AND POLLUTION PREVENTION 28
49. Mercury-Free High CRI Efficient Lamp 28
Fusion Systems Corporation
Rockville, MD 20855
50. An Aqueous-Based, Sulfur-Free Pulping Process - Phase H 29
Guild Associates, Inc.
HilUard, OH 43026
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51. Elimination of Hazardous Waste Via Advanced Composite Dry 29
Plating System
lonEdge Corporation
Fort Collins, CO 80526
52. Elimination of Toxic Effluent and Metallizing Process Waste via Jet ...... 30
Vapor Deposition
Jet Process Corporation
New Haven, CT 06511
53. Waste Reduction Through Benzeme-Free Polymerization Technology 30
KSE, Inc.
Amherst, MA 01004
54. Development of an Ultrasonic Prototype Instrument to Replace an 31
Environment-Pollutmg Measurement Practice in the Composite
Materials Industry
Xxsys Technologies, Inc.
San Diego, CA 92123
TOPIC L: IMPROVED MEASUREMENT TECHNOLOGIES FOR LEAD 31
DETECTION IN LEAD-BASED PAINTS
55. Improved Technology for Measuring Lead Detection in Lead-Based 31
Paint Phase n
Niton Corporation
Bedford, MA 01730-0368
INDEX BY COMPANY 33
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INTRODUCTION
U.S. Environmental Protection Agency
Small Business Innovation Research Program
This publication contains abstracts of the Phase I and Phase II awards made in 1993 by the Environmental
Protection Agency's (EPA) Small Business Innovation Research (SBIR) Program. The SBIR Program funds high-
risk research in EPA program areas that could lead to significant opportunities and public benefits if the research
is successful.
The EPA SBIR Program encourages proposals in advanced application areas in the fields of environmental
engineering and environmental monitoring instrumentation, where it is directly connected to pollution control
processes.
Objectives of the three-phase program, in addition to supporting high-quality research, include stimulating
technological innovation, increasing the commercial applications of EPA supported research, and improving the
return on investment from federally funded research for its economic and social benefits to the nation.
The SBIR Program is highly competitive. In 1993, the SBIR Program received 442 Phase I proposals
which resulted in 34 awards. Phase I provides up to $50,000 for six months to determine, as much as possible
within these limitations, the small firm's concept feasibility and their capability to perform high-quality research.
If a Phase I project achieves these goals sufficiently, and excels competitively, larger government support in Phase
II is justified. The Phase I final report serves as a base for follow-on funding commitment discussions assisting in
ascertaining success.
Phase II is the principal research effort for those projects that appear most promising after the first Phase
and averages $150,000 for a period of one to two years. In 1993, 21 Phase II awards were selected from 41 Phase
II proposals resulting from the 41 Phase I awards made in 1992.
Phase III is the product (or process) development phase, which may involve follow-on funding, such as
from venture capital or large industrial firms, to pursue potential commercial applications of the government-funded
research. No SBIR funds are provided in Phase III, however, EPA may use non-SBIR funds to support selected
SBIR projects if deemed advantageous to the Agency's mission.
Donald F. Carey, Program Manager
U.S. Environmental Protection Agency
Office of Exploratory Research (8703)
401 M Street, SW
Washington, DC 20460
(202) 260-7899
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1993 PHASE I ABSTRACTS
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TOPIC A: DRINKING WATER TREATMENT
1. Membrane Dissolution of Hydrogen Gas for Nitrate Removal From Drinking Water and
Brines
Membran Corporation
1037 10th Avenue, SE
Minneapolis-, MN 55414 (EPA Region 5)
(612) 378-2160
Dr. Charles J. Gantzer, Principal Investigator and Business Representative
Amount of Award: $50,000
Nitrate contamination of drinking water supplies is a recognized problem in certain locations of the U.S.
Several technologies are capable of removing nitrate. Two promising related technologies are the direct biological
denitrification of drinking water and the removal of nitrate by ion exchange with the subsequent removal of the
nitrate from the regenerant brine.
Denitrification of drinking water and brines requires the addition of an electron donor, which can either
be organic compounds or hydrogen gas. The use of hydrogen offers several operational and economic advantages
over the use of organic compounds. The factor limiting hydrogen use is its low solubility, i.e., existing gas-
dissolution technologies cannot dissolve high concentrations of hydrogen in a cost effective manner. Membran
Corporation's patented membrane gas-dissolution technology provides a cost-effective means for dissolving the
hydrogen required for denitrification.
The proposed study examines the technical feasibility of a Membran gas-dissolution device as the hydrogen
source for the biological denitrification of drinking water and simulated regeneration brines.
2. Drinking Water Treatment by Directional Freeze Crystallization
Polar Spring Corporation
3501 Edison Way
Menlo Park, CA 94025
(415) 368-2852
Dr. William M. Conlon, Principal Investigator and Business Representative
Amount of Award: $50,000
Small water systems are increasingly challenged to comply with the Safe Drinking Water Act. Existing
technologies impose heavy operational burdens on small systems and provide only narrowly focused solutions.
Polar Spring Corporation proposes to demonstrate the feasibility of Directional Freeze Crystallization (DFC)
to significantly reduce the concentration of dissolved solids, organic chemical and particulates. The DFC method
is expected to be especially suitable for small water systems because of its modularity, low maintenance, no
expendable filters or membranes, and long life-time. Innovative process simplification and thermal optimization
would minimize energy consumption. It uses commercially available vapor compression refrigeration equipment
for cooling, so reliability is enhanced and field deployment can be accelerated. The DFC process is expected to
remove a broad spectrum of contaminants, yet it works without expendable filters or membranes.
Water to be treated would fill a cylinder, and be cooled through the cylinder wall by a refrigerant. Crystals
of purified ice would form on the wall, concentrating the contaminants within an unfrozen core. Typically, one-half
or more of the water would be crystallized in batches. The liquid core would then be drained from the vessel and
the purified ice melted using heat rejected from the refrigerant condenser.
(EPA Region 9)
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TOPIC B: MUNICIPAL AND INDUSTRIAL WASTE
TREATMENT AND POLLUTION CONTROL
WATER
3. A Novel Process for Heavy Metal Removal From Industrial Waste Water
LSR Technologies, Inc.
898 Main Street
Acton, MA 01720 (EPA Region 1)
(508) 635-0123
Dr. ZhenWu Lin, Principal Investigator
Mr. S. Ronald Wysk, Business Representative
Amount of Award: $50,000
Protection of ground-water and marine waters is a complex issue and a vital public concern. Once
contaminated, it can be technically difficult and enormously expensive to clean up. One way to protect these waters
from contamination is through the control of industrial discharges. Often though, control processes are not practical
in treating high flow rates or those with relatively low contaminant concentrations. This proposal involves a novel
liquid membrane process for removing heavy metals from industrial wastewater streams. The specific contaminant
addressed in this work is copper removal, which has become a serious concern because of its toxicity to aquatic life.
The proposed liquid membrane process has several advantages over other methods such as solvent extraction,
conventional supported liquid membrane and emulsion liquid membrane processes. Some of these advantages
include: high permeability, membrane stability, combining extraction and stripping steps in the same unit, and the
potential to produce high contaminant concentrations in the stripping solution. If the concept can be demonstrated
on a small scale, it can also be applied to several contaminants other than copper.
4. Emulsion Liquid Membrane Extraction of Selenium from Refinery Waste Waters
TDA Research, Inc.
12345 West 52nd Avenue
Wheat Ridge, CO 80033 (EPA Region 8)
(303) 422-7819
Mr. John D. Wright, Principal Investigator
Mr. Michael E. Karpuk, Business Representative
Amount of Award: $50,000
Selenium is presently the primary wastewater treatment challenge for many West Coast petroleum
refineries, and selenium is also present in significant quantities in wastewaters from coal-fired power plants. A
suspected carcinogen, selenium is also harmful to fish and fowl when present in surface waters. Processes
developed for selenium removal from drinking water (anion exchange and activated alumina) have technical
limitations which make them too expensive for the treatment of industrial wastewaters. In particular, these processes
are appropriate for small volumes of water with low levels of dissolved and suspended solids. For these processes
to achieve high removal efficiencies, the selenium must be present as only one anionic species, and competing
anions like sulfate or carbonate must not be present. Therefore, TDA Research proposes using Emulsion Liquid
Membranes (ELM) to remove selenium from industrial wastewater streams. Based on their previous research with
chromium (VI) contaminated water, TDA expects ELM to concentrate selenium by a factor of approximately 1000.
In Phase I, they will conduct experiments to demonstrate process feasibility, and carry out economic analyses to
compare their ELM process with other competing selenium concentration and/or removal processes.
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TOPIC C: PREVENTION AND CONTROL OF NOX, VOC'S, AND TOXIC
AIR EMISSIONS
5. Removal of Automotive Pollutants Using New Metal-Supported Metal Catalyst
ACCEL Catalysis, Inc.
Technology Innovation Center
Oakdale Campus, University of Iowa
Iowa City, IA 52242 (EPA Region 7)
(319)335-1359
Dr. Man-Yin Lo, Principal Investigator
Dr. Darrell P. Eyman, Business Representative
Amount of Award: $50,000
A new technique is proposed for the preparation of metal-supported metal (MSM) catalysts. The key
feature of this technique involves the preparation of a thin layer of porous metal on top of a metal substrate such
that the porous metal surface is an integral part of the metal support. Subsequent integration of Pt and Rh on the
porous metal surface will produce the MSM catalyst. This catalyst is used as a three-way catalyst in catalytic
converters for the removal of NOX, hydrocarbons and CO from automobile exhaust gas. The MSM catalyst has a
much better thermal conductivity than the state-of-the-art three-way catalyst using ceramic supports. The
improvement in heat transfer will result in a more thermally stable catalyst, which will extend the life of the
catalytic converter. The improvement in heat transfer will also give more efficient use of the precious metal
components of the catalyst because of more homogeneous heat distribution. Better utilization of the precious metals
would result in lower costs of the catalyst converter unit. The proposed MSM catalyst will be more durable and
more cost effective than the state-of-the-art three-way catalyst presently used.
(EPA Region 9)
6. Low NOX Multiple Flame Burner Concept
Altex Technologies Corporation
650 Nuttman Road, #114
Santa Clara, CA 95054
(408) 982-2302
Mr. John Kelly, Principal Investigator and Business Representative
Amount of Award: $49,941
Stringently regulated ozone nonattainment air quality regions will require the implementation of ultra-low-
NOX systems. Currently, only costly Selective Catalytic Reduction (SCR) systems can achieve very high levels of
NOX reduction. Inexpensive low NOX burners, that can meet the regulations without SCR, are urgently needed by
industry. Recently, progress has been made towards developing a sub-9 ppm NOX gas-fired burner. However, the
flexibility of this porous matrix surface burner is very limited, and its wide use is not expected.
Altex Technologies Corporation has identified the Multiple Flame Burner that has the potential to achieve
very low NOX, while maintaining the flexibility needed for widespread use of the burner. The burner uses the
interaction of several flames to control emissions and enhance burner flexibility. To show the feasibility of this
burner under the Phase I program, analyses will be used to refine the burner concept for an application of interest.
A preprototype of the burner will then be fabricated and tested, under conditions simulating the application of
interest. Lastly, the results of the analyses and testing will be used to evaluate the burner performance and costs,
relative to existing burners with and without SCR.
7. Reducing Diesel NOX and Soot Emissions Via Particle-Free Exhaust Gas Recirculation
CeraMem Corporation
12 Clematis Avenue
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Waltham, MA 02154 (EPA Region 1)
(617)899-0467
Dr. Daryl L. Roberts, Principal Investigator
Dr. Robert L. Goldsmith, Business Representative
Amount of Award: $50,000
Diesel engines play an important role in the United States economy for power generation and transportation.
However, NOX and soot emissions from both stationary and mobile diesel engines are a major contributor to air
pollution. Many engine modifications and exhaust-after-treatment devices have been proposed and tested to reduce
the NOX and soot emissions form diesel exhausts. Simple techniques for NOX control such as exhaust gas
recirculation (EGR) and injection timing retard increase soot formation. The control of soot formation is possible
with diesel particulate filters (DPF's) with intermittent thermal oxidation of carbon soot. However, such filters have
limitations associated with filtration efficiency and durability.
In this program, a novel diesel emissions control system will be developed. The system will utilize a high-
efficiency ceramic filter to filter the exhaust gas. the filter will generate a particulate free exhaust gas, a portion
of which will be used in EGR for NOX emissions reduction. The ceramic filter will be regenerated by backpulsing
with quick pulses of compressed air. In Phase I, a prototype filter/EGR system will be tested with exhaust from
a 35 Kw diesel source and operated for up to one year.
8. Removal of Volatile Organic Compounds From Gaseous Effluent Streams by Novel
Perfluoromembranes
Compact Membrane Systems, Inc.
325 Hampton Road
Wilmington, DE 19802 (EPA Region 3)
(302)984-1762
Dr. Stuart Nemser, Principal Investigator and Business Representative
Amount of Award: $50,000
Volatile organic compound (VOC) effluent streams are a serious air pollution problem. Control
technologies for VOCs have been oxidation or carbon absorption but recently membranes have shown effectiveness.
Present membrane processes work by preferentially passing VOCs (versus air) through the membrane and then
compressing and condensing out downstream VOCs. Advantages of this membrane process include simplicity,
continuous operation, excellent small volume economics, and compactness. Key limitations of existing membrane
processes include (1) excess costs from extra pumping stages whenever VOCs permeate the membrane and (2) high
design costs since membrane-VOC interactions must be studied in each case.
Compact Membrane Systems, Inc., proposes developing a novel family of perfluoropolymer membranes
having high air permeability, low VOC permeability, and chemical inertness. These perfluoro-polymer membranes
should give (1) reduced capital and operating costs due to staging efficiencies since VOC stays on high pressure side
of membrane and (2) low cost standardized universal design since performance is based primarily on known air
permeabilities versus variable VOC permeabilities. Therefore, developing these fluoropolymer membranes will
significantly reduce VOC recovery costs.
9. NOX Stripping from Spark Ignition Automotive Engine Exhaust
Energy and Environmental Research Corporation
18 Mason
Irvine, CA 92718 (EPA Region 9)
(714) 859-8851
Mr. Jerald A. Cole, Principal Investigator
Dr. W. Randall Seeker, Business Representative
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Amount of Award: $49,970
Approximately half of automotive NOX is released in the initial minutes after startup, when the catalytic
converter is cold, and is a significant source of acid rain. This project will determine the feasibility of reversibly
adsorbing this "cold-Start NOX in a sorbent bed and subsequently releasing the NOX into a three-way catalytic
converter to be reduced. This could reduce the environmental NOX burden in many urban areas by as much as 25 %.
It could also permit the use of "lean-start" engines, which have the added advantage of reducing CO and
hydrocarbon emissions. This device would be similar in design to existing catalytic converters.
Phase I will address the technical questions needed to determine feasibility. These include determining the
capacity of the sorbent, the temperature/partial pressure relationship (adsorption isotherms), the kinetics of NOX
adsorption, thermal or chemical deactivation of the adsorbent, and any negative environmental effects. The
experiments will be carried out in an isothermal packed bed reactor with on-line instrumental gas analysis. In
demonstrating feasibility the Phase I effort will produce a model of sorbent behavior to allow design of a pilot-scale
unit for development and evaluation in subsequent Phase II research.
10. Ultra Low NOX Gas Fired Domestic Appliances
Energy and Environmental Research Corporation
Salem Industrial Park
Box 189
Whitehouse, NJ 08888
(908) 534-5833
Dr. Richard K. Lyon, Principal Investigator and Business Representative
Amount of Award: $50,000
(EPA Region 2)
Energy and Environmental Research Corporation (EER) has discovered a radically new method of burning
natural gas. While the best presently available gas combustion technologies produce NOX at the 10 to 20 ppm level,
this new method allows the combustion of natural gas to be done with a production of NOX well below 1 ppm.
This new technology is particularly well suited to application in gas fired domestic appliances such as hot
water heaters. Pending regulations in Southern California and other regions of critical air quality problems would
effectively ban gas' fired appliances which are based on presently available technology, forcing the use of electrical
appliances. Such a gas to electricity conversion would destroy much of the value of the natural gas distribution
system, require major investment in new electrical generation capacity, and result in considerably less efficient use
of energy resources.
Use of EER's new combustion technology would allow domestic gas fired appliances to satisfy the pending
regulations by operating with extremely low NOX emissions. In addition to providing a far more cost effective
method of NOX control, EER's new technology also has the potential for making hot water heaters less expensive
to operate through improved energy efficiency, eliminating indoor air pollution from cooking ranges, and eliminating
a major safety problem which is inherent in all gas fired appliances based on present technology.
11. In-Duct Selective Catalytic Reduction of NOX
KSE, Inc.
P.O. Box 368
Amherst, MA 01004
(413) 549-5506
Dr. J. R. Kittrell, Principal Investigator and Business Representative
Amount of Award: $49,975
(EPA Region 1)
The conventional control device for NOX emissions from stationary sources at 90% removal efficiency is
the Selective Catalytic Reduction (SCR) system. Conventional SCR systems rely on monolithic catalysts; these
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catalysts often represent nearly one-half the capital investment. In recent years, European regulations have prompted
development of in-duct dust injection control processes for certain gaseous emissions. These in-duct systems have
been demonstrated to provide lower capital and operating costs than alternative systems.
In the Phase I research, the technical feasibility is to be demonstrated of an in-duct SCR control process
for NOX control from gas-fired stationary sources. From preliminary laboratory experiments, this in-duct SCR
technology appears able to utilize highly active, small particle SCR catalysts to achieve remarkable reactor
productivity, with space velocities of approximately 1,000,000 hr1. The process reduces internal catalyst diffusion
limitations, thereby capturing the inherent catalyst activity. The in-duct SCR technology holds promise of
approaching the low life-cycle costs of NOX control through non-catalytic urea injection, while achieving the high
NOX removal efficiencies of conventional catalytic SCR systems. Ammonia slip may also be more effectively
controlled.
12. Improved Method for Heating Catalytic Converters of Vehicles to Attain Ultra-Low
Emissions
Lynntech, Inc.
Ill East 27th Street, Suite 204
Bryan, TX 77803 (EPA Region 6)
(409)822-3149
Dr. Oliver J. Murphy, Principal Investigator
Dr. G. Duncan Kitchens, Business Representative
Amount of Award: $50,000
The three-way catalytic converter is the most important device making today's automobiles comply with
existing emission laws. The first two or three miles in a typical 22-minute, 12-mile commute in today's vehicles
result in the emission of half of the total non-methane hydrocarbons, which result in the production of urban smog,
as well as half of the toxic CO emissions. This occurs because the catalyst in the converter will operate
ineffectively until it reaches its optimal operating temperature. To meet new California and Federal standards
specified for transitional low emission vehicles, low emission vehicles, and ultra-low emission vehicles, new
technologies are presently being developed to lower the warm-up time for catalytic converters. This is required to
bring about significant reductions in emissions of HC's primarily and CO and to a lesser extent in NOX1
Technologies involving "passive" and "active" methods for rapidly bringing catalytic converters to useful operating
temperatures (250°C under cold-start conditions (nominally -10°C to 25°C) are currently being investigated.
However, all of these technologies, including "close-coupled" catalytic converters, on-board heat storage systems,
Exhaust Gas Ignition approach and electrically heated converters suffer from various disadvantages and drawbacks.
In this proposal, a new chemical method of rapidly heating catalytic converters is proposed that addresses the
weaknesses of the alternative technologies. Basically the new method involves using an on-board hydrogen bleed
into the exhaust system upstream of the catalytic converter which will instantly allow the catalyst to reach its light-
off temperature.
13. Recycle and Reuse of VOCs from Fugitive Emissions and Small Vent Streams
Membrane Technology and Research, Inc.
1360 Willow Road, Suite 103
Menlo Park, CA 94025 (EPA Region 9)
(415)328-2228
Dr. J. G. Wijmaris, Principal Investigator
Ms. E. G. Weiss, Business Representative
Amount of Award: $50,000
The Clean Air Act amendments of 1990 included standards for volatile organic compound (VOC) emissions
from equipment leaks (fugitive emissions) and from small vent streams. Such emissions are estimated to total 330
million kg/year; additional controls required by the new act are expected to cost industry almost $120 million/year
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(EPA Region 1)
for the next decade and beyond. Very small (1-3 scfm) membrane vapor separation systems will be a simple,
energy-efficient method of VOC emissions control for many vent streams. Large cost savings could result since
membrane systems recover the VOC as a condensed liquid, allowing recycling to the process.
However, before membrane systems can be applied to these small streams, a significant modification to
the technology is required. The membrane module design must be modified so that good separations can be
achieved with gas streams 50 - 100 times smaller then the streams treated to date. In the Phase I program, the
technical and economic feasibility of a system incorporating a new module design will be determined.
14. Plasma Ignition Retard for NOX Reduction
Plasmachines, Inc.
11 Mercer Road
Natick, MA 01760
(508) 650-9600
Mr. Michael P. Manning, Principal Investigator
Mr. Voislav Damevski, Business Representative
Amount of Award: $50,000
Plasmachines, Inc., has recently determined that an innovative plasma ignition system appears to extend
the operating limits of ignition systems. This allows significantly improved NOX reduction. An immediate
application would be the large scale natural gas reciprocating engines used to drive natural gas transmission pipeline
compressors.
15. Catalysts for the Control of Automotive Cold Start Emissions
IDA Research, Inc.
12345 West 52nd Avenue
Wheat Ridge, CO 80033
(303) 422-7819
Mr. Michael E. Karpuk, Principal Investigator
Mr. John D. Wright, Business Representative
Amount of Award: $50,000
Automotive catalytic converters are quite efficient once they reach operating temperature, typically
destroying over 98% of the incoming hydrocarbons (HCs) and carbon monoxide (CO). However, up to 80% of
the emissions during the Federal Test Procedure occur during the first few minutes when the engine is running rich,
the oxygen sensor is not yet operational, and the catalytic converter has not reached its light-off temperature. Thus,
to significantly reduce automotive emissions of HCs and CO, a method must be found which will reduce the
emissions during the cold start period.
TDA has developed a new form of base metal oxide catalyst which has very high activity at low
temperatures (these catalysts can completely oxidize CO at -70°C, and can be significantly more active than
platinum for HC oxidation), and whose activity is not inhibited by the presence of water. In the Phase I project,
TDA will use the best of the catalysts developed to date, test their activity in the laboratory under conditions which
are representative of the automotive cold start application, prepare the catalyst in pellet form, prepare a packed bed
catalytic converter, and test the effect of the converter on the start-up emissions of a 1984 Volkswagen Jetta.
16. Catalysts for the Oxidation of Chlorinated Hydrocarbons
TDA Research, Inc.
12345 West 52nd Avenue
Wheat Ridge, CO 80033 (EPA Region 8)
(303) 422-7819
(EPA Region 8)
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Dr. Ron Cook, Principal Investigator
Mr. Michael E. Karpuk, Business Representative
Amount of Award: $50,000
Widely used chlorinated hydrocarbons (CHCs) such as trichloroethylene, perchloroethylene and methylene
chloride are recognized as carcinogens and mutagens, and contribute to global warming and ozone depletion.
Therefore, there is an increasing need for low cost and efficient methods for the control of GHC emissions.
Catalytic incineration is generally the technology of choice because it has low energy requirements and produces
few toxic byproducts. However, the current catalysts do not perform nearly as well as those used in the destruction
of non-chlorinated volatile organic compounds. Precious metal catalysts such as platinum have low activity and
must be run at temperatures in excess of 500 °C to oxidize the CHCs and avoid catalyst degradation. Base metal
catalysts are much more active, but are powerfully poisoned by water.
In Phase I, TDA will synthesize and characterize a series of highly active modified metal oxide catalysts
whose activity is enhanced by the presence of water. TDA will test them against a range of CHCs, evaluate their
kinetic performance, and carry out an engineering analysis to determine whether they are superior to currently
available catalysts.
17. Selective Catalytic Reduction of NOX with Methane
TDA Research, Inc.
12345 West 52nd Avenue
Wheat Ridge, CO 80033 (EPA Region 8)
(303)422-7819
Mr. David T. Wickham, Principal Investigator
Mr. Michael E. Karpuk, Business Representative
Amount of Award: $50,000
Nitrogen oxides (NO and NO2 or NOJ are among the most pervasive and difficult emissions to control.
Currently, there are no commercial catalytic processes capable of decomposing NOX without the addition of a
reducing gas. Current selective catalytic reduction (SCR) systems for use in oxidizing environments use ammonia
as the reducing agent. Ammonia SCR requires the handling of large quantities of toxic gases, tight temperature
control, relatively high reaction temperatures, and requires large amounts of catalyst because of the relatively low
reaction rates. An SCR catalyst which could use methane instead of ammonia could lower the cost and difficulty
of handling the reducing agent, and if it had higher activity than current catalysts, would reduce the catalyst cost
and decrease the operating temperature. ,
TDA Research, Inc., has identified a family of SCR catalysts which have high reaction rates at 100°C and
use methane as a reducing agent. They will synthesize and characterize a range of such catalysts, test them to
determine their activity as a function of temperature, NO and CH4 concentrations, carry out detailed kinetic analyses
and long term testing of the best catalysts, and perform a preliminary engineering analysis to determine whether
they merit further development.
TOPIC D: SOLID AND HAZARDOUS WASTE DISPOSAL
18. Silo Sulfonation Reactor for Waste Plastic and Rubber for Inclusion in High Performance
Concrete
Coalition Technologies, Ltd.
P.O. Box 1391
3072 Vantage Point Drive
Midland, MI 48641-1391 (EPA Region 5)
(517) 832-8415
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Dr. W. E. (BUI) Walles, Principal Investigator
Mr. Luis C. Mulford, Business Representative
Amount of Award: $50,000
Coalition Technologies, Ltd., (CTL) research had improved a simple gas phase treatment (sulfonation) of
waste rubber and plastics. Results from laboratory scale experiments done at Michigan State University have shown
that concrete made from sulfonated rubber and plastic provided by CTL has improved impact resistance as measured
by ASTM standard tests. In many cases, waste plastics and rubber are contained in mixtures such as Auto Shredder
Residue.
These mixtures of plastic and rubber are cost prohibitive to recycle with current technology. The
sulfonation process provides chemical compatibility so that waste plastic and rubber can be diverted to High
Performance concrete, the value of the waste plastic and rubber can be increased and the resulting product can be
sold to the concrete industry. Sulfonation provides key advantages over other recycling technologies because
mixtures of plastic and rubber can be used.
19. An Innovative Technology for the Destruction of Chlorinated Compounds in the Vapor
Phase
Eckenfelder, Inc.
227 French Landing Drive
Nashville, TN 37228 (EPA Region 4)
(615) 255-2288
Dr. Ann N. Clarke, Principal Investigator and Business Representative
Amount of Award: $49,740
The cost of off-gas treatment during remediation of hazardous waste sites can typically increase the cost
by 50% or more. This research is targeted towards developing a simple cost effective technology to destroy
chlorinated organic solvents in the vapor phase. The process uses a dry chemical at a slightly elevated temperature.
The research involves testing of a variety of related dry chemicals in a temperature range of 500°C or less. The
thermodynamics have been evaluated for the destruction of several chlorinated solvents. The very large negative
value for the Gibbs Free Energy of Formation, deltaG0, on the order of -l,000kj/mole, for each reaction indicates
that the reactions should occur spontaneously, the kinetics, however, are unknown and will be studied during the
conduct of this research.
20. Fixation of Lead and Select Organic Compounds Using a Cold Mix Asphalt Process
Eckenfelder, Inc.
227 French Landing Drive
Nashville, TN 37228 (EPA Region 4)
(615)255-2288
Dr. Ann N. Clarke, Principal Investigator and Business Representative
Amount of Award: $50,000
Many contaminants of concern at hazardous waste sites are difficult to treat because of their chemical and
physical characteristics. Constituents which have low vapor pressure, low water solubility, and low potential for
biodegradability are not candidates for many technologies. Metals are a prime example as are poly chlorinated
biphenyls (PCBs). The proposed technology is a cold mix asphalt emulsion process which is based upon a
proprietary process successfully being used for the remediation of sites containing petroleum products. Not only
will this process target mixed wastes of metals and organic compounds in soils, but this process also has the added
benefit of being able to incorporate contaminated building rubble as part of the asphalt aggregate system. The
materials thus produced can be used in various applications including road paving, parking lots, capping landfills,
etc.
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21. Utilization of Scrap Prepreg Wastes as a Reinforcement in a Wholly Recycled Plastic
Foster-Miller, Inc.
350 Second Avenue
Waltham, MA 02154-1196 (EPA Region 1)
(617) 890-3200
Dr. Kent G. Blizard, Principal Investigator
Mr. Ross R. Olander, Business Representative
Amount of Award: $49,951
Foster-Miller proposes to utilize scrap prepreg waste as a reinforcement in recycled polyethylene. By
reinforcing recycled plastics such as polyethylene with scrap prepreg and suitable binders, an economical useful
product can be obtained. At the same time, this innovation will also help to reduce 2.5 million pound/yr of
hazardous waste — uncured prepreg scrap. Foster-Miller is working with a composites user who is developing
alternative high value uses for scrap prepreg in order to eliminate the hazardous waste disposal problems. By
utilizing post-consumer plastic waste as the matrix material, this product will also contribute to eliminating the
landfill space problem. In addition, since the.raw material costs of this recycled reinforced plastic are nominal,
Foster-Miller's material will be cost-effective and consequently attractive to the commercial sector.
Since carbon fiber has a tensile modulus of 200 GPa and strength of 2760 MPa, Foster-Miller's innovative
recycled material should be ideal for construction applications, overcoming the mechanical property limitations of
current reinforced recycled plastics that utilize reinforcements such as wood fiber or fiberglass which have
substantially lower properties than carbon fiber. With proper interfacial control between the reinforcement and the
plastic matrix, their proposed recycled construction material should have mechanical properties competitive with
wood, such as tensile strength of 75 MPa and modulus of 15 GPa. To show feasibility, they will compare the
properties of their material to wood and demonstrate the effectiveness of the binder they choose. Practical extrusion
processing conditions will be determined and a prototype extruded construction material produced. Phase I to thus
enable them to move quickly to full-scale development in Phases II and III.
22. Scrap Tire Pyrolysis - Production of Highly Enhanced Marketable Products
HiChem Corporation
1800 West Cornelia Avenue
Chicago, IL 60657 '* • (EPA Region 5)
(312) 871-2289
Dr. Martin E. Carrera, Principal Investigator
Dr. V. B. Kulkarni, Business Representative
Amount of Award: $50,000
Research will be conducted by HiChem Corporation, to develop a new technology for pyrolysis of scrap
tires. Disposal of used tires is a big problem in the world, especially USA, since more than 2.5 million tires are
discarded each year. Most of these tires are disposed in landfills. Pyrolysis of scrap tires helps to recover and
reuse most of the valuable chemical available in tires. Pyrolysis of scrap tires under inert atmospheres produces
reusable gas, oil, and char. However, at present, these products have low market value because of their poor
quality. Therefore, disposal of the tires by pyrolysis is marginally attractive as a business venture. The proposed
research aims to prove that pyrolysis products produced by the HiChem process will produce reusable oil and char
of higher quality. These products will be competitively marketable in the existing market with an advantage of low
priced feedstock. The researchers also aim to show how to significantly shift the proportionality of the byproducts
(carbon and oil) produced using the HiChem process to a higher quality and quantity product.
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23. Application of Artificial Intelligence to Automated Waste Recycling
National Recovery Technologies, Inc.
566 Mainstream Drive
Nashville, TN 37228-1223 (EPA Region 4)
(615) 734-6400
Dr. Edward J. Sommer, Jr., Principal Investigator
Mr. Charles T. Crow, Business Representative
Amount of Award: $49,972
Diversion of plastics from landfill to recycling can potentially save the energy equivalent of 60 million
barrels of oil annually and reduce landfill volume requirements by up to 20 %. The U.S. Environmental Protection
Agency has recommended that source reduction, recycling, volume reduction, and landfilling be applied, in that
order, in the treatment of municipal solid waste (MSW). Recycling has recently become a major component of
municipal waste management programs. High cost of labor intensive curbside recycling programs have brought
about a second generation technology, mixed waste processing, for accomplishing higher levels of recycling at
reduced costs. The economics of mixed waste processing depends upon efficient automated processes for recovering
recyclables from MSW. Efficient automated technology exists for recovery of steel, aluminum, compostable food
waste and paper products from MSW. These items make up the bulk of MSW. However, the only existing method
to recover glass and plastic containers from MSW is to manually handpick them from the waste. The objective of
the Phase I research program is to determine feasibility for development of an efficient automated process for
recovering post-consumer plastic and glass containers from MSW using recognition algorithms incorporating
artificial intelligence techniques.
24. A Process for Increasing the Amount and Quality of Recycled Plastics Resins
National Recovery Technologies, Inc.
566 Mainstream Drive
Nashville, TN 37228-1223 (EPA Region 4)
(615) 734-6400
Dr. Edward J. Sommer, Jr., Principal Investigator
Mr. Charles T. Crow, Business Representative
Amount of Award: $49,948
Each year, Americans dispose of an estimated 29 billion pounds of plastics which consume up to 20% of
our nation's annual landfill capacity. Recent environmental and political pressures have led to rapid establishment
of plastics recycling facilities. Limited markets for low quality recycled resins require reclaimers to produce the
highest quality recycled resins in order to compete with virgin resins. An increasing number of reclaimers are
turning to automated sorting technology to help achieve this goal.
Currently, PET from soda bottles is the most recycled plastic. The second most recycled plastic is HDPE
comprised mostly of milk jugs and bases from PET bottles. It is presently difficult to expand post-consumer plastics
recycling beyond the easily recognized PET soda bottles and HDPE milk jugs, which together constitute only 6%
of plastics disposed annually and only 14% of plastic containers and packaging. According to the U.S.
Environmental Protection Agency a major limiting factor in quality of recycled resins and in expanding plastics
recycling to include a broader spectrum of plastics is lack of automated plastics sorting technology. The objective
of the Phase I research program is to determine feasibility for development of a high speed automated system for
high accuracy sorting of plastics by polymer type.
25. Separation of Post-Consumer PET and PVC Plastics in the Regrind Flake Form
National Recovery Technologies, Inc.
566 Mainstream Drive
Nashville, TN 37228-1223 (EPA Region. 4)
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(615)734-6400
Dr. Edward J. Sommer, Jr., Principal Investigator
Mr. Charles T. Crow, Business Representative
Amount of Award: $49,903
The last three years have seen a dramatic increase in the number of companies processing post-consumer
plastics from products such as soft drink containers, detergent bottles, milk jugs and water bottles. While this has
to some extent diverted these materials from landfills, it has caused an economic anomaly. The high costs of
manually sorting the plastics so they can be reprocessed makes them unattractive to most processors resulting in an
oversupply which drives the price of recycled resins below the cost of production expenses. Processors are
increasingly turning to automated sortation technology as a means of cutting costs. National Recovery Technologies,
Inc., has developed and successfully commercialized a system for automatically sorting PVC and PET bottles. This
system routinely produces a PET product with less than 50 ppm PVC contamination. While this level is adequate
for processors at this time, it is predicted that the purity specification will drop to 5 to 10 ppm in the near future.
Therefore, a secondary sortation system will be necessary to detect and remove residual PVC. Residual PVC is
present due to bottle cap liners, shrink labels and PVC bottle pieces broken during handling which are too small
to detect with existing technology. This proposal seeks to design, test and begin commercialization of a secondary
sortation system for handling post consumer plastic flake to meet the demanding standards of plastic processors.'
This system will greatly improve the quality of the product while reducing costs resulting in an overall increase in
plastic recycling.
(EPA Region 10)
26. Development of a New Lead Fixation Technology
Wamax, Inc.
4473 142nd Avenue, SE
Bellevue, WA 98006
(206) 643-4755
Dr. Rong Wang, Principal Investigator
Mrs. Dora F. Wang, Business Representative
Amount of Award: $49,941
Lead in soil must be treated in order to reduce the exposure risk associated with lead migration and lead
bioavailability. Since the level of lead in contaminated soil is usually very low, a cost-effective and safe lead
fixation technology is needed. This research will investigate a novel lead fixation technology based on natural soil
chemical reactions with environmentally safe materials. Phase I will demonstrate the effect of soil impregnation
and lead fixation. Phase II will develop commercial materials and engineering practices for fixation of contaminated
soils and reduce lead leachability in these soils.
TOPIC G: POLLUTION PREVENTION
27. Extraction of Copper and Zinc From Mixed-Metal Cyanide Solution Using Solid Phase
Extraction
ChromatoChem, Inc.
2837 Fort Missoula Road
Missoula, MT 59801-7407 (EPA Region 8)
(406) 728-5897
Dr. Richard F. Hammen, Principal Investigator and Business Representative
Amount of Award: $50,000
Removal of toxic metals from wastewater streams has become a problem of increasing national importance,
as a result of increasing concern for our environment, and increasingly stringent waste disposal regulations.
ChromatoChem, Inc., has developed an economical and effective new technology for the removal of low levels of
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toxic metal ions from wastewater streams, using Solid Phase Extraction (SPE). This SPE technology uses metal-
selective reagents covalently bound to a silica solid support by means of a proprietary hydrophilic tether molecule.
This research will use SPE to address the environmental and economic problems resulting from the copper and zinc
cyanide waste products created by heap-leaching practices used in the gold mining industry. The Phase I work will
investigate methods to separate the copper and zinc cyanide complexes from gold cyanide. The benefits of such
separation will include: decreased introduction of metal cyanide complexes into the environment, and reduced
mining costs by recycling of cyanide and the recovery of copper and zinc metals.
28. Selective Elimination of Waste in a Metal Finishing Operation
lonEdge Corporation
1713 Hull Street
Fort Collins, CO 80526 (EPA Region 8)
(303) 223-0665
Mr. Mandar Sunthankar, Principal Investigator and Business Representative
Amount of Award: $50,000
Chromate conversion coatings are routinely applied to cadmium in electroplating. This metal finishing
process generates large quantities of hazardous hexavalent chromium and heavy-metal waste. This is a major
environmental concern. Consequently, an environmentally benign coating finish is proposed as a suitable alternative
to the chromate conversion coating. This coating will be applied using the unique dry plating process developed
at lonEdge Corporation. This benign material will eliminate chromium waste in cadmium plating. Simultaneously,
the dry plating will eliminate liquids, and will in situ recycle solid cadmium, In this research, the feasibility of
applying a desired quality of this material to the dry plated cadmium will be investigated. Variation in its physical
properties related to the processing conditions will be studied. A successful demonstration of this new concept could
result in total elimination of hazardous liquids in a cadmium plating operation. In addition, the dry plating will
minimize solid waste.
29. A New Membrane Process for Air Pollution Minimization in Chlor-Alkali Plants
Membrane Technology and Research, Inc.
1360 Willow Road, Suite 103
Menlo Park, CA 94025 (EPA Region 9)
(415) 328-2228
Dr. Ingo Pinnau, Principal Investigator
Ms. E. G. Weiss, Business Representative
Amount of Award: $50,000
Chlorine ranks among the ten most important commodity chemicals. Approximately 54 %
of the total U.S. chlorine production is liquefied for sale or for in-plant transport. Tail gas
produced from the chlorine liquefaction process is the principal source of chlorine-containing
waste gas streams produced by chlor-alkali plants. Currently, such streams are treated by
absorption in carbon tetrachloride; however, carbon tetrachloride has a high ozone depletion
potential. It is estimated that at least 8.8 x 106 Ib/yr of carbon tetrachloride are emitted by
chlorine liquefaction tail gas treatment. Because of the serious environmental threat of carbon
tetrachloride emissions the Environmental Protection Agency had mandated that these emissions
be eliminated; carbon tetrachloride production will cease after 1995. Therefore, the chlor-alkali
industry must find an alternative treatment technology.
Membrane Technology and Research, Inc. (MTR), proposes to develop a new membrane
process to recover chlorine from tail gas streams in the chlor-alkali industry that will eliminate
the use of carbon tetrachloride. The chlorine recovery will be recycled back to the plant.
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Preliminary studies at MTR have demonstrated that rubbery membranes are highly selective for
chlorine. In the Phase I program,, a laboratory system using these membranes will be tested for
its chlorine removal efficiency. An application study will be performed to identify the most
efficient methods to capture chlorine from liquefaction tail gas.
30. In-Process Recycling of Acetic Acid From Dilute Aqueous Waste Streams
Membrane Technology and Research, Inc.
1360 Willow Road, Suite 103
Menlo Park, CA 94025 (EPA Region 9)
(415) 328-2228
Dr. Richard W. Baker, Principal Investigator
Ms. E. G. Weiss, Business Representative
Amount of Award: $50,000
Dilute acetic acid wastewater streams are produced in large quantities by the synthetic organic chemical
industry, for example, in the synthesis of terephthalic acid, the precursor of polyethylene terephthalate. Recovery
of acetic acid from these wastewaters for in-process recycling of the acid would reduce waste and save valuable
resources. This proposal describes the development of a process that combines selective dialysis followed by
bipolar-membrane electrolysis to recover and concentrate this acid. Although the program focuses on acetic acid
recovery, the technology could be applied to recovery and recycling of other weak acids such as acrylic acid, lactic
acid, and phenols.
31. Development of Ink Recycling Process Technology
Resource Recycling & Remediation, Inc.
800 Vinial Street
Pittsburgh, PA 15212 (EPA Region 3)
(412)323-1733
Mr. Michael Jones, Principal Investigator and Business Representative
Amount of Award: $49,993
While printing packages for the consumer products industry printers generate hazardous ink waste in
quantities that qualify the industry as one of the nation's largest sources of hazardous waste. In fact, solvent
components in ink waste are among 17 chemicals targeted by the Environmental Protection Agency (EPA) for
minimization.
The proposed process technology recycles ink waste on-site versus disposal. By merging state-of-the-art
spectrophotometry, new software and innovative filtration methods, ink waste destined for incineration becomes
reusable ink.
This prototype process originated from a successful study funded in part by an EPA grant. The process
begins with a procedural change from waste management to resource management and requires disciplined ink waste
collection and segregation into chemical type and primary color. Segregated materials are analyzed using advanced
spectrophotometric instrumentation, identified by a unique software, and remanufactured using proprietary
technology. The process results in a closed loop of ink and solvent resources recycled into press-ready ink.
Success of the project will result in a demonstration of the commercial feasibility of recycling for nearly
1,000 package printers and 300+ product printers. Further success will lead to other segments in the printing
industry comprising over 52,000 plants.
32. Unique, On-Site Destruction of Transformer Askarels Using a Low-Temperature, Mild
Chemical Method
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Veritay Technology, Inc.
4845 Millersport Highway
P.O. Box 305
East Amherst, NY 14051 (EPA Region 2)
(716) 689-0177
Dr. Ian Webber, Principal Investigator
Dr. Kathy L. Bernard, Business Representative
Amount of Award: $49,999
These is a great need for a safe, energy-efficient, on-site method for decontaminating various chemical
toxins. Nearly all (i.e., 99.8%) of the polychlorinated biphenyls (PCBs) found in current applications are used as
dielectic fluid. This amounts to about 30,000,000 gallons of PCB-contaminated fluid. To reduce this exposure risk
the Environmental Protection Agency is requiring the accelerated phaseout of PCB transformers. Presently, there
is no cost-effective method for providing on-site decontamination of PCB-contaminated fluids; nor is there a mild
chemical method for their ultimate disposal.
A novel PCB dechlorination method has been identified, which has potential utility for the detoxification
of transformer PCB fluids that presently represent a significant health hazard. Initially investigated at the University
of Louisville and evaluated by the proposed Principal Investigator, the hydrogenation method, which uses an
expensive noble metal catalyst but operates at room temperature, has been shown to achieve virtually complete
dehalogenation in minutes. By systematically evaluating different catalysts, solvents, and processes, Veritay
Technology, Inc., proposes to find and demonstrate a commercially feasible, mobile PCB treatment protocol based
on the chemical dechlorination of concentrated PCBs. The approach offers numerous advantages including the
avoidance of extreme conditions such as high temperature, which, in the case of partial pyrolysis, leads to the
increased production of dioxins and dibenzofurans.
TOPIC H: CONTINUOUS MONITORING OF PROCESSES FOR
COMPLIANCE AND CONTROL EFFECTIVITY
DETERMINATION
33. Continuous Emission Monitor for Halogenated Compounds
ADA Technologies, Inc.
304 Inverness Way South, Suite 110
Englewood, CO 80112
(303) 792-5615
Dr. David E. Hyatt, Principal Investigator
Dr. Judith A. Armstrong, Business Representative
Amount of Award: $49,971
(EPA Region 8)
The emission of halogen containing pollutants from a variety of power generating, waste processing,
chemical production, and solvent using industries is an environmental concern of major significance. Inorganic
halogen species, including hydrogen chloride and hydrogen fluoride, represent major potential health threats to both
human, animal, and plant communities. Organic halogenated compounds (HOCs) have been indicted as severe
health risks at very low levels, have been found to be carcinogenic in several instances and a class of these materials
(CFCs in particular) are at the center of ozone depletion chemistry and the subject of recent control under the
Montreal Protocol.
At present, these is no continuous emission monitoring (CEM) technique or instrumentation to reliably
monitor emissions of these halogenated materials at the thousands of sites at which they may be released in the
United States (and in fact, worldwide). Without this CEM capability, minimization of emission of these dangerous
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pollutants and optimization of control system performance to assure continued emission minimums cannot be a
reality.
The Phase I proposal presents an innovative spectrometric concept which will be ideal for the continuous
monitoring of organic and inorganic haiogenated compound emissions from all sources. The concept is based on
the use of a microwave plasma emission instrument, well suited for continuous on-site operation as a CEM, which
will respond to all of the halogen species at concentrations extending down to trace levels. The results of the
successful Phase I effort will lead directly to the development of a prototype monitor in Phase II and to on-site
testing of this instrument at actual field sites during that project stage.
34. Catalytic Bridge, Chemical Monitor
Envirochem, Inc
54 Bridge Street
Lexington, MA 02173
(617) 863-1334
Dr. David Ham, Principal Investigator and Business Representative
Amount of Award: $50,000
(EPA Region 1)
This proposal presents a concept for a chemical monitor based on differential catalytic reactivities and large
reaction exothermicities. The simplicity of the proposed sensor concept promises an economic and reliable monitor
for in-situ measurement of a variety of gases. In this project, Envirochem, Inc., will investigate the application of
this concept for measuring ammonia in flue gases. A sensitive, in-situ, real-time ammonia monitor is required for
control of many NOX control processes that either use or produce ammonia.
The goal of a Phase I project is to measure the sensitivities, selectivities, and linearities of a laboratory
instrument version of the proposed as functions of catalyst material, catalyst temperature, arid gas composition. For
selected promising cases, they will test the catalyst wires for longevity and poisoning by likely contaminants. In
a Phase II project, a prototype commercial system can be assembled and tested over a broader range of parameters
and compared with other monitors in real environments.
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1993 PHASE H ABSTRACTS
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TOPIC B: MUNICIPAL AND INDUSTRIAL WASTEWATER
TREATMENT AND POLLUTION CONTROL
35. A Low Life-Cycle Cost UV Source and Reactor to Oxidize Aqueous Phase Organics
Energy & Environmental Engineering, Inc.
P.O. Box 215
East Cambridge, MA 02141 (EPA Region 1)
(617) 666-5500
Dr. James H. Porter, Principal Investigator and Business Representative
Amount of Award: $150,000
The oxidation of dilute concentrations of organics in aqueous solutions using hydrogen peroxide and/or
ozone as the oxidant in the presence of ultraviolet (UV) light has been demonstrated and is offered commercially
by several corporations. Present systems seem to be limited to low concentrations of organics ( < 10 ppm), if costs
are to be maintained at less than a few dollars per thousand gallons of water treated. Further, oxidation is often
not complete and low molecular weight acids, aldehydes, and ketones may remain in the treated water as final
oxidation products.
Improved photochemical reactor design using low life-cycle cost UV sources is proposed. The reaction
system will exploit newly discovered oxidation chemistry which leads to the complete oxidation of unsaturated
organics in aqueous streams.
TOPIC D: SOLID AND HAZARDOUS WASTE DISPOSAL
36. Photo-Thermal Conversion of CFCs and Halons to Valuable and Environmental Safe
Materials
M.L. Energia, Inc.
P.O. Box 1468
Princeton, NJ 08542 (EPA Region 2)
(609) 799-7970
Dr. Moshe Lavid, Principal Investigator
Ms. Nira Lavid, Business Representative
Amount of Award: $150,000
There is presently a wide range of applications using vast amount of chloroflurocarbons (CFCs) and
bromochlorofluorocarbons (Halons). However, these compounds pose a serious threat to the stratospheric ozone
layer, and thus must be removed from service, as specified in the Montreal Protocol and by new Federal
regulations. Consequently, it would be of great economic and environmental benefit if these materials could be
safely and efficiently converted into less ozone-depleting substitutes.
A novel technology has been proposed by M.L. Energia, Inc., for on-site conversion of CFCs/Halons to
environmentally benign and saleable materials. The process is Photo-Thermal Hydrodehalogenation (PTH). It
converts CFCs and Halons into hydrochlorofluorocarbons (HCFCs), hydrofluorocarbons (HFCs), fluorocarbons
(PCs) and other high-value materials. The scientific foundation of this innovative PTH process lies in the combined
use of reducing atmosphere and ultraviolet light to efficiently remove chlorine and bromine atoms from CFCs and
Halon molecules at moderate temperatures. These atoms participate in chain-propagating reactions promoting high
conversion of CFCs/Halons to valuable HCFCs, HFCs, and PCs depending on the specific compound and the
operating conditions.
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Phase I results have already demonstrated the feasibility of the PTH process and identified potential
commercial applications. The primary goal of Phase II is to obtain all the necessary technical information for design
and construction of a prototype PTH reactor. To this end, a comprehensive four-task work plan has been proposed.
Under Phase III, the PTH process will be ultimately commercialized in collaboration with M.L. Energia, Inc.'s
industrial partner, which has already provided a Follow-on Funding Commitment.
37. A Low Cost Automated Process for Recovery of Recyclable Plastic and Glass Containers
from Solid Waste
National Recovery Technologies, Inc.
566 Mainstream Drive
Nashville, TN 37228-1223 (EPA Region 4)
(615) 734-6400
Dr. Edward J. Sommer, Jr., Principal Investigator
Mr. Mark T. Schell, Business Representative
Amount of Award: $149,936
The disposal of municipal solid waste (MSW) is a costly problem for all municipalities. The U.S.
Environmental Protection Agency has recommended that source reduction, recycling, reduction and landfilling be
applied for the treatment of MSW. Recycling programs are rapidly becoming the most popular method for waste
reduction. Municipalities are implementing curbside programs and central Material Recycling Facilities (MRF) to
recover valuable items such as newspaper, cardboard, aluminum, glass and ferrous alloys. Increasingly,
municipalities are realizing the cost advantages of using automated technology to separate the recyclable materials.
National Recovery Technologies, Inc., has completed a Phase I research program which successfully demonstrated
the feasibility of using the bounce characteristics of most recyclables to cause them to be separated from non-
recyclable items. This research culminated in the manufacture of a working prototype which has been further tested
with true MSW since the end of the Phase I program with very positive results. These results indicate that this
device produces a concentrated stream of recyclables from mixed MSW. This proposal will outline those results
and propose a means for developing and testing a commercial scale unit. This unit would be economically feasible
for MRF's of all sizes, or facilities separating mixed recyclables collected through curbside programs.
38. Method for Opening and Emptying the Contents of Plastic Bags Entering Recycling
Facilities
National Recovery Technologies, Inc.
566 Mainstream Drive
Nashville, TN 37228-1223 (EPA Region 4)
(615)734-6400
Dr. Edward J. Sommer, Jr., Principal Investigator
Mr. Mark T. Schell, Business Representative
Amount of Award: $149,999
Many U.S. municipalities are integrating recycling programs into the management of their solid waste in
order to minimize landfill requirements. These program often include a Materials Recycling Facility (MRF) where
the municipal solid waste (MSW), curbside collected recyclable materials, and other bagged waste are transported
to a central facility for the retrieval of recyclable materials before landfilling or incineration. Operators of these
facilities have long noted the need for an automated device which can open and empty the thousands of plastic bags
entering the MRF daily. In the Phase I research, a prototype system was tested which takes advantage of the
weakness of plastic bags to heat as the means for opening the bags and which uses a mechanical vibratory system
for emptying the opened bags. In the Phase II research, testing will continue on several Phase ffl prototypes to
quantify performance of the technology and to determine avenues for improvement. Modifications to the design
will be investigated to improve bag opening and emptying, to ensure the environmental soundness of the technology,
and to extend the technology to perform additional valuable functions in the processing of waste.
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39. Conversion of Waste Stream Plastics Into Polymer Matrix Composite Materials
Robert Morgan & Company, Inc.
271 Helmer Road
Battle Creek, MI 49015 (EPA Region 5)
(616) 962-5592
Mr. Michael D. Monfore, Principal Investigator and Business Representative
Amount of Award: $149,998
Secondary recycling of many waste materials has been limited by chronic technical and economic barriers.
However, recent advances in the processing of mixed waste plastics has led to the development of innovative
polymer matrix composites. Materials research by the Robert Morgan & Company, Inc., has shown great promise
for the utilization of mixed waste materials, including plastics, paper and fiberglass. This formulation and
processing technology allows direct conversion of commingled post-consumer and post-industrial waste into useful
composite materials. Phase ISBIR research by Robert Morgan & Company, Inc., has demonstrated these materials
capable of delivering mechanical performance similar to many reinforced and non-reinforced polymer materials used
in automotive components. It is anticipated this technology has the potential to provide many industries with a new
source of inexpensive, high performance engineering materials. Phase II research will provide a practical
demonstration of this technology through the production of full-scale prototype products. The investigators will
produce a prototype pallet system from a range of materials demonstrated in Phase I. The design of this prototype
will allow evaluation of the research materials across a variety of design features and attributes. Success of the
Phase II research will finalize commitments with several commercialization opportunities.
TOPIC G: CONTROL OF ACID RAIN PRECURSORS
40. ENOX Process for NOX and Unturned Hydrocarbon Emissions from Combustion Sources
Plasmachines, Inc.
11 Mercer Road
Natick, MA 01760 (EPA Region 1)
(508) 650-9600
Mr. Michael P. Manning, Principal Investigator
Mr. Voislav Damevski, Business Representative
Amount of Award: $150,000
The proposed research will open new areas of electronically excited chemical plasma reduction of pollutant
emission rates. The proposed research will determine the efficacy and mechanism of the process and report data
allowing comparison of this process with previous proposed processes.
41. Direct Sulfur Recovery
Sorbent Technologies Corporation (formerly Sanitech, Inc.)
1935 East Aurora Road
Twinsburg, OH 44087
(216) 425-2354
Mr. Sidney G. Nelson, Principal Investigator and Business Representative
Amount of Award: $150,000
(EPA Region 5)
The objective of the proposed project is to develop and demonstrate a low-cost alternative to a modified
Glaus plant for conversion of SO2 to elemental sulfur. More specifically, the objectives are to optimize an existing
acid-rain sorbent regeneration process developed by Sorbent Technologies Corporation to yield directly a pure
elemental sulfur product and to apply the technology to gas streams having a wide range of compositions.
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In Phase I, of three strategies examined to increase elemental sulfur yields, one strategy, gas recycling,
was observed to be exceptionally effective, yielding 100% conversion of the sulfur released during regeneration to
elemental sulfur, with no sulfur species remaining in the exiting gas. Later, an important discovery was made.
It was observed that MgO or TiO2 will act as a catalyst for the direct conversion of SO2 to elemental sulfur.
In Phase n, the research in Phase I will be carried forward. The technology will be scaled up to a larger
size, evaluated in continuous, long-term runs, and optimized.
42. Bifunctional Catalysts for the Decomposition of Nitric Oxide
TDA Research, Inc.
12345 West 52nd Avenue
Wheat Ridge, CO 80033 (EPA Region 8)
(303)940-2301
Dr. David T. Wickham, Principal Investigator
Mr. Michael E. Karpuk, Business Representative
Amount of Award: $150,000
Nitrogen oxides (NO and NO2 or NOJ are among the most pervasive and difficult emissions to control.
Although the decomposition reactions of both NO and NO2 are thermodynamicalry favored, there is no commercial
catalytic process capable of decomposing NOX without the addition of a reducing gas. This is because the oxygen
produced during the decomposition remains strongly chemisorbed on the catalyst, blocking access of the NO to the
catalytic sites and reversibly poisoning the catalyst. NOX decomposition catalysts would be useful in stationary
applications because the reducing gas and associated equipment contribute roughly one-half of the total clean-up cost.
Such catalysts would also find ready acceptance in mobile applications as there is currently no practical catalytic
method for NOX reduction in diesel exhaust.
TDA Research, Inc., proposes to synthesize and test coprecipitated bifunctional catalysts capable of carrying
out the decomposition reaction, In Phase I, they modified a metal oxide catalyst to reduce the affinity of the catalyst
for oxygen, therefore, allowing the NO decomposition reaction to proceed at rates much greater they those observed
on the unmodified catalyst. In Phase II, they will synthesize and test new catalyst formulations. They will perform
additional characterization experiments with the goal of understanding the nature of the bifunctional catalyst effect
in order to optimize the catalyst composition.
TOPIC I: AIR POLLUTION CONTROL
43. A Novel Membrane System for Recovering Volatile Organic Contaminants from Air
Bend Research, Inc.
64550 Research Road
Bend, OR 97701-8599 (EPA Region 10)
(503) 382-4100
Dr. Scott B. McCray, Principal Investigator
Dr. Rod Ray, Business Representative
Amount of Award: $149,706
The removal of volatile organic contaminants (VOCs) from industrial process gases constitutes a significant
industrial and environmental problem worldwide. Recovery of VOCs is advantageous for environmental process-
efficiency reasons, but conventional technologies and "first generation" membrane technologies for VOC removal
have drawbacks that limit their use for this application. These drawbacks include limitations on the percentage of
VOCs that can be removed, excessive energy consumption, and inability to withstand exposure to the feed-stream
components and harsh operating conditions.
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The overall goal of this program is to develop a membrane-based system for recovering VOCs that avoids
the drawbacks of conventional unit processes and first-generation membrane technologies. This new membrane-
based VOC-recovery system will be applicable to a wide range of VOCs and will be capable of reducing the
concentrations of VOCs from very high concentrations to the 20-ppm level or below, recovering the VOCs in liquid
form for disposal of reuse.
In Phase I, system feasibility was demonstrated. Hollow-fiber membranes were successfully developed
from new solvent-resistant polymers, incorporated into high-efficient modules, and tested. The modules effectively
reduced the concentration of a target VOC-toluene~in nitrogen feed streams from 5,500 ppm to 20 ppm and
maintained performance in long-term (650-hour) tests. An economic analysis showed the proposed system offers
major cost advantages over competing technologies.
The focus of the Phase n program is to:
1. Optimize the VOC-selective coatings used on the hollow fiber membranes;
2. Scale up the membrane modules to a size that will allow field tests and pilot tests at a reasonable
scale; and
3. Field-test this technology.
44. A Low Cost Catalytic Filter for Simultaneous VOC and Particulate Removal
CeraMem Corporation
12 Clematis Avenue
Waltham, MA 02154 (EPA Region 1)
(617) 899-0467
Dr. Daryl L. Roberts, Principal Investigator
Dr. Robert L. Goldsmith, Business Representative
Amount of Award: $150,000
Emissions of VOC's are subject to control by the EPA both because VOC's are regarded as ozone
precursors and because many specific VOC's are hazardous air pollutants (HAP's) under the Clean Air Act
Amendments. A number of industries generate offgases with both fine particulate matter and VOC's and require
emission control technology for both. The research in this program expands on the successful Phase I proof-of-
principal testing of a novel catalytic filter for simultaneous removal of VOC's and particulate matter. The overall
objective of the Phase n program is to develop improved catalytic filters which have the performance required for
industrial acceptance of the technology. Specific product development technical objectives for industrial acceptance
of the technology. Specific product development technical objectives include the following (at a space velocity of
40,000 hr1; and operating temperature of about 55Q°F; and a pressure differential of < 15 inches water):
1. VOC removal efficiency of 95 % or greater for a variety of organic vapors, including chlorinated
hydrocarbons.
2. Substantially complete particulate removal efficiency (>99.9%); and
3. Ability to maintain clean catalytic filter pressure drop over repetitive filtration cycles.
Other projects objectives include:
1. Demonstration of a catalytic filter at an asphalt concrete plant for a 4-6 week period; and
2. Development of system installation and operating costs and comparison with costs for conventional
technology.
45. A New Vapor Recovery Nozzle for Air Pollution Control
H&R Technology, Inc.
15 Voss Terrace
Newton, MA 02159
26
(EPA Region 1)
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(EPA Region 9)
(617)969-0650
Mr. Joshua E. Rabinovich, Principal Investigator and Business Representative
Amount of Award:$149,978
The vapor recovery nozzle is an air pollution control device which relates to Stage II emission control
equipment designed to capture gasoline vapors during automobile refueling at service stations. The existing vapor
recovery nozzles are difficult to handle, the bellows prone to cuts, and the vacuum assist pumps require frequent
and costly maintenance.
The primary objective of this project is to develop a new, more effective, low initial cost and low
maintenance cost vapor recovery technology. This technology is based on a proprietary bellowless vapor recovery
nozzle with an onboard vapor recovery pump, and aims at solving major problems inherent in previous designs.
In Phase I of the project a preliminary model of this nozzle was constructed, tested and evaluated. It has
proved the proposed technology's feasibility of achieving compliance with all UL, California Air Resource Board,
Weights and Measures, EPA and Fire Marshal agencies standards and regulations.
Phase II of the project will consist of the improvement and fine-tuning of the vapor recovery nozzle
developed hi Phase I and the building of Phase n preproduction prototypes, which will comply with all standards
and regulations of the regulating agencies.
46. Carbon Adsorption/Membrane Regeneration Hybrid System
Membrane Technology and Research, Inc.
1360 Willow Road
Menlo Park, CA 94025
(415) 328-2228
Dr. Kaaid Lokhavdwala, Principal Investigator
Ms. Elizabeth G. Weiss, Business Representative
Amount of Award: $150,000'
Current and future legislation will require U.S. industry to treat many low-concentration, organic solvent-
containing air streams now being discharged to the atmosphere. Although carbon adsorption is a cost-effective,
efficient treatment process for such streams, the regeneration step used to remove adsorbed organic from the carbon
presents problems. Membrane Technology & Research, Inc., is developing a hybrid carbon adsorption/membrane
vapor separation process that uses a membrane vapor separation system to regenerate the carbon bed. The organic
compound is recovered as a pure product; secondary waste streams are eliminated. In the proposed process, both
the carbon adsorption and membrane vapor separation technologies operate in their most favorable range.
The Phase I program demonstrated the feasibility of the hybrid carbon adsorption/membrane vapor
separation process. The process was evaluated by using a small carbon drum to represent the carbon bed and a
pilot-scale membrane system as the regeneration unit. The laboratory data were used to prepare an optimum process
design and an economic and technical analysis. The analysis showed the process offers substantial operating cost
advantages compared with steam regeneration. In Phase n, a 1,000-scfm proof-of-concept system will be
constructed and operated in the laboratory and at a field site.
47. Novel High Efficiency Catalytic Converter for Utility and Other Engines
Precision Combustion, Inc.
25 Science Park
New Haven, CT 06511 (EPA Region 1)
(203) 786-5215
Dr. William C. Pfefferle, Principal Investigator
Mr. J. Kevin Burns, Business Representative
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Amount of Award: $149,850
The thirteen million two and four-stroke gasoline utility engines sold in the U.S. each year are a major
source of total U.S. air emissions. The California Air Resources Board (CARB) has set emissions standards for
these previously unregulated devices, and the U.S. Environmental Protection Agency is now considering setting such
standards.
In Phase I, the advantageous performance of Precision Combustion, Inc. 's innovative low cost utility engine
catalytic converter was demonstrated through prototype testing. The emissions of hydrocarbon and carbon monoxide
from both the two-stroke and a four stroke engine were reduced by 95-99%, to well below the CARB 1999
standards. NOX emissions were not reduced, but can be controlled by other means (e.g., richer operation, EGR).
The necessary excess air addition and cooling were accomplished simply and integrally to the converter.
In Phase n, optimized, manufacturable prototypes will be developed for several test engines, and long term
durability will be demonstrated.
48. Novel Catalysts for the Low Temperature Oxidation of Volatile Organic Compounds
TDA Research, Inc.
12345 West 52nd Avenue
Wheat Ridge, CO 80033 (EPA Region 8)
(303) 940-2301
Mr. John D.-Wright, Principal Investigator
Mr. Michael E. Karpuk, Business Representative
Amount of Award: $150,000
New regulations are forcing the control of very dilute volatile organic compound (VOC) emissions.
Although catalytic incineration is increasingly the technology of choice, energy and catalyst costs rise dramatically
as the VOC concentration decreases. Energy costs could be reduced dramatically if catalysts were available which
were active at lower temperatures. In addition, the use of metal oxide based catalysts (instead of the platinum group
catalysts currently used) would lower the initial cost of VOC control.
In Phase I, TDA Research synthesized and tested a fundamentally new type of metal oxide based catalyst
that has the ability to oxidize CO, hydrocarbons and oxygenates at temperatures which are 100°C to 150°C (18Q°F
to 270°F) lower than is possible with current catalysts. In Phase II, TDA will develop methods of supporting these
catalysts on a honeycomb,determine the activity of the supported catalysts as a function of temperature against
compounds representative of the various categories of VOC's, test their resistance to common catalyst poisons, and
carry out an engineering analysis to determine their economic potential.
TOPIC J: WASTE REDUCTION AND POLLUTION PREVENTION
49. Mercury-Free High CRI Efficient Lamp
Fusion Systems Corporation
7600 Standish Place
Rockville, MD 20855
(301) 251-0300
Dr. Donald A. MacLennan, Principal Investigator
Dr. Leslie S. Levine, Business Representative
Amount of Award: $148,996
(EPA Region 3)
Fusion Systems Corporation's efficient, mercury-free, lamp has the potential of significant environmental
mercury reduction by removing all mercury from light sources and by the reduction of electrical energy
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(EPA Region 5)
consumption. During Phase I, they estimated the 96 LPW, buss bar, can be achieved in two years in a high-power
mercury-free electrodeless, 480,000 lumen source. The 96 LPW figure represents a 140% improvement, closer
to their Phase I objective of 150 %. During Phase n, they will focus on improving bulb efficacy and starting, using
the energy-saving ideas developed during Phase I. At the conclusion of Phase n work, they will have available
tested high-efficiency mercury-free prototype bulbs. The major application, centralized/distributed lighting, would
replace commercial fluorescent lamps with a high, efficiency mercury-free source. Centralized/distributed lighting
has the potential to significantly reduce the total energy requirements associated with the heating, cooling, and
illuminating of commercial and industrial buildings. Key to unlocking this commercial opportunity is the
development of high powered, compact, high efficiency light sources that can be easily coupled to a centralized light
distribution system.
50. An Aqueous-Based, Sulfur-Free Pulping Process - Phase II
Guild Associates, Inc.
4089 North Leap Road
Hilliard, OH 43026
(614) 876-5252
Mr. Salvatore T. DiNovo, Principal Investigator
Mr. Roy S. Brown, Business Representative
Amount of Award: $150,000
Kraft pulping, the accepted method for preparing chemical pulp for generations, is beset with problems.
New kraft mills require enormous investments, over $1 tnillon per ton of pulp. An equally important problem is
environmental aspects associated with the emissions of reduced sulfur compounds and the accompanying odors.
These volatile sulfur compounds are pestiferous smelling gases which are released to the atmosphere. Thus siting
a new kraft mill is virtually impossible. Another pollution problem exists with the nature of the pulp produced by
the kraft sulfide reduction process. The pulp is very dark, requiring extensive bleaching. Bleaching is accomplished
through use of chlorine, chlorine dioxide and sodium hypochlorite. These compounds are not only hazardous to
handle but are implicated in the production of toxic organic chlorides (e.g., dioxins) which appear in the effluent
wastewater streams and outfalls.
In Phase I, Guild Associates, lac. proposed a process development effort which totally eliminated sulfur
from the pulping process. Their target was to produce pulp at or below kappa no. 30. Phase I results demonstrated
this capability unequivocally. Ancillary processing benefits in the chemical recovery section of the plan were also
evident. The Phase II project will build on this base, examining key technical issues that were identified in Phase
I as crucial to commercial development.
51. Elimination of Hazardous Waste Via Advanced Composite Dry Plating System
lonEdge Corporation
1713 Hull Street
Fort Collins, CO 80526 (EPA Region 8)
(303) 223-0665
Mr. Madar Sunthankar, Principal Investigator amd Business Representative
Amount of Award: $150,000
Liquid chemical electroplating is known to generate large quantities of solid and liquid waste. On the other
hand, a unique dry plating process developed by the lonEdge Corporation eliminates liquid chemical and recycles
pure solid metals in situ during plating. Recently, a composite electroplating process has emerged as an alternative
to hazardous cadmium electroplating in the fastener industry. The feasibility of dry plating this composite in an
environmentally safe manner was demonstrated in Phase I.
The dry plating of the composite was developed using a laboratory set-up. In Phase II, the lonEdge
Corporation proposed to advance this method into a pilot-scale batch plating process and system. This apparatus
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will be a scaled-tip model of the Phase I proof-of-concept. The in situ reclaim features of the dry plating process
will be incorporated. The physical properties of the composite will be optimized using statistical design of
experiments. The composite plated components will be tested for commercial applications. After successful
demonstration, the system will be evaluated on pilot-line by the commercial collaborators of lonEdge during Phase
in.
52. Elimination of Toxic Effluent and Metallizing Process Waste via Jet Vapor Deposition
Jet Process Corporation
25 Science Park
New Haven, CT 06511 (EPA Region 1)
(203)786-5130
Dr. Bret L. Halpern, Principal Investigator
Mr. Jerome J. Schmitt, Business Representative
Amount of Award: $150,000
Jet Vapor Deposition (JVD) is Jet Process Corporation's innovative, patented, proprietary process for
manufacturing high quality coatings on substrates for diverse industrial consumer and military applications. JVD
can be used to efficiently deposit many types of metal, ceramic and semiconductor coatings at low cost and high
rate. The new JVD process is clean, dry, non-toxic, and pollution free. In this program of SBIR research, Jet
Process Corporation further developed JVD's ability to compete technically and economically with electroplating.
Electroplating is a major industrial process which generates significant water pollution nationwide. There can,
therefore, be important environmental benefits if JVD is able to replace electroplating in major applications. There
would be a significant reduction in generation of process waste and toxic effluent. In Phase I, Jet Process
Corporation succeeded in broadening JVD's capabilities by developing jet sources for the important electroplating
metals: chromium, nickel, copper, zinc, iron, tin, and silver. Jet Process Corporation tested the sample metal
coatings and verified that quality was equivalent to or better than conventional coatings. They also deposited test
coatings on larger substrates, and devised a reel-to-reel mechanism for JVD deposition on tapes. They investigated
means to recycle JVD process gases. They analyzed the economics and projected markets for JVD processing.
The latter effort involved significant communication with potential commercial customers of JVD processing service
and equipment; in several cases, they supplied prototype coatings to those potential customers. They also succeeded
in profitably supplying JVD production coating service to a commercial client, AT&T Bell Labs; based on this
production, Jet Process Corporation have further proof of JVD's ability to compete on price and performance with
electroplating. In sum, the Phase I effort succeeded in all respects, providing compelling evidence that JVD has
enormous potential as a low-cost, pollution-free coating process, capable of displacing electroplating. Jet Process
Corporation proposes in Phase n to build on their Phase I success and develop the JVD process further so that they
may commercialize it widely in Phase HI. General Electric Company (GE) has written a letter in support of this
proposal; Jet Process Corporation plans to work with GE during Phase II.
(EPA Region 1)
53. Waste Reduction Through Benzene-Free Polymerization Technology
KSE, Inc.
P.O. Box 368
Amherst, MA 01004
(413) 549-5506
Dr. J. R. Kittrell, Principal Investigator and Business Representative
Amount of Award: $149,949
Waste reduction can be a highly cost-effective means of pollution control, by modifying the basic
technology to fundamentally alter the raw materials used. Many organic chemical reactions use benzene as a
classical reaction solvent, and are excellent waste reduction candidates.
In Phase I, the elimination of benzene as a solvent in a free radical organic polymerization process has been
achieved, to produce a very high profile consumer product. All Phase I objectives have been met, providing critical
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confirmation of the technical feasibility of using a novel "solvent-free" approach. The process has been scaled up
to 1000 pound levels. As a result of an order of magnitude enhancement of reactor productivity, over 200% return
on investment is forecast for production capacity less than 10% of the U.S. market. The elimination of benzene
promises not only to be an effective waste reduction process, but also to provide technology which is more efficient
and cost-effective than that based on the classical benzene technology.
A Phase II program is proposed to enhance ancillary polymer properties, to explore applications of the
technology to a new derivative product, and to finalize manufacturing cost estimates and financial return forecasts.
54. Development of an Ultrasonic Prototype Instrument to Replace an Environment-Polluting
Measurement Practice in the Composite Materials Industry
Xxsys Technologies, Inc.
4619 Viewridge Avenue
San Diego, CA 92123 (EPA Region 9)
(619) 974-8200 ext. 22
Dr. Yan Li, Principal Investigator
Mr. James L. Russell, Business Representative
Amount of Award: $150,000
The objective of this Phase II proposal is to develop an ultrasonic Lamb wave demonstration prototype to
replace a widely-used, environmentally polluting industrial practice in composites manufacturing. The goal is to
dramatically reduce industrial wastes and minimize health hazards to workers. The current practice generates about
1 million gallons of industrial wastes per year. Composites are increasingly replacing metals in many applications.
This megatrend of metal replacement means increasing testing and escalating production of industrial wastes.
Phase I of this program developed an innovative waveguide design for selecting the Lamb wave mode and
frequency to be transmitted and received. It demonstrated that propagation velocity of symmetrical mode Lamb
waves, combined with accurate cutting and weighing, can be used to determine both resin content and fiber areal
weight with high precision. Phase II v/ill focus on the manufacture of a demonstration prototype to be used for
validation of Lamb wave technology for measurement of resin content and fiber areal weight of uni-directional
graphite prepregs, and for evaluation of its applicability to woven prepregs. Success in this program will alleviate
the toxic waste problem anticipated as the megatrend of metal replacement accelerates in the next decade.
TOPIC L: IMPROVED MEASUREMENT TECHNOLOGIES FOR LEAD
DETECTION IN LEAD-BASED PAINTS
55. Improved Technology for Measuring Lead Detection in Lead-Based Paint Phase II
Niton Corporation
74 Loomis Street, P.O. Box 368
Bedford, MA 01730-0368 (EPA Region 1)
(617) 275-9275
Dr. Charles G. Parsons, Principal Investigator
Ms. Anne McGuineas, Business Representative
Amount of Award: $150,000
Lead paint is a primary source of lead poisoning, particularly in children. A central problem to a more
vigorous attack on finding lead-paint surfaces is the lack of an inexpensive, portable method for measuring levels
of lead in concentrations as least as low as 1 mg per cm2. In Phase I, Niton Corporation proposed to show the L
x-ray lines of lead rather than K x-rays could be used to measure lead concentrations buried beneath many layers
of non-lead paint. They further proposed to develop a portable, high-resolution detector of L x-rays of lead. They
have surpassed all of the goals of Phase I. They have proved that L x-ray fluorescence can quickly measure lead
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concentrations to well below 1 mg/cm2, even when the lead is covered by many layers of paint of unknown
thickness and composition. Niton Corporation has built a laboratory prototype of a small, portable unit, with
excellent energy resolution and spectrum analysis, that demonstrates the effectiveness of the method. The response
from lead inspection professionals has been very positive. It is the primary purpose of Phase II to develop the
technique further with the specific aims of dramatically reducing the costs of the instrument. The commercial
potential for such an instrument is extremely high.
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INDEX BY COMPANY
ACCEL Catalysis, Inc 6
Iowa City, IA 52242
ADA Technologies, Inc 18
Englewood, CO 80112
Altex Technologies Corporation 6
Santa Clara, CA 95054
Bend Research, Inc 25
Bend, OR 97701-8599
CeraMem Corporation 6, 26
Waltham, MA 02154
ChromatoChem, Inc 15
Missoula, MT 59801-7407
Coalition Technologies, Ltd H
Midland, MI 48641-1391
Compact Membrane Systems, Inc 7
Wilmington, DE 19802
Eckenfelder, Inc 12
Nashville, TN 37228
Energy & Environmental Engineering, Inc 22
East Cambridge, MA 02141
Energy and Environmental Research Corporation 8
Whitehouse, NJ 08888
Energy and Environmental Research Corporation 7
Irvine, CA 92718
Envirochem, Inc *"
Lexington, MA 02173
Foster-Miller, Inc. ^
Waltham, MA 02154-1196
Fusion Systems Corporation 28
Rockville, MD 20855
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Guild Associates, Inc 29
HiJliard, OH 43026
H&R Technology, Inc 26
Newton, MA 02159
HiChem Corporation 13
Chicago, IL 60657
lonEdge Corporation 16, 29
Fort Collins, CO 80526
Jet Process Corporation 30
New Haven, CT 06511
KSE, Inc 8, 30
Amherst, MA 01004
LSR Technologies, Inc.
Acton, MA 01720
Lynntech, Inc 9
Bryan, TX 77803
M.L. Energia, Lie 22
Princeton, NJ 08542
Membran Corporation 4
Minneapolis, MN 55414
Membrane Technology and Research, Inc 9, 16, 17, 27
Menlo Park, CA 94025
National Recovery Technologies, Inc 14, 23
Nashville, TN 37228-1223
Niton Corporation 31
Bedford, MA 01730-0368
Plasmachines, Inc 10 24
Natick, MA 01760
Polar Spring Corporation 4
Menlo Park, CA 94025
Precision Combustion, Inc 27
New Haven, CT 06511
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Resource Recycling & Remediation, Inc 17
Pittsburgh, PA 15212
Robert Morgan & Company, Inc. 24
Battle Creek, MI 49015
Sorbent Technologies Corporation (formerly Sanitech, Inc.) 24
Twinsburg, OH 44087
TDA Research, Inc. TV 5, 10, 11, 25, 28
Wheat Ridge, CO 80033
Veritay Technology, Inc 17
East Amherst, NY 14051
Wamax, Inc .15
Bellevue, WA 98006
Xxsys Technologies, Inc 31
San Diego, CA 92123
3 5 -tfU.S. GOVERNMENT PRINTING OFFICE: 1994 - SSO-OOI/80335
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