&EPA
United States Office of Air Quality
Environmental Protection Planning and Standards
Agency Research Triangle Park NC 27711
Air
EPA-453/B-93-019
April 1993
Medical Waste Incinerator
Operator Training Program
Instructor's Guide
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EPA-453/B-93-019
MEDICAL WASTE INCINERATOR
OPERATOR TRAINING PROGRAM
INSTRUCTOR'S GUIDE
U. S. Environmental Protection Agency
Industrial Studies Branch/BSD
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
April 1, 1993
Osl
&
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HEADQUWTERS LIBRARY
fWWWNTAL PROTECTION AGENCY
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NOTICE
This Instructor's Guide and the Course Handbook constitute the training materials for a
model state training program which addresses the training needs of medical waste incinerator
(MWI) operators. Included are generic equipment design features, combustion control
relationships, and operating and maintenance procedures which are designed to be consistent
with the purposes of the Clean Air Act Amendments of 1990.
This training program is not designed to replace the site-specific, on-the-job training
programs which are crucial to proper operation and maintenance of medical waste incinerators.
Proper operation of combustion equipment is the responsibility of the owner and
operating organization. Therefore, owners of medical waste incinerators and organizations
operating such facilities will continue to be responsible for employee training in the operation
and maintenance of their specific equipment.
DISCLAIMER
This Instructor's Guide was prepared by the Industrial Studies Branch, Emission
Standards Division, U. S. Environmental Protection Agency (USEPA). It was prepared in
accordance with USEPA Contract Number 68-CO-0094, Work Assignment Number 8. Partial
support was also provided by the University of Virginia through its Sesquicentennial Associates
Program.
Any mention of product names does not constitute an endorsement by the U. S.
Environmental Protection Agency.
The U. S. Environmental Protection Agency expressly disclaim any liability for any
personal injuries, death, property damage, or economic loss arising from any actions taken in
reliance upon this Handbook or any training program, seminar, short course, or other
presentation based on this Course Handbook.
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AVAILABILITY
This Instructor's Guide and the accompanying Course Handbook are issued by the Office ^^
of Air Quality Planning and Standards of the U. S. Environmental Protection Agency. These
training materials were developed to assist operators of medical waste incinerators in becoming
certified as required by the federal and state regulatory agencies.
Individual copies of the publications are available to state regulatory agencies and other
organizations providing training of operators of medical waste incinerators. Copies may be
obtained from the Air Pollution Training Institute (APTI), USEPA, MD-17, Research Triangle
Park, NC 27711. Others may obtain copies, for a fee, from the National Technical Information
Service, 5825 Port Royal Road, Springfield, VA 22161.
Although these government publications are not copyrighted, they do contain some
copyrighted materials. Permission has been received by the authors to use the copyrighted
material for the original intended purpose as described in the section titled Handbook
Introduction. Any duplication of this material, in whole or in part, may constitute a violation
of the copyright laws, and unauthorized use could result in criminal prosecution and/or civil
liabilities.
The recommended procedure for mass duplication of the Course Handbook is as follows:
Permission to use this material in total may be obtained from the APTI, provided the
cover sheet is retained in its present form. Permission to use part of this material may
also be obtained from the APTI, provided that the APTI and the authors are properly
acknowledged.
n
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TABLE OF CONTENTS
Notice and Disclaimer
Availability
Course Materials Introduction
Course Preparation Instructions
Course Agenda
Pre-Test
Post-Test
Lesson Plans
1 . Introduction
2. Environmental Concerns and Regulations
3. Characterization of Medical Waste
4. Medical Waste Safety, Handling and Treatment
5. Municipal Waste Combustors
6. Combustion Principles I: Complete Reactions
7. Combustion Principles n: Thermochemistry
8. Combustion Principles ffl: Reaction Processes
9. Combustion System Design and Control
10. Air Pollution Formation
11. Instrumentation I: General Measurements
12. Instrumentation II: Continuous Emissions Monitoring
13. Incinerator Operations and Upsets
14. Maintenance: Corrective & Preventive
15. Flue Gas Cleaning I, Paniculate Matter
16. Flue Gas Cleaning n: Acid Gas Removal
17. Toxic Metal Characteristics and Emissions Control
18. APCD Performance & System Control Features
19. APCD Operational and Safety Considerations
20. Boilers and Other Heat Recovery Equipment
2 1 . Boiler Energy Principles
Page
i
ii
1
4
5
Pre-Test-1
Post-Test-1
1-1
2-1
3-1
4-1
5-1
6-1
7-1
8-1
9-1
10-1
11-1
12-1
13-1
14-1
15-1
16-1
17-1
18-1
19-1
20-1
21-1
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22. Boiler Water Treatment 22-1
23. Boiler Operational, Control & Safety Considerations 23-1
IV
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COURSE MATERIALS INTRODUCTION
The course materials were developed for the U. S. Environmental Protection
Agency (USEPA) in support of improving the air pollution control practices at medical
waste incinerators (MWIs). The USEPA was required to develop a model state
training and certification program for MWI operators under Title III, Section 129 of
the Clean Air Act, as amended 1990. The Instructor's Guide is an integral part of the
model state MWC operator training and certification program. As such, state and
regional air pollution control agencies are encouraged to develop training programs
which make use of this manual.
This Instructor's Guide and the corresponding Course Handbook make up the
materials for the model state training program which addresses the training needs
of MWI operators.
The Instructor's Guide presents information generally required by course
directors and instructors, including an agenda, copies of tests, specific information
about each learning unit, and masters for making overhead projection transparencies
or slides.
The Course Handbook of the training program describes the equipment design
features, combustion control relationships, and operating and maintenance
procedures which are designed to be consistent with the purposes of the Clean Air Act
Amendments of 1990.
TRAINING PROGRAM GOAL
The primary goal of the training program is to provide an adequate level of
understanding to MWI operators to successfully complete the requirements of the
ASME QMO Standard for certification as medical waste incinerator operators and
operator supervisors.
The training program focuses on the knowledge required by operators for
understanding the basis for proper operation and maintenance of MWIs. Particular
emphasis is placed on the various aspects of combustion which are important for
environmental control. Fundamental information is related to applications and to the
operator's own work experiences. Trainees are encouraged to comment and ask
questions during the training program. Such discussion will both increase the utility
of the program and make it more interesting.
The program was designed to augment the normal site-specific, on-the-job and
supervised self-study training programs which are provided by the vendor, owner or
operating company. The program is not a substitute for such operator training.
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TRAINING PROGRAM INTENDED AUDIENCE
The primary goal of the training program is to provide an adequate level of
understanding to MWI operators to successfully complete the Operator Certification
Examination of the ASME Standard for Qualifications and Certification of Medical
Waste Incinerator Operators (ASME QMO-1). Certification through the ASME or an
equivalent state-approved program will likely be required when the USEPA
promulgates standards for new MWIs and emission guidelines for existing MWIs.
The training program focuses on the knowledge required by operators for
understanding the basis for proper operation and maintenance of medical waste
incinerators in minimizing air pollutant emissions. Particular emphasis is placed on
the various aspects of combustion which are important for environmental control.
Fundamental information is related to applications and to the operator's own work
experiences.
Participants are encouraged to make comments and ask questions throughout
the program, as such discussion will help establish a creative environment for the
course.
The program is designed to augment the normal site-specific, on-the-job, and
supervised self-study training programs which are typically provided by the vendor,
owner, or operating company. The program is not a substitute for such hands-on
operator training programs.
COURSE LIMITATIONS
To the extent possible, this Course Handbook was written in a manner
consistent with USEPA policy regarding medical waste incinerators and the
demonstrated features of good combustion practice.
Detailed administrative and legal aspects of unit operations are not
emphasized in the program because the regulations under which units operate will
vary with location and time. Operators are urged to obtain specific regulatory
information and permit requirements from the owner/operator organization.
INSTRUCTOR'S GUIDE ORGANIZATION
The Instructor's Guide presents information generally required by course
directors and instructors, including a sample agenda, copies of a pre-test and post-
test, objectives and discussion questions for each learning unit, and masters for
making overhead projection transparencies or slides.
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COURSE MANUAL ORGANIZATION
The Course Handbook presents information in the subject areas addressed in
the ASME Examination for Certification as Operators and Operator Supervisors.
Additional information about qualifications may be obtained from a review of the
ASME Standard.
The course is divided into three parts, which generally correspond to the three
areas of the ASME MWI certification examination. The sequence of topics was
selected to reinforce the integration of the basic aspects with the operational aspects.
Each part considers the relevant automatic control systems, trouble shooting, and
preventive maintenance.
Part I constitutes Learning Units 1 through 14. It begins by introducing the
relation of the training program to the certification process, the regulatory aspects
of medical waste disposal, and the operator's role in public relations. However, the
emphasis in Part I is on the consideration of the combustion principles, MWI
equipment design and operational aspects, air pollution formation, and emissions
monitoring systems.
Part II constitutes Learning Units 15 through 19. It focuses on air pollution
control devices. The design and operational aspects of air pollution control devices
(APCDs) for particulates, acid gases, and heavy metals are considered.
Part III constitutes Learning Units 20 through 23. It addresses the topic of
heat recovery systems. The basic concepts of heat transfer and thermodynamics are
presented first. The design and operational features of heat recovery systems
(boilers) are then considered.
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COURSE PREPARATION INSTRUCTIONS
This course requires 3.5 days for a complete presentation. Planning and
administrating the activities are the responsibilities of the course director. This
includes making provisions for activities before and during the course as follows:
1. Making arrangements for scheduling and announcing the course.
2. Recruiting an appropriate group of instructors who have:
a. general knowledge of the design principles and operational aspects of
MWI equipment and specific expertise in their assigned topical area.
b. relevant practical and operational experience.
c. knowledge of the job requirements of operators.
d. an understanding of their responsibilities and the ability to instruct
adult MWI operators.
e. a positive attitude about environmental management.
3. Briefing of the instructors before the course (emphasizing the course schedule
and accommodations and the requirement of preparation before the course,
including projection materials) and providing feed-back during the course.
4. Arranging for accommodations, including proper classroom size and seating,
projection equipment, and possible provisions for breaks and meals.
5. Managing and confirming course registration.
6. Arranging for the preparation and distribution of the course materials (agenda,
Course Manual, roster, "name tents," pretest and post-test, certificates, and
critique or feed-back sheets).
7. Providing appropriate lecture presentations.
8. Maintaining continuity and coordination throughout the course, such as asking
questions and leading discussions with the participants, grading tests,
requesting course critique, and preparing certificates of course completion.
PROGRAM AGENDA
The training program is designed around a 3.5-day sequence of learning units
in which the agenda follows the sequence in the manual. However, the course agenda
can be rearranged to accommodate the special scheduling needs of the speakers.
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MEDICAL WASTE INCINERATOR OPERATOR TRAINING PROGRAM
PRE-TEST
Instructions: The entire test is to be taken as a closed book test.
Each question has only one best answer.
Circle the letter corresponding to the best answer on the Answer Sheet.
The Clean Air Act Amendments of 1990 require the USEPA to develop a
training and certification program for operators of medical waste incinerators.
The statement is:
a. true; although many of the states will require their own certification
procedures which must be acceptable to the USEPA.
b. false, because the states can develop their own training and certification
programs.
c. false, because the Clean Air Act Amendments were passed in 1971.
d. false, because the ASME has developed a testing and certification
program which is acceptable to the USEPA.
Identify the component material of medical waste which is the major source of
chlorine:
a. plastics
b. paper
c. metals
d. glass
e. pathological waste
Identify the following item which is a chemical element in medical waste:
a. volatile matter
b. chlorine
c. paper
d. water
Identify the component material in medical waste which is composed of organic
materials:
a. aluminum
b. plastic
c. glass
d. saline solution
Pre-Test-1
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5. Identify the following item which is not generally included in segregated
medical waste:
a. cultures and stocks
b. sharps
c. animal wastes
d. unused sharps
e. hospital cafeteria wastes
6. Although it varies significantly, the average moisture content of segregated
medical waste is approximately:
a. <5%
b. 5-40%
c. 50-75%
d. 85-95%
e. >95%
7. Most hospitals produce about of medical waste which is segregated for
special handling and treatment:
a. < 0.25 pound per bed per day
b. 2 to 4 pounds per bed per day
c. 10 to 30 pounds per bed per day
d. > 50 pounds per bed per day
8. The primary reason for concern about ash disposal practices is related to the
fact that:
a. ash contains metals which should be recycled.
b. heavy metals can be leached into the groundwater.
c. methane gas should be developed as an alternative energy source.
d. recycling goals require reducing the waste stream by at least 25%.
9. In recent years, major national attention was focused on medical waste
disposal primarily because:
a. numerous cases were reported of waste handling personnel contracting
infectious diseases from the handling of medical waste.
b. numerous cases were reported of the general public contracting
infectious diseases from the handling of medical waste.
c. untreated medical waste items washed up on the beaches in the
Northeast.
d. the Clean Air Act Amendments were passed.
Pre-Test-2
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10. The typical start-up sequence for single-batch operated MWIs begins with the
removal of the ash from the previous burn and proceeds as follows:
a. load the batch of waste, lock the charging door, operate the fans to purge
gases, use the primary burners if necessary to begin burning the waste.
b. load the batch of waste, lock the charging door, operate the fans to purge
gases, ignite the secondary burners to preheat the secondary chamber,
ignite the primary burners if necessary to begin burning the waste.
c. operate the fans to purge the gases, ignite the primary burners to
preheat the primary chamber, load the batch of waste which will
instantaneously ignite.
d. operate the fans to purge the gases, ignite the secondary burners to
preheat the secondary chamber, ignite the primary burners to preheat
the primary chamber, load the first of a number of intermittently
delivered batches of waste into the primary chamber.
11. The refractory in the primary chamber of a controlled-air incinerator:
a. assures that the steel enclosure of the unit is adequately heated, thereby
limiting the thermal stresses which would otherwise damage the
structure.
b. keeps the combustion gases from leaking out of the unit.
c. assures that there is adequate heat loss from the primary chamber so
that starved air combustion will not create gas temperatures that are too
high.
d. limits the heat loss from the primary chamber and the corrosion and
erosion of the primary chamber's metal enclosure.
12. A typical secondary chamber operates at a temperature of 1800°F or about
13.
a.
b.
c.
d.
3300°C
2280°C
980°C
450°C
Identify the following item which is not included in the ultimate analysis of a
fuel:
a. carbon
b. sulfur
c. volatile matter
d. moisture
Pre-Test-3
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14. The collection efficiency for particles in a venturi scrubber system can be high
because:
a. the low gas velocity in the throat provides a long residence time for
particles to collide and stick on the droplets.
b. the high gas velocity in the throat provides a high rate of collisions of
particles with the droplets.
c. the water absorbs most of the HC1 and forms acids which attack the
particles.
d. the pressure drop is a constant that does not go up when the gas flow
drops.
15. A characteristic difference between intermittent duty incinerators and
continuous duty incinerators is that
a. continuous duty units suffer more thermal shocks and refractory
problems because of the cycling of their temperatures.
b. continuous duty units are operated 24 hoursVday and have automatic ash
removal.
c. intermittent duty units produce bottom ash which has greater carbon
contents and more waste residues.
d. intermittent duty units have small batches of waste charged about every
6 to 15 minutes, rather than being fed by an auger.
16. An OSHA "lock-out" procedure is designed to:
a. keep members of the public out of facilities where they could get hurt.
b. keep workers from being damaged by the unexpected discharging of
hazardous materials by carelessly opening hopper doors and observation
hatches.
c. lock circuit breakers in the "off* position during maintenance to prevent
personal injuries.
d. assist employees in gaining a reasonable wage for the work.
17. Toxic equivalence regulations for dioxin/furan emissions provide for
calculations which multiply the concentrations of each dioxin/furan compound
by a factor which indicates the ratio of that compound's toxicity to the toxicity
of the most toxic of all polychlorinated dibenzo-p-dioxin compounds. Identify
that most toxic compound from the following list:
a. 2,3,7,8 tetrachlorinated dibenzo-p-dioxin.
b. penta chlorodibenzo-p-dioxin.
c. octa chlorodibenzo-p-dioxin.
d. mono chlorodibenzo-p-dioxin.
Pre-Test-4
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18. When increased underfire air blows through the bed of medical waste on a
hearth, the burning process generally:
a. entrains fewer large particles in the combustion gas leaving the
secondary chamber.
b. becomes more intense (burns faster and hotter).
c. produces less carbon monoxide.
d. occurs with & more uniform distributed of combustion air.
19. Automatic control systems can maintain the temperature in the primary
chamber of a controlled-air unit below a maximum set point by regulating the
delivery of heat sink materials, such as
a. water (moisture content) in the fuel.
b. water sprays.
c incombustibles (glass and metals) in the medical waste.
d. all of the above.
20. An example of a high energy wet scrubber would be:
a. a pack tower with countercurrent flow
b. a baffle plate scrubber
c. an impingement scrubber.
d. a venturi scrubber.
21. Operating a MWI above its charging rate capacity (Ib/hr):
a. is anticipated in MWI unit designs. For example, the heating value of
waste is reduced when excessive body fluids and moisture are in the
medical waste, so waste can be charged at a higher rate.
b. will generally result in excessive pollutant emissions.
c. is routinely accommodated by operating with greater air flow rates.
d. is routinely accommodated by operating with higher primary and
secondary chamber temperatures.
22. A modern MWI facility was equipped with both in situ and extractive monitors
for CO and a moisture analyzer. The in situ monitors indicated 64 ppm CO,
while the extractive monitor indicated 75 ppm CO. The moisture analyzer
reading was 15%. Indicate your evaluation of the situation:
a. The in situ monitor reading was too low.
b. The extractive system was reading too high.
c. Both instruments were reading correctly.
d. There was an air leak in the extractive system sampling line.
Pre-Test-5
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23. Flue gas opacity can be used by the operator (and regulator) as an indication
of:
a. overall thermal efficiency of the boiler.
b. the carbon dioxide of the plume.
c. the temperature of the waste material in the fuel bed.
d. the quality of the bottom ash.
e. the particulate emissions from the stack.
24. In any combustion system, a portion of the inorganic material (ash) in the fuel
will be released as fly ash. For a pulverized coal-fired utility boiler, about 70%
of the ash leaves the boiler as fly ash. The approximate fraction of the ash
which leaves a modular starved-air MWI as fly ash is:
a. 60 - 80%.
b. 40 - 60%.
c. 15 - 40%.
d. 5 - 15%.
e. less than 5%.
25. A properly operating in situ monitor indicates 300 ppm of SO2 in the flue gas,
and the moisture in the flue gas is known to be 20%. If an extractive
instrument which has an in-line dryer indicates 320 ppm of SO2> then
a. the two instruments are reading consistently.
b. the extractive instrument is reading too high.
c. the extractive instrument is reading too low.
d. the in situ monitor is in need of calibration or replacement
26. The pressure drop across a conventional venturi scrubber for particulate
removal often ranges from
a. 1" to 5" w.c.
b. 10" to 15" w.c.
c. 30" to 70" w.c.
d. 80" to 100" w.c.
27. The thermal conversion efficiency (based on the conversion of flue gas sensible
energy to steam energy) of conventional waste-heat boilers at MWIs is about:
a. 25-40%.
b. 65-80%.
c. 85-95%.
d. greater than 95%.
Pre-Test-6
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O
29.
30.
31.
32.
Properly operating extractive CEMS instruments indicate 200 ppm of S02 and
10% carbon dioxide in the flue gas. The standard emission concentration of
SO2 corrected to 12% flue gas carbon dioxide would be:
a.
b.
c.
200ppmofS02.
greater than 200 ppm of S02
less than 200 ppm of S02.
Extractive CEMS for measuring flue gas concentrations of oxygen or carbon
monoxide have special features which:
a. either dry the gas or provide significant dilution before it is analyzed.
b. heat the gas to the stack temperature to prevent chemical reactions.
c. provide for automatic calibration without the need of calibration gases.
d. are less sensitive than in situ units because their temperatures are
lower.
In situ instruments for measuring oxygen and carbon dioxide concentrations in
the flue gas typically have features which:
a. allow them to give the same numerical readings as those of extractive
monitoring instruments.
b. provide concentration readings which are higher than extractive
instruments due to the influence of water vapor.
c. are more sensitive than extractive systems because of their high
temperature exposures.
d. allow for monitoring the gas under its actual stack conditions.
In a starved-air incinerator, approximately what percent of the sulfur in the
medical waste feed is converted to S02 by the combustion processes?
a.
b.
c.
d.
20-40%
40-60%
>80%
The particle concentration (mass/volume) in the flue gas leaving the secondary
chamber of typical modular, starved-air incinerators is that of excess-
air incinerators.
a. less than
b. greater than
c. approximately the same as
Pre-Test-7
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33. Particulate matter collection efficiencies for fabric filters are:
a. improved just after the fabric filter has been cleaned.
b. at the highest level just before the fabric filter is cleaned.
c. improved with frequent cleaning of the fabric filter.
d. improved by increasing flue gas temperatures above 500 °F.
34. An impingement spray scrubber has special features under which:
a. the liquid is injected at a high pressure
b. the gas causes the atomization of the liquid film or layer.
c. particulate matter is removed by cyclonic deposition.
d. the gas flow and main liquid flow are in the same direction.
35. A pH value of 7,0 for boiler water is an indication that the water is:
a. acidic and potential tube corrosion will be problem.
b. basic and water tube corrosion will be a problem.
c. basic but water tube corrosion problems are probably under control.
d. neutral, neither basic or acidic. •
36. Modern wet scrubbing systems for MWIs are typically capable of removing
a. 10% to 35% of the HC1 in the flue gas.
b. 40% to 55% of the HC1 in the flue gas.
c. 60% to 85% of the HC1 in the flue gas.
d. 90% to 99% of the HC1 in the flue gas.
37. Modern dry scrubbing systems for MWIs are typically capable of removing
a. 10% to 35% of the HC1 in the flue gas.
b. 40% to 55% of the HC1 in the flue gas.
c. 60% to 85% of the HC1 in the flue gas.
d. 90% to 99% of the HC1 in the flue gas.
38. Smoke leaking through the seals of the charging door is an indication that:
a. the pressure inside the primary chamber is equal to the atmospheric
pressure.
b. the gage pressure inside the primary chamber has a negative value.
c. the gage pressure inside the primary chamber has a positive value.
d. the unit is operating under excessive draft conditions.
Pre-Test-8
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39. Identify the following statement which is incorrect.
a. Dry hydrated lime (calcium hydroxide) is a common material injected
into the flue gas by dry sorbent injection systems for acid gas control.
b. A hydrated lime (calcium hydroxide) slurry is a common solution which
is used in spray dryer absorber systems for acid gas control.
c. An aqueous solution of sodium hydroxide is a common caustic liquid
used in wet scrubbing systems.
d. A dry mixture of sodium hydroxide is a common powdered material
which is used in dry sorbent injection systems for acid gas control.
40. Particles in an electrostatic precipitator are charged by:
a. subjecting the particles to high humidity.
b. a corona produced by the discharge electrode with a high negative
voltage is applied.
c. a corona produced by high positive voltage applied to the collecting
plates.
d. an intense electrical field which is created by applying a.c. voltage to the
discharge electrodes.
41. Slowdown is a standard operation in wet scrubbers for controlling the:
a. pH in the scrubber solution which could cause corrosion of the scrubber.
b. suspended and dissolved solids the scrubber solution which could cause
blockages to form.
c. dissolved gases in the scrubber solution which would lead metal
corrosion.
d. air bubbles formed at the top of the scrubber reservoir.
42. Soot blowing may be routinely performed on MWIs with waste-heat boilers and
air pollution collection devices to:
a. remove the accumulated filter cake from the fabric filter.
b. remove slag from the incinerator walls.
c. remove ash build-up from the tube surfaces in boilers.
d. discharge the contaminated water which accumulates in the boiler's mud
drum.
e. provide attemperation to maintain the desired temperature of steam.
Pre-Test-9
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43. Identify the final control element of an automatic system which can be used to
control the drum level in a boiler:
a. level indicator.
b. level controller.
c. feed water regulator valve.
d. set point.
e. all of the above.
44. A pH value of 9.0 for boiler feedwater is an indication that the water is:
a. acidic and potential tube corrosion will be problem.
b. basic and excessive water tube corrosion will probably occur,
c. basic but water tube corrosion problems are probably under control.
d. approximately neutral, so that tube corrosion problems are probably
under control.
45. Absolute pressure when measured at an elevation above sea level:
a. is 29.92 inches of mercury.
b. is equivalent to atmospheric pressure plus gage pressure.
c. is more useful than gage pressure in understanding incinerator
conditions.
d. tends to go down as the temperature is increased.
46. Pulse-jet is a type of mechanism used to clean fabric filters which uses:
a. a blast of dry air that causes the bags to expand like a bubble and
dislodge the dust.
b. pulsating air which causes the bags to shake back and forth, dislodging
the filter cake.
c. the oscillating motion or sonic horns which dislodge the dust.
d. a blast of air outside the bags to knock off the filter cake.
47. A pulse-jet cleaned fabric filter system has a cage for each bag which is
designed to:
a. help the bags collapse and clean easier.
b. help the bags shake better.
c. support the bags.
d. help filter out large pieces of fly ash.
Pre-Test-10
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48. The units of the air-to-cloth ratio in fabric filter systems are:
a. volumetric flow rate units
b. volume units divided by area units
c. velocity units divided by volumetric flow rate units
d. velocity units,
49. The pressure drop across a fabric filter system:
a. provides an indication of the amount of dust deposited on the filter.
b. provides an indication of the temperature of the baghouse.
c. is much greater just after cleaning of the bags.
d. goes down as the velocity increases.
50. The energy which forces droplets and particles to be separated by a cyclonic
mist eliminator after a venturi scrubber is typically supplied by:
a. a pump.
b. a forced draft fan.
c. an induced draft fan.
d. a motor which causes the cyclonic device to rotate.
Pre-Test-11
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ERATOR OPERATOR TRAJNINC
ANSWER SHEET
jwer on this Answer Sheet.
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Pre-Test- Answer-1
-------
NAME: CORRECT ANSWERS
MEDICAL WASTE INCINERATOR OPERATOR TRAINING
PRE-TEST ANSWER SHEET
Instructions: Enter the appropriate answer on this Answer Sheet.
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Pre-Test-Answer-2
-------
MEDICAL WASTE INCINERATOR OPERATOR TRAINING
POST-TEST
Instructions: The entire test is to be taken as a closed book test.
Each question has only one best answer.
Circle the letter corresponding to the best answer on the Answer Sheet.
1. The ASME's MWI operator certification procedures include provisions for
Special Operator certification. Special Operators include:
a. General MWI Operators.
b. General MWI Operators and Operator Supervisors.
c. Factory field representatives who may direct MWI start-up or
maintenance operations.
d. Government officials who perform inspections of MWIs.
e. Both c and d.
2. ASME's MWI certification program has four classes of certification which
depend upon the types of equipment to be operated. In general,
a. Class A Operators are certified to operate MWIs with or without heat
recovery and with or without air pollution control equipment.
b. Class D Operators are certified to operate MWIs with or without heat
recovery and with or without air pollution control equipment.
c. Class B Operators are certified to operate only MWIs with heat recovery
devices.
d. Class C Operators are certified to operate only MWIs with air pollution
control devices.
e. All of the above.
3. A 500 bed hospital produces about of segregated medical waste
a. 500 Ib/day.
b. 1,500 Ib/day.
c. 20,000 Ib/day.
d. 40,000 Ib/day.
4. Identify the following item which is not included in the proximate analysis:
a. volatile matter
b. hydrogen
c. fixed carbon
d. ash (inorganic)
e. moisture
Post-Test-1
-------
5. Operating a MWI above its rated operating load (Btu/hr) is
a. a serious problem. For instance, the charging of waste with higher
plastic and lower moisture contents can cause the volatiles to surge,
overloading the secondary chamber and creating excessive pollutant
emissions.
b. not a serious problem, because the temperature will increase and
reaction rates increase with temperature.
c. a routine problem which is can be accommodated by operating with
greater air flow rates.
d. a routine problem which is can be accommodated by operating with
higher primary and secondary chamber temperatures.
6. The Clean Air Act
a. prohibits the states from having MWI regulations that are more strict
than the federal standard.
b. instructs the USEPA to set MWI emission standards at the maximum
degree of control possible.
c. does not allow the consideration of economics in the setting of new
source performance standards.
d. allows the states to establish MWI regulations that are more strict than
the federal standards.
7. An average higher heating value of the medical waste is somewhere around:
a. 1,000 to 3,000 Btu/lb.
b. 5,000 to 9,000 Btu/lb.
c. 12,000 to 15,000 Btu/lb.
d. 16,000 to 20,000 Btu/lb.
8. Smoke leaking through the seals of the charging door is an indication that:
a. the primary chamber temperature is too high.
b. the seals will also leak in an adequate amount of tramp air.
c. the unit is operating under positive pressure conditions.
d. the unit is operating under excessive draft conditions.
9. Hospitals are responsible for approximately of the total segregated
medical waste produced:
a. 40-50%
b. 50-60%
c. 70-85%
d. >90%
Post-Test-2
-------
10. Identify the largest component material of the average segregated medical
waste produced by general hospitals (based on weight):
a. plastics
b. paper
c. metals
d. glass
e. pathological waste
11. The average moisture content of pathological waste is approximately:
a.
b.
c.
d.
e.
o
5-40%
45-65%
65-75%
>75%
12. The Clean Air Act requires each state to submit plans for implementing air
pollution control and the EPA to review and approve them. If this is not done
the state will be:
a. under threat of losing their ability to regulate air pollutants.
b. under threat of losing all federal highway funds.
c. both of the above.
d. neither of the above.
13. Identify the waste management activity which can reduce the quantity of acid
gases formed during the burning of medical waste.
a. Change the type of plastics used (waste minimization).
b. Removal of metals and glass (recycling).
c. Composting of organic materials (recycling).
d. Create new markets for recycled paper.
e. Add a flue gas scrubber.
14. The water-walls in the primary chamber of a waterwall MWI:
a. assures that the steel enclosure of the unit is adequately heated, thereby
limiting the thermal stresses and structural damage.
b. keeps the combustion gases from leaking out of the unit.
c. provides adequate heat loss from the primary chamber to the
surrounding water, so that the gas temperatures will not be too high
even though combustion occurs with more air than a starved-air unit.
d. are used to heat the steam from the waste heat boiler considerably above
the saturation temperature.
Post-Test-3
-------
15. Controlling the temperature in the primary chamber of a controlled-air unit
can be accommodated by:
a. controlling the rate of fuel feed.
b. controlling the rate of underfire air supplied.
c. the use of water sprays (heat sink)
d. all of the above.
16. The typical start-up sequence for an intermittent duty MWIs begins with the
removal of the ash from the previous day's burn and proceeds as follows:
a. load the batch of waste, lock the charging door, operate the fans to purge
gases, use the primary burners if necessary to begin burning the waste.
b. load the batch of waste, lock the charging door, operate the fans to purge
gases, ignite the secondary burners to preheat the secondary chamber,
ignite the primary burners if necessary to begin burning the waste.
c. operate the fans to purge the gases, ignite the primary burners to
preheat the primary chamber, load the batch of waste which will
instantaneously ignite.
d. operate the fans to purge the gases, ignite the secondary burners to
preheat the secondary chamber, ignite the primary burners to preheat
the primary chamber, load the first of a number of intermittently
delivered batches of waste into the primary chamber.
17. Mercury emissions can be a problem for combustion systems such as MWIs,
because:
a. the incinerator's combustion environment provides unique conditions for
vaporizing mercury.
b. mercury is easily vaporized because it has a very high vapor pressure,
even at relatively low temperatures.
c. mercury causes ash particulates to become sticky.
d. mercury substantially increases the weight of MWI ash.
18. The excess air in gases leaving the typical MWI unit is about:
a. 2 to 4 percent.
b. 6 to 10 percent.
c. 20 to 80 percent.
d. 100 to 150 percent.
Post-Test-4
-------
19.
20.
21.
The theoretical amount of air required to burn a pound of average medical
waste with no excess air is about:
a.
b.
c.
d.
0.5 pounds.
3 pounds.
7 pounds.
15 pounds.
Greater than 90% of the chlorine in the medical waste feed to an MWI will
leave the secondary chamber in the flue gas stream. A majority of that
chlorine will be in the form of:
a.
b.
c.
d.
NaCl
CuCl2
HgCl2
HC1
The combustion efficiency of a typical MWI unit (based on the flue gas carbon
monoxide to carbon dioxide ratio) is generally:
a. between 25 and 40%
b. between 70 and 85%
c. between 85 and 97%
d. greater than 99%
22. The main purpose of a deaerator in a boiler water system is to:
a. remove moisture from the air supply.
b. remove dissolved gases from the condensate or feedwater.
c. introduce additives to the water system for control of scaling.
d. remove suspended solids, total solids, and silica from the boiler water.
23. Identify the following item which is an inorganic material in medical waste:
a.
b.
c.
d.
paper
glass
gauze
plastic
Post-Test-5
-------
24. Dioxin and furan stack emissions from MWIs have been shown to:
a. increase with an increase in the operating temperature of the participate
matter control device.
b. increase with an increase in the plastic content of the waste
c. increase with increased CO emissions.
d. be increased as the combustion conditions deteriorate.
e. all of the above.
25. Volatile metals tend to be found in larger concentrations in the smaller sub-
micron particulate matter in the MWI exhaust. This phenomena occurs
because:
a. those metals are contained on small diameter particulates in the waste
fuel.
b. upon being heated in the furnace, the particles swell up and burst into
fine particles.
c. they are absorbed and/or condensed onto the available surfaces of the
particulate matter, which are mostly small particulates.
d. the small particles are hotter so the metals melt and flow to the surface.
26. Of the total carbon in the medical waste, the fraction which is converted to C02
in a modern, starved-air MWI unit is:
a. about 25 to 40%.
b. about 70 to 85%.
c. about 85 to 95%.
d. greater than 95%.
27. Properly operating extractive GEMS instruments indicate 200 ppm of SO2 and
9% oxygen in the flue gas. The standard emission concentration of SO2
corrected to 7% flue gas oxygen would be:
a. 200 ppm of S02.
b. 233ppmofSO2.
c. 171ppmofSO2.
d. 156ppmofSO2.
28. The pressure drop across a fabric filter often ranges from
a. 1" to 10" w.c.
b. 10" to 20" w.c.
c. 30" to 70" w.c.
d. 80" to 100" w.c.
Post-Test-6
-------
29.
30.
31.
32.
33.
The most toxic of all the dioxin (polychlorinated dibenzo-p-dioxin) compounds
is:
a.
b.
c.
d.
2,3,7,8 tetrachlorinated dibenzo-p-dioxin.
penta chlorodibenzo-p-dioxin.
octa chlorodibenzo-p-dioxin.
mono chlorodibenzo-p-dioxin.
A properly operating in situ monitor indicates 200 ppm of SO2 in the flue gas,
and the moisture in the flue gas is known to be 15%. If an extractive
instrument which has an in-line dryer indicates 235 ppm of S02, then
a. the two instruments are reading consistently.
b. the extractive instrument is reading too high.
c. the extractive instrument is reading too low.
Properly operating extractive GEMS instruments indicate 200 ppm of SO2 and
10% carbon dioxide in the flue gas. The standard emission concentration of
S02 corrected to 12% flue gas carbon dioxide would be:
a.
b.
c.
d.
e.
less than 167 ppm of S02.
167ppmofS02.
200ppmofS02.
240ppmofS02.
more than 240 ppm of S02.
Sample extraction lines from the stack to a flame ionization type of instrument
are heated to:
a. keep water from condensing out of the gas sample, causing the blockage
of the sample lines.
b. accommodate the fact that these GEMS have faster response times if the
gases are hot.
c. keep organic gases from condensing out of the gas and causing a low
reading at the total hydrocarbon or unburned hydrocarbon analyzers.
d. accommodate the fact that certain CEMS will only function if the sample
gases are above the boiling point of water.
The collection mechanism(s) responsible for removal of particles by a venturi
scrubber is (are):
a. impaction.
b. impaction and interception.
c. impaction, interception, diffusion.
d. adsorption.
Post-Test-7
-------
34. The pressure drop across a packed tower (wet scrubber) often ranges from
a. 1" to 5" w.c.
b. 10" to 15" w.c.
c. 30" to 70" w.c.
d. 80" to 100" w.c.
35. Typical units describing the air-to-cloth ratio in fabric filter systems are:
a. cfm/ft-min
b. cfm/ft2
c. cfm/ft
d. inches w.c.
36. When using a woven material for a fabric filter, the efficiency will be low
before:
a. high pressure drops occur
b. the open spaces in the weave are bridged and the cake is formed.
c. an air-to-cloth ratio of 16 to 1 is achieved.
d. the temperature of the baghouse reaches 250°F.
37. Modern wet scrubbing systems for MWIs are typically capable of removing:
a. 10% to 35% of the S02 in the flue gas.
b. 40% to 55% of the SO2 in the flue gas.
c. 60% to 85% of the S02 in the flue gas.
d. 90% to 99% of the S02 in the flue gas.
38. Modern dry scrubbing systems for MWIs are typically capable of removing:
a. 10% to 35% of the S02 in the flue gas.
b. 40% to 55% of the SO2 in the flue gas.
c. 60% to 85% of the S02 in the flue gas.
d. 90% to 99% of the SO2 in the flue gas.
39. Blowdown is a standard operation in recovery boilers for controlling the:
a. pH in the boiler water which could cause fireside corrosion.
b. dissolved solids in boiler water which could cause deposits to form.
c. dissolved gases in the feedwater which would lead to formation of
deposits which often lead to tube failures.
d. hardness of the condensate and the accumulation of deposits on the
condenser.
e. silica level in the feedwater which could harm the feedwater pump.
Post-Test-8
-------
40. A MWI fabric filter has an inlet dust loading of 0.02 Ib/acfm with a volumetric
flow rate of 2,500 acfin. If the nominal velocity through the filter is 10 ft/min,
the air-to-cloth ratio will be:
a. .2 ft-lb/min
b. 2,500 ft2/min
c. 50 Ib/min
d. 10 cfm/ft2
41. In comparison to teflon coated fiberglass, natural fibers (e.g., cotton & wool)
used for bags in a fabric filter:
a. have unique wear resistance advantages for pulse-jet cleaning of wet
scrubber applications.
b. have maximum operating temperature limits which are lower.
c. are more expensive to purchase.
d. have better chemical resistance to acids.
42. Approximately of the total weight (mass) of particulates leaving the final
combustion chamber of typical MWIs is associated with particles that are
smaller than 1.0 micrometers.
a.
b.
c.
d.
e.
15%
50%
85%
> 95%
43. A pH value of 7.0 for the liquid leaving a wet scrubber is an indication that the
solution is:
a. acidic and potential tube corrosion will be problem.
b. basic and water tube corrosion will be a problem.
c. basic but water tube corrosion problems are probably under control.
d. neutral, neither basic or acidic.
44. The major collection mechanism(s) responsible for droplets removed by mist
eliminator of a wet scrubber is (are) , depending upon the droplet size.
a. impaction.
b. impaction and interception.
c. impaction, interception and diffusion.
d. adsorption.
Post-Test-9
-------
45. A typical low energy wet scrubber used with a lime-based scrubbing liquid for
acid removal would be:
a. a pack tower with countercurrent flow.
b. a baffle plate scrubber.
c. a system with a venturi scrubber with an impingement scrubber.
d. a venturi scrubber.
46. The major collection mechanism(s) responsible for removal of particles by a
fabric filter is (are):
a. impaction.
b. impaction and interception.
c, impaction, interception and diffusion.
d. absorption.
47. The phenomena of a boiler level changing as the steam flow increases is
characterized by:
a. shrink, associated with a decrease in steam pressure.
b. swell, associated with an increase in steam pressure.
c. shrink, associated wit an increase in steam pressure.
d. swell, associated with a decrease in steam pressure.
48. Reverse-air cleaning of fabric filters use:
a. a pulse of pressurized air which causing the bags to expand.
b. air flow changes in direction, causing the bags to collapse.
c. the oscillating motion or sonic horns which dislodge the dust.
d. baghouse pressurization achieved by closing a damper.
49. A fiber that has very good resistance to acidic and alkaline attack and a
relatively high maximum temperature limit is:
a. cotton
b. teflon
c. fiberglass
d. wool
50. The energy used to force particles to collide with liquid droplets in an
impingement plate scrubber is typically supplied by:
a. the pressure head of the gas stream.
b. the pressure head of the liquid stream.
c. gravity forces.
Post-Test-10
-------
NAME:
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SRATOR OPERATOR TRAINING
ANSWER SHEET
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Post-Test Answer Sheet-1
-------
NAME: CORRECT A N S W E R S
MEDICAL WASTE INCINERATOR OPERATOR TRAINING
POST-TEST ANSWER SHEET
Instructions: Enter the appropriate answer on this Answer Sheet,
Post-Test Answer Sheet-2
-------
LESSON PLAN NUMBER 1
INTRODUCTION
Goal: To introduce the participants to the goals of the training program and
requirements for Operator Certification.
Objectives: Upon completion of this unit, an operator should be able to:
1. Discuss the regulatory basis for operator training requirements,
2. Understand that the regulatory procedures regarding certification may
vary from state to state, but that the certification requirements should
be equivalent to those of the ASME Standard.
3. Understand the purpose of the Pre-Test and the Post-Test in the
current training program.
4. Distinguish between the testing in the training program and the
testing requirements for ASME Certification.
5. Identify the three parts of the ASME QMO Examination for
Certification as Operators and Operator Supervisors.
6. Discuss the qualifications required for Operator Certification under the
ASME Standard.
Lesson Time: Approximately 30 minutes
Suggested
Introductory
Question:
1.
Presentation
Summary
Outline:
Projection
Slides:
Where do you learn about what's happening in the area of MWI
regulation?
Regulatory Requirements: Training/Certification
Course Overview
Purpose of Pre-Test and Post-Test
ASME Certification Procedures
See the following pages.
1-1
-------
Slide 1-1
CLEAN AIR ACT
AMENDMENTS (CAAA) OF 1990
Develop Training & Certification
Require Operators to be Trained
Publish New Source Performance
Standards and Emission Guidelines
Regulate Through State Plans
-------
Slide 1-2
MEDICAL WASTE
INCINERATOR OPERATOR
TRAINING PROGRAM
Goal: Adequate Understanding to Pass
All Parts of the ASME
Certification Examination
-------
Slide 1-3
MEDICAL WASTE
INCINERATOR OPERATOR
TRAINING PROGRAM
Focus: Basis for Equipment Operation
and Maintenance
Basis for Good Combustion Practice
and Environmental Control
-------
Slide 1-4
COURSE HANDBOOK
ORGANIZATION
Unit Topic
1
2, 10
3,4
5-10
11, 12
13,14
15-17
18,19
Part I, Incineration & Monitoring
Introduction
Environmental Concerns & Regulations
Medical Waste Properties & Handling
Incinerator Equipment & Combustion
Instrumentation
System Operation & Maintenance
Part II, Air Pollution Control Devices
Control of Pollutants
System Operation & Maintenance
Part III, Heat Recovery Systems
20, 21 Basic Concepts in Boiler Systems
22, 23 Boiler Design & Operational Features
-------
Slide 1-5
TRAINING PROGRAM
TESTING
Pre-Test
Post-Test
Same Form and Difficulty
Measures Training Effectiveness
-------
Slide 1-6
ASME MWI CERTIFICATION
REQUIREMENTS
High School Diploma or Equivalent
Six Months of Acceptable Experience
Demonstration of Operational Abilities
Passing of MWI Certification Examination
-------
Slide 1-7
ASME OPERATOR
CLASSIFICATIONS
Operator
Class A: MWI with APCD & Heat Recovery
Class B: MWI with Heat Recovery System
Class C: MWI with APCD System
Class D: MWI without APCD or Heat Recovery
Operator Supervisor
Class A: MWI with APCD & Heat Recovery
Class B: MWI with Heat Recovery System
Class C: MWI with APCD System
Class D: MWI without APCD or Heat Recovery
Special Operator
Class A: MWI with APCD & Heat Recovery
-------
Slide 1-8
ASME MWI CERTIFICATION
EXAMINATION
Part I, Incineration & Monitoring
• Basic Principles (30%)
• Equipment (30%)
• Operations (40%)
Part II, Air Pollution Control Devices
• Basic Principles (30%)
• Equipment (30%)
• Operations (40%)
Part III, Heat Recovery Systems
• Basic Principles (30%)
• Equipment (30%)
• Operations (40%)
-------
-------
LESSON PLAN NUMBER 2
ENVIRONMENTAL CONCERNS AND REGULATIONS
Goal:
To provide a review of the general regulatory environment related to
MWI unit operations.
Objectives: Upon completion of this unit, an operator should be able to:
1. Discuss the basis for public concerns about medical waste
management.
2. Relate to the history of the development of solid waste and
incineration issues.
3. Name the primary federal legislative acts which provide for federal
regulation of medical waste and the emission of air pollutants.
4. Explain the relationship between federal legislation and local air
pollution and solid waste management regulations.
5. Identify the regulatory acronyms: RCRA, CAA, NAAQS, PSD, NSPS
and OSHA.
6. Identify some important aspects of an operator's role in public
relations.
Lesson Time: Approximately 35 minutes
Suggested
Introductory
Question: What is your favorite acronym?
Presentation
Outline: Environmental Concerns and Regulations
Public Relations & Public Concerns
Operator's Role in Public Relations
Solid Waste Laws & Regulations
Air Pollution Laws & Regulations
Operating Permit Requirements
Occupational Health & Safety Act
Projection Slides: See the following pages.
2-1
-------
Slide 2-1
PUBLIC RELATIONS IN
WASTE MANAGEMENT
Out of Sight, Out of Mind
Concern About Health & Environment
Support for Recycling
-------
Slide 2-2
ACRONYMS
NIMBY
YIMBY
BANANA
NIMTO
Not in My Back Yard
Yes, in My Back Yard
Build Absolutely Nothing
Anywhere Near Anybody
Not in My Term of Office
-------
Slide 2-3
SOLID WASTE INCINERATION
PUBLIC RELATIONS
Concern About Health
• Ground Water Contamination from Ash
• Toxic Air Pollutant Emissions
• Pathogens: Transmission of Disease
- Hepatitis B Virus (HBV)
- Human Immunodeficiency Virus (HIV)
-------
Slide 2-4
PUBLIC RELATIONS
PHENOMENA
Basis for Public's Mistrust:
• Impact of Past "Acceptable Practices"
• Concern About Toxic Emissions
• Potential for Traffic Accidents
-------
Slide 2-5
PUBLIC RELATIONS IN
WASTE MANAGEMENT
Problems Which Are "Owned" Can Be Solved
Public Must Be Informed
Environmental Controls Are Available
-------
Slide 2-6
OPERATOR'S ROLE IN PUBLIC
RELATIONS
O
Operators Must
• Be Trustworthy
• Be Certified as Being Qualified
• Know What Is Expected
• Demonstrate Willingness to
- Execute Responsibilities
- File Reports
- Communicate
- Assure Safety
-------
Slide 2-7
FEDERAL SOLID WASTE LAWS
& REGULATIONS
Resource Conservation and Recovery Act, RCRA
Subtitle C: Hazardous Waste Regulation
Manifest System
Subtitle D: Solid Waste Regulation
Sanitary Landfill Standards
-------
Slide 2-8
HISTORIC
INCINERATION ISSUES
Smoke & Odor From Incinerators
Toxic Emissions
Ground Water Contamination From Ash
-------
Slide 2-9
FEDERAL AIR POLLUTION
LAWS & REGULATIONS
Clean Air Act, CAA
State Implementation Plans
State Rules and Regulations Must Be
at Least as Strict as the Applicable
Federal Requirements and Approved
by the USEPA
-------
Slide 2-10
CLEAN AIR ACT
REGULATIONS
New Source Performance Standards, NSPS
-------
Slide 2-11
OTHER CLEAN AIR ACT
REGULATIONS
National Ambient Air Quality
Standards, NAAQS
Criteria Air Pollutants
Secondary Air Pollutants
Non- Attainment Areas
Prevention of Significant
Deterioration, PSD
-------
Slide 2-12
CRITERIA POLLUTANTS
Paniculate Matter (PM)
Sulfur Dioxide
Carbon Monoxide
Nitrogen Dioxide
Lead
Ozone
-------
Slide 2-13
NATIONAL EMISSION
STANDARDS FOR HAZARDOUS
AIR POLLUTANTS (NESHAP)
Identify Toxic Air Pollutants
Set Maximum Emission Limits
Apply Equally to New & Existing Units
-------
Slide 2-14
CLEAN AIR ACT
AMENDMENTS OF 1990,
CAAA
New Units: New Source Performance Standards
Existing Units: Emission Guidelines
-------
Slide 2-15
MEDICAL WASTE
TRACKING ACT
Establish a Medical Waste Tracking System
Define Regulated Medical Waste
Impose Record Keeping Requirements
Impose Penalities for Non-Compliance
Initiate Research on Risks and Exposures
-------
Slide 2-16
OPERATING PERMIT
REQUIREMENTS
Air Pollution Monitoring & Reporting
Waste Processing Records
Ash Sampling and Testing Requirements
Waste Water Permit Requirements
OSHA Accident Reporting Requirements
-------
Slide 2-17
OCCUPATIONAL SAFETY AND
HEALTH ACT, OSHA
Safety Standards to Protect Employees
Inspections Requirements & Penalties
Accident Reporting Requirements
-------
Slide 2-18
OSHA BLOODBORNE
PATHOGEN STANDARD
Exposure Control Plan
Exposure Determination
Schedule & Methods of Compliance
Procedures for Evaluating an Incident
Information, Training, and Record Keeping
Engineering and Work Practice Controls
Personal Protective Equipment
Hepatitis B Vaccination
Labels and Signs
-------
-------
LESSON PLAN NUMBER 3
CHARACTERIZATION OF MEDICAL WASTE
Goal:
To provide information about the terms used to characterize medical
waste and the physical properties of importance for incineration.
Objectives: Upon completion of this unit, an operator should be able to:
1. Identify the following acronyms: MSW, LLRW, MWC, MWI, HWI.
2. Describe four of the factors necessary for disease development.
3. Name some types of wastes excluded from segregated medical waste.
4. Name three terms used to characterize the metals in medical waste
which cause serious health effects.
5. List five types of health care facilities which generate medical waste.
6. Identify five toxic metals which are found in medical waste, and name
four items which often have toxic metals in their composition.
Lesson Time: Approximately 35 minutes
Suggested
Introductory
Questions:
1.
2.
3.
4.
What are some waste materials that are designated as undesirable or
untreatable at your MWI unit.
Give three examples of wastes which have a detrimental impact either
on MWI equipment or on unit performance.
Give an example of wastes which are acceptable for combustion in
special MWIs but not at general MWI units.
How much medical waste is produced per patient per day?
3-1
-------
Presentation
Summary
Outline: Characterization of Medical Waste
Waste Mixture Characterizations
Definitions of Medical Waste
Sources & Generation Factors
Medical Waste Composition & Fuel Properties
Heavy Metals & Ash Characteristics
Projection Slides: See the following pages.
3-2
-------
Slide 3-1
CHARACTERIZATION OF
WASTE MIXTURES
O
• Type
• Source
• Material Constituents
• Characteristic Features
-------
Slide 3-2
SOLID WASTE ACRONYMS
BMW Biomedical Waste
HWI Hazardous Waste Incinerator
LLRW Low-Level Radioactive Waste
•MSW
•MWC
•MWI
•RDF
•RMW
Municipal Solid Waste
Municipal Waste Combustor
Medical Waste Incinerator
Refuse Derived Fuel
Regulated Medical Waste
-------
Slide 3-3
MEDICAL WASTE TERMS
• Biohazardous Waste
• Biological Waste
• Biomedical Waste
• Cytotoxic Waste
• Hospital Waste
• Infectious Waste
• Low Level Radioactive Waste
• Medical Waste
• Microbiological Waste
• Pathogenic Waste
• Pathological Waste
• Potentially Infectious Waste
• Red Bag Waste
• Regulated Medical Waste
• Segregated Medical Waste
• Sharps
• Special Medical Waste
-------
Slide 3-4
DEFINITION OF
MEDICAL WASTE
Solid Waste Generated in the:
• Diagnosis, Treatment and Immunization
of Humans or Animals
• Research Related to Diagnosis,
Treatment and Immunization
• Production and Testing of Biologicals
-------
Slide 3-5
INFECTIOUS WASTE
CDC: All Blood and Body Fluids
from All Patients
USEPA: Waste Capable of Producing an
Infectious Disease
-------
Slide 3-6
FACTORS NECESSARY FOR
DISEASE DEVELOPMENT
1. Presence of a Pathogen
2. Sufficient Virulence
3. Sufficient Dose
4. Portal or Entry (Contact)
5 Susceptible Host
-------
Slide 3-7
REGULATED
MEDICAL WASTES
Class
Description
1
3
4
5
6
7
Cultures & Stocks of Infectious Agents &
Associated Biologicals (including Vaccines)
Pathological Waste (Human Tissues,
Organs, Body Parts, Body Fluids)
Human Blood & Blood Products
Used Sharps (Needles, Syringes, Scalpel
Blades, Pipettes, Broken Glass)
Animal Wastes (Carcasses & Body Parts)
Isolation Wastes
Unused Sharps (Discarded)
-------
Slide 3-8
BIOLOGICAL HAZARD
SYMBOL
-------
Slide 3-9
SOURCES OF REGULATED
MEDICAL WASTE
Type of Facility
Hospitals
Long Term Health Care
Physicians' Offices
Clinics
Laboratories
Dentists1 Offices
Veterinarians
Funeral Homes
Tons/Yr Percentage
Blood Banks
Totals
359,000
29,600
26,400
15,500
15,400
7,600
4,600
3,900
2,400
465,000
77.1
6.4
5.7
3.6
3.3
1.6
1.0
0.8
0.5
100.0
-------
Slide 3-10
HOSPITAL WASTE
GENERATION FACTORS
(Ib/bed/day)
GENERAL INFECTIOUS
Georgetown Univ. Hospital 21.6 0.28
N.Y. Department of Health 20 4.0
Rutala 17-23 2.4
Cross 24.8 3.2
Minnesota AQD 1.2
-------
Slide 3-11
FACTORS INFLUENCING THE
AMOUNT OF SEGREGATED
MEDICAL WASTE
1. Type of Facility
2. Procedures Performed & Care Provided
3. Waste Management Practices
4. Applicable Regulations
-------
Slide 3-12
SEGREGATED MEDICAL
WASTE COMPOSITION
• Plastics
• Paper
• Rubber
• Textiles
• Glass
• Body Fluids
• Metals
-------
Slide 3-13
MOISTURE & HEATING
VALUES OF SELECTED
WASTES
Waste Mixtures
Medical Waste (Dry)
Refuse Derived Fuel
Medical Waste (Wet)
Municipal Solid Waste
Pathological Waste
Plastics
Alcohol, Disinfectant
Swabs, Absorbents
Gauze, Pads, Swabs,
Garments, Paper
Bedding, Shavings,
Paper, Fecal Matter
Fluids, Residuals
Human Anatomical
Infected Animals
Moisture
(Percent)
9.0
18.4
37.3
24.2
85.0
0-1
0-0.2
0-30
0-30
20-46
80 - 100
70-90
60-90
Heating Value
(Btu/lb)
9,240
6,110
5,290
4,830
1,000
13,860-20,000
10,980-14,000
5,600-12,000
5,600-12,000
4,000-8,100
0 - 2,000
800 - 3,600
900 - 6,400
-------
Slide 3-14
INCINERATOR INSTITUTE OF
AMERICA CLASSIFICATIONS
Type 0 Trash with 8,500 Btu/lb
10% moisture, 5% incombustible
Type 1 Rubbish with 6,500 Btu/lb
25% moisture, 10% incombustible
Type 2 Refuse with 4,300 Btu/lb
50% moisture, 7% incombustible
Type 3 Garbage with 2,500 Btu/lb
70% moisture, 5% incombustible
Type 4 Human & Animal Parts, with 1,000 Btu/lb
85% moisture, 5% incombustible
Type 5 Industrial By-Product Wastes which are
gaseous, liquid, & semi-liquid
Type 6 Industrial Solid Byproduct Waste
rubber, plastic, wood wastes
Type 7 Municipal Sewage Sludge Wastes
residue from processing of raw sludge
-------
Slide 3-15
MEDICAL WASTE ULTIMATE
ANALYSIS EXAMPLES
Element
WET SAMPLE DRY SAMPLE
Carbon
Hydrogen
Oxygen
Nitrogen
Chlorine
Sulfur
Inorganics (ash)
Moisture
Percent by
Weight
Percent by
Weight
Total
36.98
5.21
8.56
0.08
1.76
0.01
10.14
37.26
100.0
51.1
6.2
21.3
0.5
4.1
0.2
7.6
9.0
100.0
-------
Slide 3-16
COMMON TERMS WHICH
CHARACTERIZE METALS
TOXIC METALS
Threat to Human Health
HEAVY METALS
High Molecular Weight
TRACE METALS
Found in Low Concentrations
-------
Slide 3-17
POSSIBLE SOURCES OF HEAVY
METALS IN MEDICAL WASTE
ITEM
METAL OF CONCERN
Batteries
Autoclave Bag
Red Bag
Sharps Container
Rubber Cap
Sharps Tray
Syringe
Urine Container
Lead, Mercury, Cadmium, Nickel
Lead, Chromium
Lead, Chromium
Lead, Chromium
Arsenic, Cadmium, Lead, Chromium
Lead, Chromium
Arsenic, Cadmium, Lead, Chromium
Cadmium, Lead, Chromium
-------
Slide 3-18
AVERAGE COMPOSITIONS OF
MEDICAL WASTE ASH
Component Unit A UnitB UnitC
Carbon (Percent): 1.8 1.7 1.8
Total Dioxin/Furan
(microgram/kg): 1,450. 10.4 25.3
Metals (mg/kg):
Arsenic 3.8 1.6 0.7
Barium 3,810. 2,130. 1,640.
Cadmium 2.7 3.1 1.5
Hexavalent Chromium 5.0 7.4 6.3
Total Chromium 28.2 29.5 13.5
Copper 15,360. 102,700. 2,300.
Lead 66.1 187.5 76.5
Manganese 54.1 73.2 17.9
Mercury 0.1 0.3 0.2
Nickel 43.2 18.6 9.7
Selenium 0.1 0.2 0.1
Silver 2.4 4.6 0.6
Tin 42.5 52.2 70.3
-------
Slide 3-19
EXAMPLES OF COMBUSTIBLES
IN ASH
UNIT D UNITE UNITF
BOTTOM ASH
Carbon, %
L-O-I, %
BAGHOUSE ASH
Carbon, %
L-O-I, %
10.4
15.3
3-16
7-20
6.2
19.5
4-5
15-20
-------
-------
LESSON PLAN NUMBER 4
MEDICAL WASTE SAFETY, HANDLING AND TREATMENT
Goal: To provide information about general safety and medical waste
handling hazards, packaging requirements, treatment technologies,
and ash disposal.
Objectives: Upon completion of this unit, an operator should be able to:
1. List three possible hazards associated with MWI operating systems.
2. Identify four other safety hazards which are also found in general
industrial facilities.
3. List six types of personal protection equipment.
4. Discuss the general features required for packaging of used sharps.
5. List three environmental conservation features of a waste
minimization program.
6. Contrast the requirements between packaging of medical waste for on-
site treatment with that of off-site treatment.
7. Discuss environmental issues associated with ash disposal and
ground water contamination.
Lesson Time: Approximately 50 minutes
Suggested
Introductory
Questions:
1.
2.
3.
4.
What advantages do MWIs have over various other treatment
technologies?
Why are MWI ash residues often testing before they can be disposed of
in a monofill?
Why are the packaging requirements for on-site disposal less
restrictive than those for off-site disposal?
Ask operator participants to discuss their experiences with special MWI
4-1
-------
hazards associated with entering a fabric filter bag house, combustion
chamber, or other confined space.
5. Ask operator participants to discuss their experiences with the general
safety issues associated with noise, rotating equipment, hot metal
surfaces, ladders, and how personal protective equipment can be misused.
Presentation
Summary
Outline:
Projection
Slides:
Source
of
Graphics:
Slide 4-18
Slide 4-19
Slide 4-20
Slide 4-22
Medical Waste Safety, Handling and Treatment
General Health and Safety
Standard Safety Concerns
Personal Protection Equipment
Waste Management: Source Reduction, Recycling
Packaging Requirements
Scale Operations & Record Keeping
Segregation of Unacceptable Wastes
Storage
Alternative Treatment Techniques:
Autoclave
Microwave
Chemical Treatment
Others
Landfill Disposal of Ash
See the following pages.
Courtesy of AMSCO International, Inc., Erie, PA
Redrawn from an illustration provided courtesy of ABB Sanitec, Inc., a
subsidiary of ABB Environmental Services, Inc.
Courtesy of Medical Safe Tec, Inc., Indianapolis, IN
Redrawn from: Donald A Wallgren, "Modern Landfill Technology: The
Cornerstone of an Integrated Solid Waste Management Program,"
Integrated Solid Waste Management. Frank Rreith, editor, Genium
Publishing Corporation, Schenectady, NY, 1990, p. 129.
4-2
-------
Slide 4-1
GENERAL HEALTH & SAFETY
1. Training About Health & Safety
2. Personal Protection Equipment
3. Recognition of Hazards
4. Consequences of Exposures
-------
Slide 4-2
MAJOR HAZARDS OF
OPERATIONAL SYSTEMS
1. Exposure to Infectious Agents
Needle Sticks: AIDS & Hepatitis
Medical Waste Spills
Inhalation of Particulates
2. Combustion System Explosions
Ignition of Explosive Mixtures
3. Boiler System Explosions
Loss of Water, Tube Failures
-------
Slide 4-3
OTHER MWI SYSTEM
SAFETY HAZARDS
Skin Burns from Contacting Hot Objects
Eye Damage from Viewing Flames
Fire Hazards
Inhalation of Fugitive Dust
Confined Space Hazards
Cuts Associated with Removing Blockages
-------
Slide 4-4
OTHER STANDARD SAFETY
CONCERNS
• Electrical Shock
• Corrosives
• Rotary Equipment
• Exposure to Hot Surfaces
• Noise
• Awkward Access
• Movement of Heavy Objects
-------
Slide 4-5
PERSONAL PROTECTION
EQUIPMENT
1. Hearing Protection
2. Heavy Gloves
3. Hard Hat
4. Respirator
5. Goggles
6. Safety Shoes
7. Proper Clothing
-------
Slide 4-6
SYMPTOMS OF ILLNESS
1. Headaches
2. Lightheadedness
3. Dizziness
4. Nausea
5. Loss of Concentration
6. Difficulty in Breathing
7. Chest Pains
8. Exhaustion
-------
Slide 4-7
MEDICAL WASTE MATERIALS
FLOW PATH
1. Generation at its Source
2. Collection & Packaging
3. Transporation
4. Receiving & Weight Scales Operation
5. Medical Waste Storage
6. Treatment (Incinerator, etc.)
7. Residue Removal & Disposal
-------
Slide 4-8
WASTE MANAGEMENT
AT THE SOURCE
Source Reduction
Recycling and Reuse
Packaging
Treatment (Decontamination)
Transporation
-------
Slide 4-9
SOURCE REDUCTION —
WASTE MINIMIZATION
REDUCE QUANTITY
Reusable versus Throwaway
Packaging Materials
REDUCE TOXICITY
Material Substitution
-------
Slide 4-10
RECYCLING
Has Public Support
Reduces the Quantity of Waste
Conserves Natural Resources
Reduces Environmental Impact
May Reduce Disposal Costs
-------
Slide
PACKAGING OF SHARPS
Plastic Sharps Container
• Disposable or Reusable
• Puncture and Leak Resistant
• Closable
• Label or Biohazard Symbol
-------
Slide 4-12
PACKAGING FOR
ON-SITE TREATMENT
Plastic Bags: Single or Double
Plastic Containers: Sealed Lids
Colors: Red, Orange, Blue, White, Clear
Labels: Biohazard Stickers
Biohazard Symbol
Open Carts for On-site Transport
-------
Slide 4-13
PACKAGING FOR OFF-SITE
TREATMENT
II
Rigid
Leak-Resistant
Impervious to Moisture
Strong to Prevent Bursting & Tearing
Sealed to Prevent Leakage
Puncture-Resistant for Sharps
Break-Resistant, Lids/Stoppers for Liquids
-------
Slide 4-14
RECEIVING & SCALE
OPERATIONS FUNCTIONS
1. Establish Performance Records
2. Satisfy Record Keeping Requirements
3. Quantify Ash Removal
4. Restrict Delivery to Facility
-------
Slide 4-15
UNACCEPTABLE AND/OR
UNDESIRABLE MATERIALS
1. Not Permitted - Hazardous, Radioactive
2. Cause Damage - Explosive Chemicals
-------
Slide 4-16
STORAGE
• Locate Indoors or Outdoors
Buildings, Dumpsters, Tractor Trailers
• Limit Access to Authorized Persons (Locked)
• Keep Animals Away
• Protect Against Water, Rain, Wind Damage
• Maintain in Non-Putrescent State
Refrigeration for Pathological Waste
-------
Slide 4-17
MEDICAL WASTE
TREATMENT TECHNIQUES
1. Incineration
2. Autoclave (Steam Sterilization)
3. Microwave Irradiation Treatment
4. Chemical Treatment
5. Thermal Inactivation
6. Irradiation
-------
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-------
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I
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-------
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CN
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rt-
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s
I
3
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-------
Slide 4-21
ISSUES REGARDING ASH
DISPOSAL IN LANDFILLS
Environmental Impact
Landfill or Monofill
Leachate Effect on Combustor
Heavy Metals Concentrations
Fugitive Emissions
-------
C/5
Q
O
o
-------
Slide 4-23
LANDFILL REQUIREMENTS
UNDER RCRA
• Containment System
Cap System
Bottom Liner
• Leachate Collection & Treatment
* Groundwater Monitoring
* Gas Monitoring & Collection
-------
Slide 4-24
MONOFILL
Hazardous Waste: Concentrations
Below Specified Limits
Chemical Waste
HWIAsh
MWIAsh
-------
LESSON PLAN NUMBER 5
MEDICAL WASTE INCINERATORS
Goal;
To provide descriptive information about modern combustion
equipment used for burning medical waste, including various
incinerator designs with automatic feeders, hearths and ash removal
systems.
Objectives: Upon completion of this unit, an operator should be able to:
1. Identify three of the basic types of MWIs and contrast the combustion
features of each.
2. Characterize the major design and construction features of the older,
multiple chamber, excess-air incinerator units.
3. Note the similar and contrasting features of controlled-air incinerators
and membrane waterwall units.
4. Distinguish between starved-air and controlled-air units.
5. Describe the typical two-stage combustion features of modular
incinerators.
6. Contrast the differences between integral boilers and waste heat
recovery boilers.
7. Contrast the combustion environment in a refractory wall incinerator
with a waste heat recovery boiler with that of in an integral boiler.
8. List the unique features of a rotary kiln incinerator.
9. Describe operating strategies which are designed to help overcome the
combustion problems caused by medical waste being a highly variable
material.
10. Describe the four principal burning processes or activities which are
found on continuous hearth burning systems.
Lesson Time: Approximately 60 minutes
5-1
-------
Suggested
Introductory
Activity:
Presentation
Summary
Outline:
Projection
Slides:
Source
of
Graphics:
Slide 5-5
Slide 5-6
Slide 5-9
Slide 5-10
During the introduction of MWI technology, it is recommended that
selected individuals from among the participants be invited to describe
the general features of the MWI unit which they operate. Projection of
an illustration of the basic unit design will be helpful. You may want
to ask them to describe the best features or those which cause the
most operational "headaches."
Medical Waste Incinerators
MWI Designs & Applications
Multiple Chamber, Excess-Air
Modular Controlled-Air
Air & Flue Gas Flow Path
Rotary Kiln
Recovery Boilers & Waterwall Units
Feeding Equipment & Charging Strategies
Fuel-Bed Combustion
Hearth Designs & Ash Removal
See the following pages.
"Medical Waste Incinerators -- Background Information for Proposed
Standards and Guidelines: Process Description Report for New and
Existing Facilities," U. S. Environmental Protection Agency, Draft
Reports, April 30, 1992.
Peter Torkelson, "Report on the Assessment of Operations and
Emissions of On-Site Medical Waste Incinerators," Minnesota Pollution
Control Agency, December 1991, pp. 1-6.
Peter Torkelson, "Report on the Assessment of Operations and
Emissions of On-Site Medical Waste Incinerators," Minnesota Pollution
Control Agency, December 1991, pp. 1-6.
Shenandoah Manufacturing Company, Inc., Harrisonburg, VA,
Undated Brochure.
5-2
-------
Slide 5-11 "Operation, Maintenance and Parts Manual, Pyrolytic Incinerator,"
• Publication Number CBK-6826 9/88, Cleaver Brooks Division of Aqua-
Chem, Inc., Milwaukee, Wisconsin, p. 1-3.
Slide 5-12 "Controlled Air Incineration," Joy Energy Systems, Inc., Charlotte, NC,
Undated Brochure.
Slide 5-14 R G. Barton, et al., "State-Of-The-Art Assessment of Medical Waste
Thermal Treatment," Report to Risk Reduction Engineering
Laboratory, USEPA, and California Air Resources Board, June 15,
1990, pp. 37-80.
Slide 5-16 R. G. Barton, et al., "State-Of-The-Art Assessment of Medical Waste
Thermal Treatment," Report to Risk Reduction Engineering
Laboratory, USEPA, and California Air Resources Board, June 15,
1990, pp. 37-80.
Slide 5-18 Steam. Its Generation and Use. 39th Edition, Babcock and Wilcox,
New York, 1978, p. 16-3.
Slide 5-20 Basic Environmental Engineering, Inc., Glen Ellyn, IL, Undated
Brochure, Received: April 1992.
Slide 5-22 R. G. Barton, et al., "State-Of-The-Art Assessment of Medical Waste
Thermal Treatment," Report to Risk Reduction Engineering
Laboratory, USEPA, and California Air Resources Board, June 15,
1990, pp. 37-80.
Slide 5-25 W. D. Turner, Thermal Systems for Conversion of Municipal Solid
Waste. Vol. 2: Mass Burning of Solid Waste in Large-Scale
Combustors: A Technology Status Report. Report ANL/CNSV-TM-120,
Vol. 2, Argonne National Laboratory, December 1982, pp. 43-168.
Slide 5-27 R. G. Barton, et al, "State-Of-The-Art Assessment of Medical Waste
Thermal Treatment," Report to Risk Reduction Engineering
Laboratory, USEPA, and California Air Resources Board, June 15,
1990, pp. 37-80.
Slide 5-28 R. G. Barton, et al., "State-Of-The-Art Assessment of Medical Waste
Thermal Treatment," Report to Risk Reduction Engineering
Laboratory, USEPA, and California Air Resources Board, June 15,
1990, pp. 37-80.
Slide 5-30 "Integrated Waste Services, Information Summary," Consumat
Systems, Inc., Richmond, Virginia, Undated Brochure.
5-3
-------
Slide 5-1
PURPOSE OF MEDICAL WASTE
INCINERATION
Decontamination
Destruction by Oxidation for:
• Mass Reduction
• Volume Reduction
• Making Waste Unrecognizable
-------
Slide 5-2
EXISTING MEDICAL WASTE
INCINERATORS
Multiple Chamber, Excess-Air, Refractory Wall
Single Chamber, Excess-Air, Refractory Wall
Modular, Controlled-Air, Refractory Wall
Rotary Kiln, Excess-Air, Refractory Wall
Multistage Combustion, Waterwall
-------
Slide 5-3
EXISTING MWIs WITH
CAPACITY ABOVE 50 LB/HR
TYPE OF DESIGN NUMBER OF UNITS
Batch Controlled-Air &
Batch Pathological
Hospital 115
Intermittent Controlled-Air
Hospitals 775
Laboratories & Research Units 73
Nursing Homes 39
Animal Shelters & Veterinaries 10
Intermittent Pathological
Hospitals 158
Animal Shelters & Veterinaries 86
Laboratories & Research Units 50
Nursing Homes 14
Continuous Controlled-Air
Hospitals 62
Commercial 39
Municipal Waste Combustors 17
Laboratories & Research Units 4
Rotary Kiln, Excess-Air
Hospitals 10
Municipal Waste Combustors 2
Commercial 2
Total 1,456
-------
Slide 5-4
MULTIPLE CHAMBER
EXCESS-AIR UNITS
Refractory Wall Designs
High Excess Air & Gas Velocities
Particle Entrainment
Smoke
-------
Slide 5-5
MULTIPLE CHAMBER
"RETORT1 INCINERATOR
Charging
Door
Sladt
Ignition Chamber
Hitflh
Flam*
Port
Secondary
Air Ports
Secondary
Bumtr Port
Miring
Chamber
First
Undtftitanh
Port
-------
WH
S
<
-------
Slide 5-7
MODULAR CONTROLLED-AIR
UNITS
Factory Manufactured
Refractory-Wall
Starved-Air (in Primary Chamber)
Low Velocity in Primary
Low Paniculate Entrainment
-------
Slide 5-8
TYPICAL AIR & FLUE GAS
FLOW PATH
1. Forced Draft Fans
2. Underfire Air
3. Primary Combustion Chamber
4. Flame Port Secondary Air
5. Secondary Fuel Burner
6. Recovery Boiler
7. Air Pollution Control Devices (APCDs)
8. Induced Draft Fan
9. Stack
-------
Slide 5-9
MANUALLY CHARGED
MODULAR
CONTROLLED-AIR UNIT
Wall
Charging Door
Stack
t
Air Inductor Ring
Secondary
Chamoer
Primary Chamber
o
Burner
Burner
Ash Clean
Out Door
Source: Cross/Tessiioie & Associates. P.A., Orlando, FL.
-------
Slide 5-10
CONTROLLED-AIR UNIT
WITH A PNEUMATIC
LOADER
STACK CAP
STACK
SECONDARY
CHAMBER
AUXILIARY
BLOWER
SECONDARY
BURNERS
PRIMARY
BURNER
PRIMARY
CHAMBER
CONTROL
CABINET
WATER SPRAY
Source: Shenandoah Manufacturing Company, Harrisonbuig. VA
-------
Slide 5-11
MODULAR
CONTROLLED-AIR OR
STARVED-AIR UNIT
SPARK SCREEN
DRAFT CONTROL
DAMPER ASSEMBLY
PYROLYTIC
INCINERATOR
ASSEMBLY
STACK ASSEMBLY
THERMAL REACTOR -i
THERMOCOUPLE
-EXPANSION
JOINT
RETENTION
CHAMBER
ASSEMBLY
PPER
FLOW
CONTROL
ORIFICE
THERMAL REACTOR-J
ASSEMBLY
RETENTION CHAMBER
THERMOCOUPLE
LOWER FLOW
CONTROL ORIFICE
HEAT RECOVERY
OR SYNCHROF1RE
BOILER ASSEMBLY
Courtesy of Clever Brooks, Division of Aqua-Chem. Inc., Milwaukee, Wl.
-------
i
°
!L
CO
t
i
-------
Slide 5-13
ROTARY KILN INCINERATORS
Ram or Auger Feeding System
Refractory Lined Rotary Chamber
Excess-Air Combustion
Tumbling Action in Primary
Secondary Combustion Chamber
-------
1
in
o
>,
(J
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o
-------
Slide 5-15
COMBUSTION CHAMBER WALL
CONSIDERATIONS
REFRACTORY WALL
Thermal Insulation
Protection Against Thermal Damage
WATERWALL
Radiant Energy Extraction
-------
ae
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-------
Slide 5-17
WATERWALL INCINERATION
Tubes of Water: Membrane Wall
Waste-to-Energy
Radiant Energy Extraction
-------
u
o
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ii
Erl
-------
Slide 5-19
WATERWALL MWIs
Waterwall in Primary Chamber
Stoichiometric Air Supply
Special Moveable Hearth
Special Air Nozzle System
Multistage Combustion
Auxiliary Fuel Burner
Special Air Injector Designs
-------
J
I
s
g
5
05
•s
(U
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-------
Slide 5-21
FEEDING EQUIPMENT
Manual Batch Charging
Manual Intermittent Charging
Automatic Ram Feeders
Intermittent Charging
Transfer Rams: Bed Agitation
Continuous Auger System
-------
Slide 5-22
INTERMITTENT WASTE
FEEDING
WASTE LOAD INTO HOPPER
START
FIRE DOOR OPENS
STEP1
J
RAM REVERSES TO CLEAR
FIRE DOOR
STEP 3
FIRE DOOR CLOSES
STEP 4
••
RAM COMES FORWARD
STEP 2
RAM RETURNS TO START
STEPS
-------
Slide 5-23
ISSUES OF FUEL VARIABILITY
1. Fuel Size
2. Heating Value
3. Volatility
4. Fuel Moisture
5. Ash (Incombustibles)
-------
Slide 5-24
OPERATING STRATEGIES FOR
FUEL VARIABILITY
1. Mix Wet and Dry Wastes
2. Mix Heavy Boxes With Light Boxes
3. Compensate Through Equipment Design
-------
H
OH
U
O
U
O
H
C/3
P
p
CQ
OT5
-------
Slide 5-26
HEARTH DESIGNS
1. Single Fixed Hearth
2. Multiple Stepped Fixed Hearths
3. Moveable Fixed Hearths
4. Rotary Kiln Hearths
-------
Slide 5-29
BOTTOM ASH REMOVAL
SYSTEM OPTIONS
Manual Ash Removal
• Batch & Intermittent Charged Units
• Removal of Dry Residues
Mechanical Ash Removal
• Continuous Duty Units
• Dry Ash Removal Systems
• Wet Ash Removal Systems
• Automatic or Semi-Automatic Operations
-------
H
P
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ffiffi
s
" 5 >«—i ®
Q CD
-------
-------
LESSON PLAN NUMBER 6
COMBUSTION PRINCIPLES I: BASIC COMBUSTION
Goal: To provide basic information about the chemical changes which take
place during medical waste combustion.
Objectives: Upon completion of this unit, an operator should be able to:
1. List five chemical elements in medical waste (from ultimate analysis).
2. Contrast the behavior of organic and inorganic materials during
combustion.
3. Name examples of hydrocarbon (organic) material found in medical
waste.
8. Distinguish between a chemical element and component material.
4. Name examples of inorganic material found in medical waste.
5. List three major products of complete combustion.
6. List two major products of incomplete combustion.
7. State the general meaning of a stoichiometric fuel/air mixture.
8. Describe the application of a fuel's ultimate analysis in calculating the
combustion air required.
9. Define excess air and compare its definition with that of theoretical or
stoichiometric air.
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions:
1. How can an operator be helped by knowing about chemistry?
2. What are the differences between excess air, excess oxygen, theoretical
air and stoichiometric air?
6-1
-------
Presentation
Summary
Outline: Combustion Principles I: Basic Combustion
Basic Combustion Concepts
Combustible & Incombustible Substances
Stoichiometric Considerations: Excess-Air & Starved-Air
Complete & Incomplete Combustion Products
Chemical Reaction Equations
Theoretical Combustion of Medical Waste
Combustion Under Excess Air Conditions
Projection
Slides: See the following pages.
6-2
-------
Slide 6-1
BASIC COMBUSTION
CONCEPTS
Fuel and Air Characteristics
Products of Complete Combustion
Complete Combustion Reactions
Excess Air Considerations
-------
Slide 6-2
COMBUSTION: CHEMICAL
REACTION
Rapid Oxidation (Fuel & Oxygen)
Heat and Light Given Off
Products of Combustion:
• Oxides
• Other Compounds
-------
Slide 6-3
COMBUSTIBLE SUBSTANCES
Hydrocarbons, Organic Materials
• Paper & Wood (Cellulose)
• Fossil Fuels
• Plastics
-------
Slide 6-4
INCOMBUSTIBLE SUBSTANCES
Inorganic Materials
• Metals
• Glass, Sand, Ceramics, Concrete
-------
Slide 6-5
EXAMPLE ULTIMATE
ANALYSIS COMPARISONS
Element
Carbon
Hydrogen
Oxygen
Nitrogen
Chlorine
Sulfur
Inorganics (ash)
Moisture
Total
"WET" SAMPLE "DRY" SAMPLE
Percent by
Weight
Percent by
Weight
36.98
5.21
8.56
0.08
1.76
0.01
10.14
37.26
100.0
51.1
6.2
21.3
0.5
4.1
0.2
7.6
9.0
100.0
o
-------
Slide 6-6
ATOMIC STRUCTURE
OF MATTER
• Atoms
• Molecules of One Element
• Molecular Compounds
* Mixtures
* "String Compounds"
-------
Slide 6-7
AIR
Mixture of Oxygen and Nitrogen
Oxygen -21% by Volume
Nitrogen - 79% by Volume
3.76 Moles of Nitrogen
Per Mole of Oxygen in Air
-------
Slide 6-8
DEFINITION OF A
POUND-MOLE
Mass or Weight of Gas Equal to Its
Molecular Weight in Pounds
A Unique Number of Molecules,
Regardless of the Gas
379 Cubic Feet of Gas at Standard
Conditions, Regardless of Gas
-------
Slide 6-9
STOICHIOMETRIC
(THEORETICAL) AIR-FUEL
MIXTURE
• Fuel Completely Burned
• Oxygen Completely Consumed
• Products of Complete
Combustion Are Formed
-------
Slide 6-10
PRODUCTS OF COMPLETE
COMBUSTION
Carbon Dioxide
Water (vapor)
Sulfur Dioxide
Hydrogen Chloride (acid)
Nitrogen (molecular)
Oxygen (molecular)
-------
Slide 6-11
O
PRODUCTS OF INCOMPLETE
COMBUSTION
Carbon Monoxide
Dioxins
Furans
-------
Slide 6-12
OTHER COMBUSTION
PRODUCTS
Nitrogen Oxides
Metal Vapors
Metal Oxides
Metal Chlorides
-------
Slide 6-13
CHEMICAL REACTION
EQUATION
Carbon: C + O2 > CO2
^j ^^
-------
Slide 6-14
BALANCED CHEMICAL
REACTION EQUATIONS
COMBUSTION IN OXYGEN
Carbon: C + Cs
£*
CO
Hydrogen: 2 H2 + O2 - > 2 H2O
Sulfur: S + O
SO2
Chlorine: H2 + 2 Cl
2 HC1
-------
Slide 6-15
BALANCED CHEMICAL
REACTION EQUATIONS
Each Type of Atom Is Conserved
Each Element's Mass Is Conserved
Total Mass Conserved
The Number of Molecules Is Not Conserved
-------
Slide 6-16
EXAMPLE OF BALANCING A
COMBUSTION EQUATION
Methane, CH,, with Stoichiometric Oxygen
L4'
CH4 + 2 02
CO2 + 2 H20
-------
Slide 6-17
COMBUSTION
REACTIONS IN AIR
3.76 Moles of Nitrogen in
Air Per Mole of Oxygen
-------
Slide 6-18
EXAMPLE OF BALANCING A
COMBUSTION EQUATION
Methane, CH., with Stoichiometric Air
4'
CH, + 2 O, + 7.52 N,
*T £• **
CO2 + 2 H2O + 7.52 N2
-------
Slide 6-19
EQUIVALENT MOLECULAR
FORM OF MEDICAL WASTE
H2°
-------
Slide 6-20
THEORETICAL COMBUSTION
OF MEDICAL WASTE IN AIR
C* HO 1SJ PI
-------
Slide 6-21
MASS ANALYSIS OF
STOICHIOMETRIC FUEL
& AIR MIXTURE
Reactants Moles Molecular Weight
Wt. lb./mole Ib.
C4.26H,201.33N.)4C1,17S.006 1.0 83.4 83.4
0.5 HJD 0.50 18 9.0
5.12 02 5.12 32 163.8
19.26 N2 19.26 28 539.3
Total 795.5
-------
Slide 6-22
EXCESS AIR
Air in Excess of Theoretical
Fraction: Extra/Theoretical
Symbol: EA
Total Supply Air is
(1 + EA) x (Theoretical Air)
Oxygen in Flue Gas is
EA x (Theoretical Oxygen)
-------
Slide: 6-23
METHANE COMBUSTION IN
THEORETICAL AIR:
CH4 + 2 O2 + 7.52 N2
CO2 + 2H2O + 7.52 N2
METHANE COMBUSTION IN
• EXCESS AIR:
CR + (1 + EA) (2) O, + (1 + EA) (7.52) N.
L j • i -*. • • j' ^ / \^^r ^+*r — i t A. • • j* *. y if* *^ ^** / 1
CO, + 2H,O + (1 + EA)(7.52)N, + (EA) (2) Q
-------
Slide 6-24
METHANE COMBUSTION,
20 PERCENT EXCESS AIR:
CH4 + 2.4 O2 + 9.024 N.
CO2 + 2 H2O + 9.024 N2 + 0.4 O
-------
Slide 6-25
PRODUCT GAS ANALYSIS,
METHANE @ 20% EA
Products Moles Molar Wt. Mass
Ib./mole Ib.
CO2 1.0 44.0 44.0
H2O 2.0 18.0 36.0
02 0.4 32.0 12.8
N2 9.024 28.0 252.7
Total 12.424 345.5
Dry Gas Total 10.424 309.5
-------
-------
LESSON PLAN NUMBER 7
COMBUSTION PRINCIPLES II: THERMOCHEMISTRY
Goal: To provide basic information about the energy which is released during
medical waste combustion.
Objectives: Upon completion of this unit, an operator should be able to:
1. Understand the concept of a higher heating value (heat of combustion).
2. List the major categories in the proximate analysis of a fuel.
3. Characterize the differences between moisture and volatile matter.
4. Describe the influence of temperature on distillation of volatile gases.
5. Recognize the differences in the general ranges of ignition temperature
of fixed carbon and volatile matter (hydrocarbon gases).
6. Name three heat sink materials which influence combustion.
7. Identify combustion parameters that would be reduced if water was
sprayed into the primary chamber of a modular starved-air unit.
8. Explain why, under excess air conditions, an increase in the excess air
will cause combustion temperatures to decrease.
9. Explain why, under starved-air conditions, an increase in the air
supply will cause an increase in the combustion temperature.
7-1
-------
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions
1.
2.
3.
Presentation
Summary
Outline:
When someone refers to the heating content of a fuel are they referring
to a "higher heating value" or a "lower heating value"?
What is the difference between an ultimate and a proximate analysis?
Why aren't tests for determining the heating value of your waste feed
routinely performed at your facility?
Combustion Principles II: Thermochemistry
Heating Values
Capacity and Operating Load
Ignition & Volatilization Temperatures
Combustion Temperature Control
Stoichiometric Considerations
Projection
Slides:
See the following pages.
7-2
-------
Slide 7-1
THERMOCHEMICAL
CONCEPTS
• Heating Values & Load
* Ignition Temperatures
• Combustion Temperatures
* Temperature Control Methods
-------
Slide 7-2
HEATING VALUES
Higher Heating Value (HHV)
• Bomb Calorimeter
• Water Formed is Condensed
Lower Heating Value (LHV)
• Computed from HHV
• Assumes Water Formed is Vapor
-------
Slice 7-3
HEATING VALUES OF
SELECTED FUELS
Fuel
Basis
Methane
Fuel Oil, #2
Fuel Oil, #6
Coal, PA Bitum
Coal, WY Subbitum.
Medical Waste
Wood, White Pine
Wood, White Oak
Lignite, ND
RDF, Ames, IA
MSW, Ames, IA
Wood, Fresh Cut
Dry
As Received
As Received
As Received
As Received
As Received
Kiln Dried
Kiln Dried
As Received
As Received
As Received
As Received
risture
%
0.0
0.0
0.7
1.5
25.0
9.0
8.0
8.0
37.0
6.5
24.2
50.0
HHV
Btu/lb
23,875
19,430
18,300
13,800
9,345
9,240
8,900
8,810
7,255
6,110
4,830
4,450
-------
Slide 7-4
INCINERATOR CAPACITY
Overall Operating Load
• Btu/hour (Energy Input)
Waste Charging Rate
• Ib/day or tons/day
• Ib/hour
-------
Slick 7-5
EXAMPLE CALCULATION OF
ACTUAL CHARGING RATE
Example: 150 Ibs/hr Unit (Design Capacity)
8,500 Btu/lb HHV (Design Basis)
9,240 Btu/lb HHV (Actual)
Operating Load = Charging Rate x HHV (Design)
(Design) = 150 Ib/hr x 8,500 Btu/lb
= 1,275,000 Btu/hr
Charging Rate = Operating Load/HHV (Actual)
(Actual) = 1,275,000 Btu/hr/9,240 Btu/lb
= 1381bs/hr
-------
Slide 7-6
IGNITION TEMPERATURES
Material
Sulfur
Charcoal
Gasoline
Acetylene
Fixed Carbon
Hydrogen
Methane
Carbon Monoxide
Phase at 60°F
& 14.7 psia
Solid
Solid
Liquid
Gas
Solid
Gas
Gas
Gas
Ignition
Temp., °F
470
650
663-702
589-825
765-1115
1065-1095
1170-1380
1130-1215
Benzene
Liquid
1335
-------
Slide 7-7
COMPONENTS IN
PROXIMATE ANALYSIS
Moisture
Volatile Matter
Fixed Carbon
Ash
-------
Slide 7-8
ADIABATIC COMBUSTION
CONDITIONS
Energy Release from Combustion
• No External Heat Losses
• Heats Combustion Product Gases
• Vaporizes Moisture
-------
Slid; 7-9
COMBUSTION TEMPERATURE
CONTROL
Fuel Modulation
Heat Transfer to Surroundings
Heat Sink Materials
-------
Slide 7-10
HEAT SINK MATERIALS
Water in Fuel
Nitrogen
Excess Air
Flue Gas
Water Sprays
-------
Slide 7-11
WATER SPRAYS
Reduce Fuel-to-Air Ratio
Reduce Temperature
Reduce Velocity
Reduce Opacity
Reduce Fires in the Charge Hopper
-------
Slide 7-12
STARVED-AIR UNITS
Two Stage Combustion
Primary Chamber: Gasifier
Low Velocities: Low Entrainment
Increased Air: Higher Primary Temperatures
Secondary Chamber: Excess Air Combustion
-------
Slide 7-13
EXCESS AIR COMBUSTION
Excess Air - Heat Sink
More Excess Air
Temperature Reduction
-------
-------
LESSON PLAN NUMBER 8
COMBUSTION PRINCIPLES III: REACTION PROCESSES
Goal: To provide general information about the influences of reaction rates
on the behavior of the combustion process, including the formation of
products of incomplete combustion.
Objectives: Upon completion of this unit, an operator should be able to:
1. Discuss some of the important transient and thermal features of
chemical reactions.
2. Recognize that an increase in temperature generally increases the rate
of reaction.
3. Describe the influence of mixing (sometimes called turbulence) of the
fuel and oxygen on the completeness of combustion.
4. Describe what happens when a flame impinges on the wall of an
incinerator as an example of the influence of reaction time on the
completeness of combustion.
5. Name the two important products of incomplete combustion.
6. Characterize the features of an oxidizing and a reducing environment.
7. Contrast the combustion phenomena in a blue flame with that of a
yellow flame.
8. Discuss the combustion processes in a fuel-bed with an underfire air
supply and the reasons that products of incomplete combustion are
formed.
8-1
-------
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions:
1. A camp stove (which typically uses either propane or gasoline) is
designed to burn with a blue flame. However, it often produces a
yellow flame when it first starts to burn. Why?
2. A camp stove's yellow flame will causes black deposits on the
pots/skillets, whereas a blue flame will not. Why?
3. Why would an increase in underfire air cause the O2 level in the flue
gas to fall and the CO level to rise?
Presentation
Summary
Outline:
Combustion Principles III: Reaction Processes
Multiple Reactions
Incomplete Combustion
Reaction Rates
Oxidation & Reduction Reactions
Diffusion Limited Combustion
Fuel-Bed Combustion Processes
Theoretical Combustion Temperatures
Moisture and Stoichiometric Operational Relationships
Char and Carbon Monoxide Reactions
Projection
Slides:
See the following pages.
Source
of
Graphics:
Slide 8-13
G. C. Williams et al., "Design and Control of Incinerators," Final
Report to Office of Research and Monitoring, U. S. Environmental
Protection Agency, Grant Number EC-00330-03, 1974.
8-2
-------
Slide 8-1
COMBUSTION REACTION
PROCESSES
* Oxidation & Reduction
• Incomplete Combustion
• Reaction Rate Variables
* Flame Phenomena
€1 • Bed-Burning
« Volatilization
• Oxidation of Carbon Monoxide
-------
Slide 8-2
IMPORTANT REACTION
CHARACTERISTICS
1. Multiple Reactions Occur in Combustion
2. Reactions May Not Go to Completion if
Temperature, Time & Mixing Are Inadequate
3. Reactions Are Somewhat Reversible
4. Reaction Rates Increase with Temperature
5. Reactions Are Influenced by Concentrations
6. Reactions Are Limited by Mixing
7. Gaseous Compositions Vary with Temperature
-------
Slide 3-3
REACTIONS OF CARBON AND
HYDROGEN IN OXYGEN
C + O9 > CO,
£i £*
H2 + 0.5 O2 > H2O
0.5 O2 > O
C + O > CO
2H9 + O2 > 2H2O
£, 4* **
2H2O > 2 OH + H2
CO +2 OH » CO2 + H2O
-------
Slide 8-4
CONSEQUENCE OF MULTIPLE
REACTIONS
Not All Reactions Can Go To Completion
Some Components May Be Depleted
-------
Slide 8-5
PRODUCTS OF INCOMPLETE
COMBUSTION
Carbon Monoxide
Dioxins and Furans
-------
Slide 8-6
REASONS FOR INCOMPLETE
COMBUSTION
1. Variable Fuel Properties
2. Irregular Fuel Feeding Characteristics
3. Inadequate Air Supply
4. Improper Distribution of Air
5. Incomplete Mixing of Oxygen & Fuel
6. Inadequate Temperature
7. Premature Cooling of Combustible Gases
(Inadequate Time)
-------
Slide 3-7
REACTION RATES
Rate of Chemical Change
Forward Reaction (Production)
Reversed Reaction (Dissociation)
-------
Slide 8-8
OXIDATION AND REDUCTION
REACTIONS
Lean Mixture - Oxidizing Atmosphere
Oxidation Reaction
Converts Reactants to Products
Rich Mixture - Reducing Atmosphere
Reduction Reaction
Converts Products to Reactants
-------
Slide 8-9
REACTION RATE
DEPENDS UPON:
Temperature
Mixture Concentrations
Stirring Process (Turbulence)
-------
Slide 8-10
PRE-MIXED GASEOUS FUEL
COMBUSTION
Blue Flame Combustion:
Natural Gas in an Appliance
-------
Slide 8-11
DIFFUSION-LIMITED
COMBUSTION
Yellow/Orange Flame Combustion:
• Inadequately Pre-Mixed Air & Fuel
• Dark Flame Tips
* Black Deposits on Adjacent Surfaces
-------
Slide 8-12
MEDICAL WASTE BURNING
CHARACTERISTICS
Volatiles Burn as Gases
Fixed Carbon Burns as a Solid
Diffusion Limited Flame
-------
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PQ
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H
O
O
O
O
O
O
cu
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•8
-------
Slide 8-14
PRIMARY CHAMBER
BURNING PROCESSES
Gaseous Products Partially Oxidize to:
H2O, CO2, CO, Methane, Hydrogen
Solids Materials Burn in Bed:
Char (Fixed Carbon)
Solid Residues Accumulate on Hearth:
Inorganic Materials (Ash)
-------
a
d 03Q '3ynivu3di/\iai
x>
-------
Slide 8-16
OPERATIONAL
RELATIONSHIPS
Starved-Air Conditions
• Increase in Primary Air Supply:
Increase in Primary Gas Temperature
* Increase in Fuel Charging Rate:
Decrease in Primary Gas Temperature1
Excess-Air Conditions
• Increase in Secondary Air Supply:
Decrease in Incinerator Temperature
• Increase in Waste Fuel Charging Rate:
Increase in Incinerator Temperature
-------
Slide 8-17
REACTIONS WITH CHAR:
C + O > CO
2
C + H2O > CO + H2
L, A*
C + COo > 2 CO
-------
Slide 8-18
DESTRUCTION OF CARBON
MONOXIDE
CO + OH
H + CO2
CO + 2 OH
CO + O
CO9 + H2O
LI +•
•> CO
2
-------
LESSON PLAN NUMBER 9
COMBUSTION SYSTEM DESIGN & CONTROL
Goal: To provide applied information about characteristic design and control
features of combustion system, including stoichiometric concepts,
automatic controls, and fans.
Objectives: Upon completion of this unit, an operator should be able to:
1. Contrast the general combustion differences between starved-air
incineration and excess air incineration.
2. Compare the air supply, velocity, and particle entrainment features in
the primary chamber of a modular starved-air unit with those of an
multiple chamber excess-air unit.
3. Describe the difference between a forced draft fan and an induced
draft fan.
4. List typical primary and secondary combustion chamber temperatures.
5. Describe what will happen to the primary chamber temperature and
volatilization rates if the underfire air and bed agitation are increased.
6. Identify four process variables used in combustion control systems.
7. List three methods of controlling air flow.
8. Define draft and identify reasonable operating values for the draft in
the primary chamber of a MWL
9. Discuss the advantage to operators of having the combustion chamber
designed and operated with a modest amount of draft.
10. List four system interlocks and explain why they are used.
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions
1. If the moisture content increases from 10% to 40%, about how much
will the primary combustion temperature drop?
9-1
-------
2. Discuss an example of the combustion consequences associated with
operating a furnace with more draft than specified in its design.
3. If your FD fan has guide vanes on the fan inlet, what do they do?
4. What are your experiences with variable speed fans?
5. What advantages do fixed speed fans have over variable speed fans?
Presentation
Summary
Outline:
Projection
Slides:
Source
of
Graphics:
Slide 9-6
Slide 9-14
Slide 9-16
Slide 9-18
Combustion System Design & Control
Design & Operational Considerations
Starved-Air & Excess-Air System Comparisons
Combustion Chamber Temperatures
Automatic Control Applications & Concepts
Centrifugal Fans & Air Flow Control
Draft & Draft Control
Combustion Control Comparisons
Starved-Air and Excess-Air Unit Operations
See the following pages.
"Integrated Waste Services, Information Summary," Consumat
Systems, Inc., Richmond, Virginia, Undated Brochure.
Gerald T. Joseph and David S. Beachler, "APTI Course 415, Control of
Gaseous Emissions, Student Manual," Report Number EPA 450/2-81-
005, U. S. Environmental Protection Agency, Research Triangle Park,
NC, December 1981, p. 9-26.
Joseph G. Singer, Combustion Fossil Power. 4th Edition, Combustion
Engineering, Inc. Windsor, CT, 1991, p. 14-14.
Adapted from an illustration which is copyrighted by Instrument
Society of America 1988. From "Boiler Feedwater and Steam -
Controlling for Safety and Efficiency," Videotape from ISA's Boiler
Control Series. Reprinted by permission.
9-2
-------
Slide 9-1
MWI DESIGN CONSIDERATIONS
1. Charging Method
2. Stoichiometric Design
3. Combustion Chamber Wall
4. Combustion Control
5. Air Pollution Control
6. Energy Recovery
-------
Slide 9-2
OPERATIONAL
CONSIDERATIONS
Steady Combustion Temperatures
• Steady Heating of the Fuel-Bed
• Controlled Evolution of Volatile Gases
• Steady Combustion Air Requirements
• Constant Velocities & Residence Times
Near-Continuous Waste Feeding
-------
Slide 9-3
GENERIC CATEGORIES
OF MWI INCINERATORS
Starved-Air Type
Modular Controlled-Air, Refractory Wall
Excess-Air Type
Multiple Chamber, Refractory Wall
Rotary Kiln, Refractory Wall
Waterwall (Integral Boiler)
-------
Slide 9-4
GENERIC COMBUSTION
COMPARISONS
Starved-Air Unit
• Volatilization in Primary Chamber
• Incomplete Combustion in Primary
• Relatively Low Gas Velocities
• Relatively Low Particle Entrainment
• Acceptable Carbon Burn-Out of Residue
Excess-Air Unit
• Volatilization & Combustion in Fuel-Bed
• Adequate Air for Complete Combustion
• Relatively High Gas Velocities
• Relatively High Particle Entrainment
• Good Carbon Burn-Out of Residue
-------
Slide 9-5
EXAMPLE MWI COMBUSTION
TEMPERATURES
CHAMBER/SYSTEM TEMPERATURE
FEATURE RANGES
Primary/Batch Operation 1,000 to 2,000 °F
Primary/Intermittent Duty 1,200 to 1,600 °F
Upper Limit
" Primary/Continuous Duty 1,400 to 1,800°F
at Charging Zone 1,600 °F
Secondary Chamber 1,800 to 2,000 °F
Upper Limit 2,200 to 2,300 °F
-------
a
o
4
§ o«
in
vo
OS
T3
-------
Slide 9-7
AUTOMATIC CONTROL
APPLICATIONS
1. Medical Waste Feeding System
2. Combustion Control System
3. Ash Removal System
4. Flue Gas Cleaning System
5. Boiler System
6. Water Treatment Systems
-------
Slide 9-8
AUTOMATIC CONTROLS
SYSTEM FUNCTIONS
1. Modulating Control
2. Sequential Control Logic
3. Process Monitoring
-------
Slide 9-9
TYPES OF AUTOMATIC
CONTROL SYSTEMS
1. Pneumatic
2. Hard-Wire Electronic Analog
3. Programmable Logic Controllers
Microprocessor-Based
Distributive Control Systems
-------
Ul
O
J
fe
O
O
u
hH
H
ON
O
"O
-------
Slide 9-11
AUTOMATIC CONTROL
SYSTEM ELEMENTS
1. Process (Manipulated) Variable
2. Measuring Device (Transducer)
3. Feedback Signal
4. Set Point (SP)
5. Controller
6. Actuating Signal
7. Final Control Element (FCE)
8. Status Indicator
-------
Slide 9-12
GAS-SIDE CONTROL
PARAMETERS
1. Air Flow Rate
2. Opacity
3. Oxygen Content
4. Carbon Monoxide
5. Draft
6. Combustion Temperature
7. Flue Gas Temperature at APCD
-------
Slide 9-13
FINAL CONTROL ELEMENTS
1. Damper Position
2. Fan and Pump Drives
3. Motor Controller
4. Auxiliary Fuel Valve Position
5. Ram
-------
Slide 9-14
CENTRIFUGAL FAN
Scroll side
Outlet
Rim
(shroud, wheel ring,
retaining ring,
wheel rim)
Scroll
(housing, volute)
Impeller
(wheel, rotor)
Forward curved
Backward curved
Radial
-------
Slide 9-15
METHODS OF CONTROLLING
AIR FLOW
1. Variable Speed Fan
2. Damper in Duct
3. Variable Inlet Vane Damper
-------
O
vo
»»""i
i
Os
u
•o
-------
Slide 9-17
DRAFT
Negative Pressure (Vacuum)
Measured in Inches of Water
Maintained Inside Incinerators
-------
Slide 94 8
SINGLE ELEMENT
CONTROL SYSTEM: DRAFT
SP
drmft
controller
• lUHBftCC
Adaptation of & Figure of the Instrument Society of America.
-------
Slide 9-19
TRIM CONTROL FEATURES
1. Oxygen Trim Control
2. Flue Gas Temperature Control
-------
Slide 9-20
COMBUSTION CONTROL
SYSTEM COMPARISONS
Conventional Fuels
Gas, Fuel Oil & Coal
Medical Waste
-------
Slide 9-21
II
STARVED-AIR UNIT
CONTROL VARIABLES
Primary and Secondary Temperatures
Underfire Air Flow in Primary
Charging Method and Bed Agitation
Secondary Air Flow
Auxiliary Fuel Burning
Solids Residence Time
-------
Slide 9-22
STARVED-AIR UNIT
OPERATIONS
PRIMARY AUXILIARY FUEL BURNER
Preheat Refractory
Initiate Ignition
Increase Gas Temperature
• Increases the Volatilization Rate
SECONDARY AUXILIARY FUEL
BURNER
Preheat Refractory
Increase Secondary Gas Temperature
• Reduces Smoking
• Reduces Incomplete Combustion
-------
Slide 9-23
CONTROL SYSTEM
INTERLOCKS
High Primary Temperatures
High Secondary Temperatures
Low Secondary Temperatures
Low Draft
Burner Flame Outage
Fan Failure during Purge
High Flue Gas Temperatures
High APCD Pressure Drop
- Stop Underfire Air
- Lock-Out Feeder
- Lock-Out Feeder
- Open Bypass Stack
- Stop Auxiliary Fuel
- Stop Auxiliary Fuel
- Open Bypass Stack
- Open Bypass Stack
-------
Slide 9-24
EXCESS-AIR UNIT
OPERATIONS
TO OBTAIN INCREASED
COMBUSTION TEMPERATURES
Increase Bed Agitation & Underfire Air
Increases the Burning Rate
Reduce Overall Excess Air (Overfire Air)
-------
Slide 9-25
EXCESS-AIR UNIT
OPERATIONS
INCREASED FUEL MOISTURE:
Gas Temperature Will Drop
Gas Temperature Can Be Restored by:
Increasing Bed Agitation
Reducing Overfire Air (Excess Air)
-------
-------
LESSON PLAN NUMBER 10
AIR POLLUTION FORMATION
Goal: To provide general information about the formation of air pollutants,
their measurement as gaseous concentrations, and the correction of
concentrations to a standard-dilution basis.
Objectives: Upon completion of this unit, an operator should be able to:
1. List air pollutants whose emissions depend on combustion quality.
2. List air pollutants whose emissions depend on fuel composition.
3. List air pollutants whose emissions are dependent on the temperature
of the flue gas entering the particulate control device.
4. Identify three different compounds or groups of compounds which can
cause the appearance of white smoke.
5. Relate the features which can cause smoke to the color the smoke will
exhibit.
6. Describe the general relationship between carbon monoxide emissions
and oxygen in the flue gas.
7. Discuss two reasons for controlling flue gas 02.
8. Describe the physical meaning of a ppm, as applied to gas
concentrations in a mixture.
9. Convert a mole fraction to a percentage and to a part-per-million (ppm)
concentration basis.
10. Understand the basis for correcting gas concentrations to standard
dilution bases, such as 12 % C02 and 7% 02
11. Generally relate carbon monoxide concentration levels to combustion
efficiency.
12. Be able to calculate combustion efficiency based on the definition
which considers conversion of carbon monoxide to carbon dioxide.
13. Understand the difference between percent excess air and percent
oxygen in the flue gas.
10-1
-------
Lesson Time: Approximately 40 minutes
Suggested
Introductory
Question:
1.
Why are pollutant gas concentrations sometimes corrected to different
types of bases (e.g., 7% O2, 12%C02)?
Presentation
Summary
Outline: Air Pollution Formation
Waste & Operations Dependent Emissions
Products of Incomplete Combustion, Smoke & CO
Dioxins/Furans
Gas Concentrations & Correction for Standard Dilutions
Conversion of [gr/dscfj to [mg/dscm]
Calculations of Combustion Efficiency
Calculations of Excess Air
Projection
Slides:
Source
of
Graphics:
Slide 10-6
Slide 10-8
See the following pages.
W. R. Seeker, W. S. Lanier, and M. P. Heap, Municipal Waste
Combustion Study. Combustion Control of Organic Emissions. U.S.
Environmental Protection Agency, EPA-530-SW-87-021-C, June 1987,
pp. 4-1 to 4-8.
"Municipal Waste Combustion Study, Report to Congress," U.S.
Environmental Protection Agency, EPA-530-SW-87-021-a, June 1987,
pp. 42-61.
10-2
-------
Slide 10-1
COMBUSTION SOURCE
AIR POLLUTANTS
Waste Dependent
Combustion Quality Dependent
Baghouse or ESP Temperature Dependent
-------
Slide 10-2
WASTE DEPENDENT
AIR POLLUTANTS
Acid Gases
Hydrogen Chloride
Sulfur Oxides
Nitrogen Oxides (Fuel NOx)
Metals (Heavy Metals)
Lead, Cadium, Mercury
Carbon Dioxide
-------
Slide 10-3
APCD TEMPERATURE
DEPENDENT AIR POLLUTANTS
Metal Vapors (Mercury)
Trace Organics (Dioxins/Furans)
-------
Slide 10-4
PRODUCTS OF INCOMPLETE
COMBUSTION (PIC)
Smoke & Particulates
Carbon Monoxide
Trace Organics: Dioxins & Furans
Volatile Organic Hydrocarbons
-------
Slide 10-5
*
SMOKE & PARTICIPATES
Black Smoke
Carbon in Particulates
Brown Smoke
Nitrogen Oxides & Particulates
White Smoke
Condensed Hydrocarbon Gases
Ammonium Chloride
Water Droplets (Not Smoke)
Blue Smoke
Condensed Hydrocarbon Gases
Ammonium Sulfate
-------
Slide 10-6
GENERAL COMBUSTION
SYSTEM CO • O2
RELATIONSHIP
LU
zuu
OCJ
CJ
A - INSUFFICIENT AIR
B - APPROPRIATE OPERATING REGION
C - "COLD BURNING"
OXYGEN CONCENTRATION
-------
Slide 10-7
DIOXINS / FURANS (CDD/CDF)
Dioxins(CDD)
Polychlorinated Dibenzo-p-dioxins
Furans (CDF)
Polychlorinated Dibenzofurans
-------
Slide 10-8
DIAGRAMS OF DIOXIN AND
FURAN STRUCTURES
C!
ci
Example Dioxin
C!
CI
Q
CI
-------
Slide 10-9
CONDITIONS FOR DIOXIN /
FURAN FORMATION
COMBUSTION ZONE
Relatively Low Combustion Temperatures
Poor Mixing — Pockets of Rich Mixtures
High Particulate Loadings
Operating Above Unit Capacity
FLY ASH COLLECTION DEVICE
Catalytic Formation on Fly Ash
High Operating Temperatures (450° F)
-------
Slide 10-10
TEST FOR DIOXINS / FURANS
Stack Test: EPA Method 23
-------
Slide 10-11
REGULATORY BASIS FOR
EMISSIONS LIMITS
Federal: Total Mass of All Dioxins & Furans
Some States: Toxic Equivalent Limitation
• Determine Mass of Each Isomer
• Toxicity Level Assigned to Each Isomer
• Multiply Masses by Levels to Obtain Total
-------
Slide 10-12
GAS CONCENTRATIONS
Molecular Fractions
Mole Fractions
-------
Slide 10-13
COMPLETE COMBUSTION OF
MEDICAL WASTE WITH 125% EA
C4.26H,20133N05C1117S006 + 0.5 H.O + 11.52 O2 +
43.36 N2 »
4.26 CO2 + 3.54 Ef) + 43.38 N2 + 0.117HC1 +
0.006 SO2 + 6.4 O2
Product
Gas
C02
Hp
N2
HC1
S02
02
Wet Gas
Moles
4.26
3.54
43.38
0.117
0.006
6.4
Dry Gas
Moles
4.26
43.38
0.117
0.006
6.4
Dry Gas
Mole %
7.87
80.09
0.22
0.01
11.81
Total 57.703 54.163 100.00
-------
Slide 10-14
EQUIVALENCE OF GAS
CONCENTRATIONS
Mole Fraction x 100
Percentage
Mole Fraction x 1,000,000 - > ppm
Percentage x 10,000
ppm
-------
Slide 10-15
GAS CONCENTRATIONS AT
STANDARD DILUTION
Example: CO Concentration Limit
50 ppm at 7% O2 on
a Dry Gas Basis
-------
Slide 10-16
EQUATION FOR CONVERTING
TO 7% OXYGEN
Assume COm is the Measured Dry Gas CO
Expressed as a ppm or %
O2m is the Measured Dry Gas O2
Expressed as a Percentage
C0(@7%02m) = C0m x (21 -7)/(21 -
= C0m x
-0)
-------
Slide 10-17
0
PRODUCT GAS ANALYSIS,
MEDICAL WASTE @ 125% EA
Product Wet Gas
Gas Moles
CO2 4.26
• KL.O 3.54
N2 43.38
HC1 0.117
SO2 0.006
O2 6.40
CO 0.005
Dry Gas
Moles
4.26
43.38
0,117
0.006
6.40
0.005
Dry Gas
Mole %
7.86
80.09
0.22
0.01
11.81
0.01
Total
57.708
54.168
100.00
-------
Slide 10-18
CONVERSION OF GAS
CONCENTRATIONS TO 7%
OXYGEN
Let: CO,
o'
2m
= 100 ppm
= 11.8% (dry gas)
CO (@ 7% O,)
= COmx (21-7)/(21-02m)
= 100 x (14)/(21 -11.8)
= 152ppm@7%O2
-------
Slide 10-19
CONVERSION OF
PARTICULATES TO 7% OXYGEN
Let: PMm = 0.035 gr/dscf (Paniculate Matter)
= 11.8% (Measured Dry Gas O2)
PM «o> 7% 02) = PMm x (21 - 7) / (21 - O2J
= 0.035 x (14)7(21-11.8)
= 0.0533 gr/dscf @ 7% O2
-------
Slide 10-20
EQUATION FOR CONVERTING
TO 12% CARBON DIOXIDE
Assume CO is the Measured Dry Gas CO
m J
Expressed as a ppm or %
CO2m is the Measured Dry Gas CO2
Expressed as a Percentage
CO (@ 12% CO9) = CO x (12/CCXJ
-------
Slide 10-21
EXAMPLE CONVERSION TO
12% CARBON DIOXIDE
Let: CO = lOOppm
m A A
CO2m = 7.86% (dry gas)
CO (@ 12% CO2)= COm x (12/COjJ
= 100 x (12/7.86)
= 153ppm@12%CO
-------
Slide 10-22
CONVERSION OF [gr/dscf]
TO [mg/dscm]
Basic Identities:
1 pound [Ib]
1 pound [Ib]
1 gram [g]
1 foot [ft]
= 7,000 grains [gr]
= 453.6 grams [g]
= 1,000 milligrams [mg]
= 0.3048 meters [m]
For Dry Gases at Standard Conditions:
1 dry standard cubic foot = 1 [dscf]
1 dry standard cubic meter = 1 [dscm]
1 cubic ft [dscf] = 0.0283 cubic meters [dscm]
So That:
1 [gr/dscf] =
1 [gr/dscf] x (1 lb/7,000 gr) x (454 g/lb)
x (l,000mg/g) x (1 dscf/0.0283 dscm]
Therefore:
1 [gr/dscf] = 2,290 [mg/dscm]
-------
Slide 10-23
EXAMPLE APPLICATION OF
THE CONVERSION FACTOR
Factor: 1 [gr/dscf] = 2,290 [mg/dscm]
Given: 34 [mg/dscm]
Therefore: 34 [mg/dscm] =
34 [mg/dscm] x (1 [gr/dscf] / 2,290 [mg/dscm])
= 34 [mg/dscm] = 0.015 [gr/dscf]
-------
Slide 10-24
EQUATION FOR COMBUSTION
EFFICIENCY (BASED ON CARBON
COMBUSTION TO CO2)
C.E. (%) = 100% x
CO
2m
C02m + CO
m
or
C.E. (%) = 100% x
1 -
CO
m
C02m + CO
m
-------
Slide 10-25
EXAMPLE COMBUSTION
EFFICIENCY CALCULATION
Let CO, be 7.86 Percent
2m
COm be 0.01 Percent (100 ppm)
C.E. (%) = (100% x C02J/(C02m + COJ
= (100% x 7.86)7(7.86 + 0.01)
= 99.9%
-------
Slide 10-26
DETERMINATION OF EXCESS
AIR FROM DRY GAS
ANALYSIS
Assume CO2m is the Percent Dry Gas CO2
COm is the Percent Dry Gas CO
O
2m
is the Percent Dry Gas O2
Therefore N2m = 100 - (CO2m + COm + O2m)
And EA = (02m - 0.5 COm) / (.264 N2m - O2m +
0.5 C0m)
-------
Slide 10-27
EXAMPLE DETERMINING
EXCESS AIR
Let CO, = 7.86%
2m
CO = 0.01%
m
O, = 11.8%
2m
Therefore N, = 100 - (CO, + CO + O, )
2m v 2m m 2m7
• N2m = 100-(7.86 + 0.01 + 11.8)
= 80.33
And EA = (O, - 0.5 CO ) / (.264 N, - O, +
v 2m m7 ' v 2m 2m
0.5 CO )
m'
EA = (11.8-0.005) / (.264 x 80.33-11.8 +
0.005)
EA = 1.25 > 125% Excess Air
-------
-------
LESSON PLAN NUMBER 11
INSTRUMENTATION I: GENERAL MEASUREMENTS
Goal: To provide introductory information about the measurement of
temperatures, pressures, and flow rates of gases and liquids.
Objectives: Upon completion of this unit, an operator should be able to:
1. Describe the operating principles of a thermocouple.
2. Express the limitations associated with placement of a thermocouple.
3. Name other instruments and/or techniques which are used to indicate
temperatures.
4. Describe the operating principle of a manometer pressure gage.
5. Describe the operating principle of a Bourdon tube pressure gage.
6. Contrast the operational features of pitot tubes and orifice plates
which use differential pressure devices to indicate flow.
7. Know the major limitation of rotameters and turbine flow meters.
8. Describe the operational similarities of equal arm balances, platform
scales, and strain gage driven scales.
Lesson Time: Approximately 40 minutes
Suggested
Introductory
Questions
1. What can happen to cause a thermocouple to give a false reading?
Presentation
Outline: Instrumentation I: General Measurements
Purposes of Instrumentation
Temperature Conversions & Measurements (Thermocouples)
Pressure Measurements: Manometers & Gages
Flow Measurements: Pitot, Orifice, Rotameter
Weight Scales
11-1
-------
Projection
Slides:
See the following pages.
Source of
Graphics:
Slide 11-5
Slide 11-7
Slide 11-8
Slide 11-9
Slide 11-12
Slide 11-13
Slide 11-14
Slide 11-15
Slide 11-16
Slide 11-17
Robert T. Cony et al., "Instruments and Control," Mark's Standard
Handbook for Mechanical Engineers. Eighth Edition, Edited by T.
Baumeister, et al., McGraw Hill Book Company, NY, 1978, p. 16-13.
Edgar E. Ambrosius et al., Mechanical Measurement and
Instrumentation. Ronald Press, New York, 1966, pp. 360-361.
Robert T. Corry et al., "Instruments and Control," Mark's Standard
Handbook for Mechanical Engineers. Eighth Edition, Edited by T.
Baumeister, et al., McGraw Hill Book Company, NY, 1978, p. 16-9.
J. P. Holman, Experimental Methods for Engineers. McGraw Hill Book
Company, New York, Fifth Edition, 1989, p. 213.
Robert T. Corry et al., "Instruments and Control," Mark's Standard
Handbook for Mechanical Engineers. Eighth Edition, Edited by T.
Baumeister, et al., McGraw Hill Book Company, NY, 1978, p. 16-15.
Robert T. Corry et al., "Instruments and Control," Mark's Standard
Handbook for Mechanical Engineers. Eighth Edition, Edited by T.
Baumeister, et al., McGraw Hill Book Company, NY, 1978, p. 16-16.
Robert T. Corry et al., "Instruments and Control," Mark's Standard
Handbook for Mechanical Engineers. Eighth Edition, Edited by T.
Baumeister, et al., McGraw Hill Book Company, NY, 1978, p. 16-17.
Robert T. Corry et al., "Instruments and Control," Mark's Standard
Handbook for Mechanical Engineers. Eighth Edition, Edited by T.
Baumeister, et al., McGraw Hill Book Company, NY, 1978, p. 16-17.
Edgar E. Ambrosius et al., Mechanical Measurement and
Instrumentation. Ronald Press, New York, 1966, p. 252.
Edgar E. Ambrosius et al., Mechanical Measurement and
Instrumentation. Ronald Press, New York, 1966, p. 255.
11-2
-------
Slide 11-1
PURPOSE OF
INSTRUMENTATION
1. Supervision of Operations
2. Automatic Control Signals
3. Management Data
4. Pollutant Emissions Surveillance
-------
Slide 11-2
GENERAL MEASUREMENTS
1. Temperature
2. Pressure
3. Flow Rate (Velocity)
4. Weight
-------
Slide 11-3
TEMPERATURE EQUIVALENTS
i>
>C = (5/9) (°F - 32)
'F = (9/5) °C + 32
>K (Kelvin) = °C + 273.15
'R (Rankine) = °F + 459.67
-------
Slide 11-4
TEMPERATURE
MEASUREMENTS
Thermometer - Expansion of a Liquid
Dial Thermometer - Expansion of Metals
Thermocouple - Thermoelectric Potential
Thermistor/RTD - Electrical Resistance
Infrared Temperature Probe - Infrared Energy
Optical Pyrometer - Infrared Energy
Temperature Paint - Change of Color
-------
Slide U-5
THERMOCOUPLE
TEMPERATURE
MEASUREMENT DEVICE
Hot
junction
Millivoltmeter
(cold junction
compensation)
Iron
Lead wire
^Constantan
Cold
junction
-------
Slide 11-6
PRESSURE MEASUREMENTS
Manometers - Height of a Column of Liquid
U-Tube, Single-Leg, Inclined
Bourdon Tube Gages - Bending of a Curved Tube
Mechanical/Electrical Devices
Diaphragm Gages
Bellows Gages
Differential Pressure (DP) Cells
Linear Variable Dif. Transformers (LVDTs)
-------
Slide 11-7
MANOMETER PRESSURE
MEASUREMENTS
Fluid 1
Low density
Fluid 2
High density
U-Tube Manometer
Single-Leg
Manometer
From Edgar E. Ambrosius et aL.
printisJ with permission.
Measurement and IimrgmmmJOT , *™** ****• Ncw Yorit- 1966'
-------
Slide 11-8
BOURDON TUBE GAGE
Bourdon tube
Scale
Pointer
Hairspring
Pinion
Case
From Robert T. Cony, et •!., "Instruments and Control," park's Standard Handjypo^c for Mechanical Engineer^ , Eighth Edition,
edited by T. Baumeisier, et. al., McGraw Book Company, NY, 1978, reprinted with permission.
-------
Slide 11-9
PRESSURE TRANSMITTER
Low Voltage Electrical and
Low Pressure Pneumatic Signals
Easy to Transmit
Safety Considerations
-------
Slide 11-10
LVDT DIFFERENTIAL
PRESSURE CELL
t
Primary
I
Pressure
T
Secondary
1
Pressure
portp2
From I.P. Hobntn, Experimental Methods fof Engineers , McGraw Hill Book Company, NY. Fifth Edition, 1989, printed with permission.
-------
Slide 11-11
MEASUREMENT OF
FLUID FLOW
MEASURING DEVICE
Pitot Static Tube
Orifice Plate
Venturi
Propeller-Type
Rotameter
APPLICATION
Combustion Air Flow
High Steam & Water Row
(Large Pressure Drop)
High Steam & Water Flow
(Small Pressure Drop)
Medium Air & Water Flow
Low Water Flow
-------
Slide 11-12
PITOT STATIC TUBE
Static opening
Manometer
From Robert T. Cony, « al., "Instruments and ConnoL" fvlaik's Standard Handbook for Mechanical Engineers
Eighth Edition, edited by T. Baumeisier, eL al., McGraw Book Company, NY, 1978, reprinied wiih permission.
-------
Slide 11-13
41
ORIFICE PLATE -
PRESSURE DIFFERENCE
Flange
Orifice plate
Upstream
tap
Vena contracta
Downstream tap
From Roben T. Cony, et al., "Insmirr.ents and Control," part's Standard Handbook for Mechanical Engineers
Eighth Idiiion. edited by T. Baumeisier. et. al., McGraw Book Company, NY, 1978. reprinted with permission.
-------
Slide 11-14
PROPELLER TYPE
FLOWMETER
Bearing
4
Propeller
Magnetic fp
sensing element
Ampi
ifier L—M
Recorder
From Robert T, Cony, et *!., "Instruments and Control," Mark's Standard Handbook for Mechanical Engineers
Eighth Edition, edited by T. Baumeisier, et. al,, McGraw Book Company, NY, 1978, reprinted with permission.
-------
Slide 11-15
ROTAMETER
Inlet
Rotameter
tube
Metering
float
Scale
From Ro sen T. Carry, et a]., "Instruments and Control," Mark's Standard Handbook for Mechanical Engineers
Eighth E
-------
Slide 11-16
EQUAL ARM BALANCE
From Edgar E Ambrosius et al., Mechanical Measurement and lmmim?T1|a|jn|i , Ronald Press. NY. 1966,
primed with permission.
-------
H
CO
CO
C*
H
a
U
O
H
£gJi
i/> 0) Q Q_
2. "c-O 5
00°-
Li «*•
>c
vc
>-
£
2
€
s
1
•a
53
!'
ui
ft.:
-------
-------
LESSON PLAN NUMBER 12
INSTRUMENTATION II: CONTINUOUS EMISSION MONITORING
Goal: To provide information about the special features of continuous
measurement of air pollutant emissions.
Objectives: Upon completion of this unit, an operator should be able to:
1. List at least five parameters which can be monitored by CEMS.
2. Distinguish between extractive and in-situ continuous monitoring
equipment.
3. Describe the operating principles and maintenance requirements of an
opacity monitor.
4. Identify the basic measurement concept used in dispersive and
nondispersive instruments for measuring gaseous concentration.
5. Identify the basic measurement concept used in chemiluminescent
instruments for measuring gaseous concentration.
6. List three operational problems which can cause extractive CEMs to
give invalid measurements.
7. List two special operational problems which can cause in-situ CEMS
to give invalid measurements.
8. Describe the general procedures for calibrating CEMS.
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions:
1. Name the CEMS in your plant.
2. How many of your instrument readings are directly transmitted to a
local or state regulatory agency?
3. What CEMS problem has caused the most difficulty for operators?
12-1
-------
Presentation
Summary
Outline:
Projection
Slides:
Instrumentation II: Continuous Emission Monitoring
Parameters Monitored & Typical Range
In-situ Measurement Concepts
Extractive Measurement Concepts
Sample Conditioning & Special Operating Concerns
Dispersive and Non-Dispersive Methods
Routine Calibration & Bias Checks
See the following pages.
Source of
Graphics:
Slide 12-5
Slide 12-6
Slide 12-7
Slide 12-11
Slide 12-12
Slide 12-13
J. A. Moore, "Key Measurements in Power Plants," Standard
Handbook of Power Plant Engineering. Thomas C. Elliott, editor,
McGraw Hill Book Co., NY, 1989, p. 6-61.
J. A. Moore, "Key Measurements in Power Plants," Standard
Handbook of Power Plant Engineering. Thomas C. Elliott, editor,
McGraw Hill Book Co., NY, 1989, p. 6-61.
James Jahnke and G. J. Aldina, Handbook, Continuous Air Pollution
Source Monitoring Systems. Technology Transfer, EPA 625/6-79-005,
June 1979.
James Jahnke and G. J. Aldina, Handbook. Continuous Air Pollution
Source Monitoring Systems. Technology Transfer, EPA 625/6-79-005,
June 1979.
James Jahnke and G. J. Aldina, Handbook. Continuous Air Pollution
Source Monitoring Systems. Technology Transfer, EPA 625/6-79-005,
June 1979.
Robert Holloway, W. S. Lanier, and S. B. Robinson, "Alternative
Approaches to Real-Time Continuous Measurement for Combustion
Efficiency of Hazardous Waste Incinerators," Contract 68-03-3365,
Work Assignment 03 Report to U. S. Environmental Protection Agency,
Office of Solid Waste and Emergency Response, March 25, 1987.
12-2
-------
Slide 12-15 James Jahnke and G. J. Aldina, Handbook. Continuous Air Pollution
Source Monitoring Systems. Technology Transfer, EPA 625/6-79-005,
June 1979.
Slide 12-16 James Jahnke and G. J. Aldina, Handbook. Continuous Air Pollution
Source Monitoring Systems. Technology Transfer, EPA 625/6-79-005,
June 1979.
Slide 12-18 John Richards, "Municipal Waste Incinerator Air Pollution Control
Inspection Course," Submitted to U. S. Environmental Protection
Agency, June 1991.
12-3
-------
Slide 12-1
CONTINUOUS EMISSION
MONITORING SYSTEMS
Temperature
• Primary & Secondary Chambers
• Temperature of Flue Gas into APCD
Fluid Flow Rate (Velocity)
Opacity
Concentrations of Gases
• Carbon Monoxide
• Hydrogen Chloride, Sulfur Dioxide
• Oxygen, Carbon Dioxide
-------
Slide 12-2
INDICATORS OF
COMBUSTION CONDITIONS
Opacity
Carbon Monoxide
Carbon Dioxide
Oxygen
Primary Chamber Temperature
Secondary Chamber Temperature
Draft in Primary Chamber
-------
Slide 12-3
TYPICAL MWI COMBUSTION
INDICATOR RANGES
PARAMETER
LOW
HIGH
Opacity, %
Primary Temp., °F
Secondary Temp., °F
Upper Limit, °F
Draft, in w.c.
0
1,000
1,800
2,200
0.03
with Door Open, in w.c.
Baghouse Inlet Temp., °F 300
Oxygen, % 11
Carbon Monoxide, ppm 0
10
2,000
2,200
2,300
0.15
0.00
450
15
100
-------
Slide 12-4
CATEGORIES OF CEMS
In-situ:
Stack Mounted Analyzer
Extractive:
Sample Flows to Remote Analyzer
-------
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Slide 12-8
EXTRACTION TYPE OF
GAS ANALYZER
• Extraction of Gas Sample by a Probe
• Removal of Particulates
• Removal or Compensation for Water
• Transport to Remote Analyzer
• Detection by Analyzer
-------
Slide 12-9
WATER REMOVAL OR
COMPENSATION SYSTEMS
1. Desiccant
2. Refrigeration
3. Dilution
4. Heating of Sample Line
-------
Slide 12-10
II
ABSORPTION SPECTROSCOPY
Dispersive Absorption
Differential Absorption
Nondispersive Absorption
™ Gas Filter Correlation Method
-------
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Slide 12-14
OTHER ANALYTICAL
TECHNIQUES
Chemiluminescence
Electrocatalytic
-------
Slide 12-15
CHEMILUMINESCENCE
ANALYZER
Flow Control
03 Generator
Sample in
Detector
Control
Optical Fitters
PhotomuiUpiier
Tube
Sample
Exhaust
-------
o
S3
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-------
Slide 12-17
GAS ANALYZER
MAINTENANCE PROCEDURES
Routine Calibration
Zero Gas or Filter
Span Gas or Filter
Delivery System Bias Checks
Probe Blockage
Probe Leaks
Electrical Circuit Problems
Component Replacement
-------
I
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-------
LESSON PLAN NUMBER 13
._ INCINERATOR OPERATIONS AND UPSETS
*
Goal: To provide information about various features of incinerator operations
and upset conditions.
Objectives: Upon completion of this unit, an operator should be able to:
1. Understand the general areas of responsibility of an operator.
2. List various system parameters which are typically recorded on an
operators inspection check-list or operating log.
3. Describe the general features of standard operating procedures for
start-up and shutdown.
4. Contrast the sequence of operator activities for starting up a single
batch fired unit with that of an intermittent duty MWI.
5. List live indicators of combustion quality.
6. Identify the problems associated with a sudden change in fuel
properties, such as a load of plastics or wet fuel suddenly arriving on
the fuel bed.
7. Identify two causes of high carbon content in bottom ash.
8. Describe how upset conditions can be associated with waste feeding
problems.
9. Identify how excessive "tramp air" can cause poor combustion.
10. Identify various remedies to combustion air upsets.
11. Describe how a high temperature in the primary chamber can cause
overloading of the secondary chamber and high pollutant emissions.
12. Describe how draft upset conditions can influence combustion.
Lesson Time: Approximately 50 minutes
13-1
-------
Suggested
Introductory
Questions:
1.
2.
Ask one of the participants to describe normal start-up procedures.
Why is it important to clean out the underfire air nozzles on a regular
basis.
Presentation
Summary
Outline: Incinerator Operations and Upsets
Operator Responsibilities
Operator Communications, Monitors & Logs
Check-Lists of Operating Systems
Potential Combustion Hazard: Explosion
Standard Operating Procedures
Operational Sequences: Loading, Start-Up & Shutdown
Typical Combustion Upsets and Remedies
Projection
Slides:
See the following pages.
13-2
-------
Slide 13-1
OPERATING RESPONSIBILITES
1. Maintain Safety of People
2. Maintain Safety of Equipment
3. Operate Within Legal Regulations
4. Optimize Equipment Performance
-------
Slide 13-2
OPERATOR JOB FUNCTIONS
Scale Operator and Waste Handler
Combustion System Operator
Specific Operational Duties
Automatic Control System Manager
Safety Officer
APCD/Boiler Operator
Maintenance Technician
Communicator/Recorder
-------
Slide 13-3
OPERATOR REQUIREMENTS
1. Know the System Characteristics
2. Know the Emergency Procedures
3. Assess the Operating Conditions
What is Happening? Why?
4. Identify Potential Modifications
What are the Options?
What are the Consequences?
5. Make Timely Decisions
6. Establish Proper Procedures
7. Keep Proper Records
-------
Slide 13-4
OPERATING SYSTEMS
Medical Waste Handling
Combustion
Ash Removal
APCD
Boiler & Feed water
Electrical Service
Fire Protection
-------
Slide 13-5
OPERATOR COMMUNICATIONS
Operator/Unit Interface
Receive Operating Information
Transmit Instructions
-------
Slide 13-6
PANEL-MOUNTED
INSTRUMENTS
Analog Displays
Digital Displays
Status Indicator Lights
Annunciators
Alarms
Recording Devices
Circular Charts
Strip Charts
-------
Slide 13-7
GRAPHIC SCREEN
DISPLAYS
Alpha/Numeric
Menus, Lists, Warnings
Two-Dimensional Equipment
Schematic with Data
Individual Component
Groups of Equipment
Overview of Performance
Trends of Selected Data
-------
Slide 13-8
COMBUSTION SYSTEM
MONITORS
Combustion Temperatures
Opacity
Carbon Monoxide
Oxygen
Acid Gas Concentrations
-------
Slide 13-9
TYPICAL WALK-DOWN
CHECK-LIST OF
OPERATING SYSTEMS
Waste Loader
Pneumatic and/or Hydraulic System
Incinerator Chamber Fuel-Bed and Ash
Incinerator Chamber Refractory
Underfire Air Supply Nozzles
Forced Draft and Induced Draft Fans
Dampers
Auxiliary Fuel Burner
Motors, Motor Controllers, Belt Drives
Water Spray Nozzle
Cooling Water System
Ash Removal System
Emergency By-Pass Stack Cap or Damper
Safety System Interlocks
-------
Slide 13-10
POTENTIAL COMBUSTION
HAZARD
Explosive Mixture of Fuel/Air
-------
Slide 13-11
STANDARD OPERATING
PROCEDURES
1. Safe Practices & Systems
2. Emergency Procedures
3. General Operations
A 4. Routine & Major Maintenance
5. Start-Up and Shutdown
6. Testing and Calibration
-------
Slide 1342
POLLUTANTS INFLUENCED
BY OPERATIONS
1. Air Pollutants
• Smoke
• Particulates
• Gases
2. Waste-Water Discharge
3. Odor
4. Noise
-------
Slide 13-13
COMBUSTION CONTROL
Air and Fuel Transients
Operator Activities
Review System Performance
Improve Equipment Setting
-------
Slide 13-14
CONTINUOUS BURNING
ON A HEARTH
1. Underfire Air
Damper Controls
Supply Air Pressure
Draft
2. Fuel Bed
Waste Feed Size & Frequency
Bed Agitation
-------
Slide 13-15
SEQUENCE OF BATCH
OPERATIONS
Remove Ash from Previous Burn
Load Batch Charge into Incinerator
Close and Lock the Charging Door
Operate Fans to Purge Gases
Preheat Secondary Chamber
Ignite Waste in Primary Chamber
Burn-Down, Cool-Down, Shut-Down
-------
Slide 13-16
INTERMITTENT DUTY
CHARGING
Charge Delivered at:
6 to 15 Minute Intervals
Charge Size Correspondingly Set At:
10% to 25% of Hourly Capacity
-------
Slide 13-17
INTERMITTENT DUTY
START-UP / SHUTDOWN
Remove Ash Residue After Cool-Down Period
Preheat Refractory in Secondary
Preheat Refractory in Primary
Deliver & Ignite the First Charge
Charge Intermittently
Implement the Burn-Down Operation
Implement the Cool-Down Operation
-------
Slide 1348
COMBUSTION SYSTEM UNIT
SHUTDOWN
Stop Feeding Waste into Unit
Burn the Waste on the Hearth
Operate Auxiliary Burners as Necessary
Maintain Underfire Air Supply
Maintain APCD Temperatures
-------
Slide 13-19
TYPICAL COMBUSTION
UPSETS
Waste Charging System
Combustion Air Supply
Ash Handling
Power Failures/Excursions
-------
Slide 13-20
INDICATORS OF
COMBUSTION QUALITY
1. Opacity
2. Carbon Monoxide
3. Temperature (Secondary)
4. Oxygen
5. Visual Appearance of Fire
6. Color of Bottom Ash
-------
Slide 13-21
HIGH CARBON CONTENT IN
BOTTOM ASH
Caused by
Insufficent Underfire Air
Inadequate Burn-Down Period
-------
Slide 13-22
UPSETS ASSOCIATED WITH
FUEL PROBLEMS
1.
Improper Feed Rate
Too High - Excessive Smoke
Poor Burn-out of the Ash
Too Low - Insufficient Fuel
Low Combustion Temperatures
2. Non-Uniform Fuel Bed Thickness
Too High - Restricted Air & Burn-Out
Too Low - Clinkering
3. Sudden Change in Fuel Properties
High Moisture - Reduces Primary Temp.
High Volatiles - Incomplete Combustion
-------
Slide 13-23
REMEDIES TO FUEL
PROBLEM UPSETS
Regulate Underfire Air Supply
Regulate Charging Rate
Mix Wastes to Reduced Surges
-------
Slide 13-24
COMBUSTION AIR UPSETS
Underfire Air Supply
Low Supply - Inadequate Oxygen
High Supply - Excessive Entrainment
Poor Distribution (Channeling)
Secondary Air Supply
Low Supply - Inadequate Mixing
High Supply - Excessive Gas Cooling
Poor Distribution, Mixing
Tramp Air Intrusion Through Poor Seals
-------
Slide 13-25
REMEDIES FOR COMBUSTION
AIR UPSETS
Check Draft Gage Readings
Adjust Fan Controls/Dampers
Modify Fuel Charging Rate
Remove Clinkers
Modify Trim Control System Settings
-------
Slide 13-26
COMBUSTION
TEMPERATURE UPSETS
1. High Secondary Chamber Temperatures
Refractory Damage
Remedy:
Reduce Auxiliary Fuel Firing
Increase the Overall Air Supply
Reduce Waste Charging Rate
Reduce the Underfire Air Supply
-------
Slide 13-27
COMBUSTION
TEMPERATURE UPSETS
2. Low Temperature in Secondary
Inadequate Combustion
Production of Pollutants
Remedy:
Decrease Secondary Air Supply
Increase Underfire Air Supply
Increase Auxiliary Fuel Burning
-------
Slide 13-28
FURNACE DRAFT
CONDITION UPSETS
1. Excessive Draft
High Velocities and Poor Mixing
Excessive Particulate Entrainment
Excessive Tramp Air
2. Inadequate Draft
Low Velocities
Pressure Transients/Puffing
3. Operation with Positive Pressure
Accumulation of Fly Ash Outside Unit
Gases/Smoke Leaking Out of Chamber
Combustion Quenching
Pollutant Exposure to Personnel
Damage to MWI Structure
-------
LESSON PLAN NUMBER 14
MAINTENANCE: PREVENTIVE & CORRECTIVE
Goal: To provide general information about the management of risks as
related to the optimization of operating equipment
Objectives: Upon completion of this unit, an operator should be able to:
1. List four types of economic losses which the owner may sustain
because of major equipment malfunctions.
2. Discuss the general goals of a preventive maintenance program.
3. List typical equipment corrective maintenance which can be performed
while the MWI unit is in service.
4. Discuss the use of maintenance records and operating logs in
identifying the need for equipment maintenance and evaluating the
effectiveness of a preventive maintenance program.
5. Name the various types of personnel who need to be involved in
establishing an annual inspection outage.
Lesson Time: Approximately 30 minutes.
Suggested
Introductory
Question:
1. Ask operator participants to discuss their experiences with the use of
maintenance records and operating logs in identifying the need for
equipment maintenance and evaluating the effectiveness of a preventive
maintenance program.
Presentation
Summary
Outline: Maintenance: Corrective & Preventive
Risk Management & Economic Losses
Operator Responsibilities
Goals & Features of Maintenance
In-Service & Outage Maintenance
Projection
Slides: See the following pages.
14-1
-------
Slide 14-1
CORRECTIVE & PREVENTIVE
MAINTENANCE
1. Risk Management
2. Efficient & Reliable Operation
-------
Slide 14-2
ASPECTS OF RISK
MANAGEMENT
Insurance Against Production & Casualty Losses
Evaluation of Current Conditions
Evaluation of Probability
Consideration of Economics
Consideration of Intangibles
OSHA Regulatory Requirements
-------
Slide 14-3
POTENTIAL ECONOMIC
LOSSES
Cost of Preventive Maintenance
Personal Injury to Employees
Injuries to Visitors and the Public
Equipment Repair/Replacement
Lost Revenue - Treatment Fees
Lost Revenue - Energy Sales
Alternative Disposal Costs
Extra Transporation Costs
Fines - Regulatory Violations
Contractual Noncompliance Losses
-------
Slide 14-4
OPERATOR RESPONSIBILITIES
1. Safety
2. Production (System Operations)
3. Corrective Maintenance
4. Preventive Maintenance
5. Record Keeping & Communications
-------
Slide 14-5
GOALS OF PREVENTIVE
MAINTENANCE
1. Minimize Total Operating Costs
2. Enhance Equipment Life
3. Assure Equipment Reliability
4. Assure Regulatory Compliance
5. Restore Unit Performance
6. Minimize Down-Time
-------
Slide 14-6
FEATURES OF A
MAINTENANCE PROGRAM
1. Review Vendor Recommendations
2. Identification of Problems
3. Evaluation of Options
4. Communication & Planning
5. Implementation
-------
Slide 14-7
IN-SERVICE MAINTENANCE
1. Follow Recommended Procedures
2. Know Special Design Features
3. Know Operational Relationships
-------
Slide 14-8
OUTAGE MAINTENANCE
1. Make & Update an Outage Plan
2. Arrange for Materials/Services
3. Make Detailed Inspections
4. Revise Plans as Necessary
5. Follow Proper Procedures
6. Inspect Upon Conclusion
-------
-------
LESSON PLAN NUMBER 15
FLUE GAS CLEANING I: PARTICULATE MATTER
Goal: To provide information about equipment designed for the control of
particulates.
Objectives: Upon completion of this unit, an operator should be able to:
1. Contrast the general features of partitioning of solid residues between
bottom ash and fly ash which vary between modular starved-air
incinerators and large MWC units.
2. Identify the characteristic 50% cut-size range for particles emitted by
MWI units.
3. Identify two types of materials which form very small particles in the
flue gas.
4. List four general types of APCD devices which can be used for
collecting particulate matter.
5. Describe three of the collection mechanisms associated with the
collection of particles by wet scrubbers.
6. Give examples of the ranges of pressure drops associated with high
collection efficiencies in venturi scrubbers and fabric filters.
7. Discuss what a filter cake is and how it influences collection efficiency.
8. List the three characteristic methods for removal of collected fly ash
from a fabric filter.
9. Characterize the sequence of actions required by the collection
mechanism of an ESP.
10. Describe the primary method used for removal of collected fly ash from
an ESP.
11. Name the monitored electrical parameters for ESP transformer-
rectifier sets.
15-1
-------
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions:
1. What makes a filter cake function as a good filter?
2. Why do you change the filter in your home heating system?
3. Which system will be "better" at collecting sub-micron particles:
an ESP, a baghouse, or a venturi scrubber?
Presentation
Outline:
Flue Gas Control I: Particulate Matter
Particle Sizes & Entrainment Factors
Particle Formation
Influences of Particulates on Dioxin/Furan Formation
Venturi & Wet Scrubbers
Fabric Filters
Electrostatic Precipitators
Projection Slides: See the following pages.
Source of Graphics:
Slide 15-7 J. Joseph and David Beachler, APTI Course SI:412C. Wet Scrubber Plan
Review-Self Instructional Guidebook. U. S. Environmental Protection
Agency, EPA-450/2-82-020, March 1984.
Slide 15-8 J. Joseph and David Beachler, APTI Course SI:412C. Wet Scrubber Plan
Review-Self Instructional Guidebook. U. S. Environmental Protection
Agency, EPA-450/2-82-020, March 1984.
Slide 15-9 "Emission Control Systems for Incinerators," Report Number TR-89-
900239, Andersen 2000, Inc., Peachtree City, Georgia, February 1989,
pp. 2 and 3.
Slide 15-10 J. Joseph and David Beachler, APTI Course SI:412C. Wet Scrubber Plan
Review-Self Instructional Guidebook. U. S. Environmental Protection
Agency, EPA-450/2-82-020, March 1984.
15-2
-------
Slide 15-11 David S. Beachler and James A. Jahnke, APTI Course 413. Control of
Particulate Emissions. Student Manual. U. S. Environmental Protection
Agency, EPA-450/2-80-066, October 1981, pp. 7-1, 8-23, 9-24, 9-25.
Slide 15-14 Courtesy of George A. Rolfes Company, Control Techniques for
Particulate Emissions from Stationary Sources. Volume 1, U, S.
Environmental Protection Agency, EPA-450/3-81-005a, September 1982.
Slide 15-15 David S. Beachler and James A. Jahnke, APTI Course 413. Control of
Particulate Emissions. Student Manual. U. S. Environmental Protection
Agency, EPA-450/2-80-066, October 1981, pp. 7-1, 8-23, 9-24, 9-25.
Slide 15-16 Illustrations of Shake/Deflate-Cleaned Baghouse, ABB Environmental
Systems, ABB Flakt, Inc., April 1992.
Slide 15-17 David S. Beachler and James A. Jahnke, APTI Course
413. Control of Particulate Emissions. Student Manual. U.
S. Environmental Protection Agency, EPA-450/2-80-066,
October 1981, pp. 7-1, 8-23, 9-24, 9-25.
iSlide 15-19 PEI Associates, Operation and Maintenance Manual for Electrostatic
Precipitators. EPA-625/1-85-017, September 1984.
15-3
-------
Slide 15-1
PARTITIONING OF
SOLID RESIDUES
FUEL/EQUIPMENT TYPE
EXAMPLE VALUES, %
BOTTOM ASH FLY ASH
MWI Modular Starved-Air
MSW Mass Burn - Grate
Pulverized Coal
RDF - Spreader
98
90
30
25
2
10
70
75
-------
Slide 15-2
PARTICLE ENTRAINMENT
FACTORS
1. Particle Size, Shape & Density
2. Underfire Air Velocity
3. Waste Charging Method
4. Fuel Burning Rate
-------
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Slide 15-4
MAJOR TYPES OF
PARTICULATES
PARTICIPATE
Refractory Oxides
Inorganic Salts
Volatile Elements
Heavy Metals
Trace Organics
PARTICLE SIZE
(Micrometers)
Greater than 0.8
Less than 0.5
Less than 0.3
Less than 1.0
Less than 0.5
-------
Slide 15-5
INFLUENCES OF PARTICULATES
ON DIOXIN / FUR AN
1. Catalytic Formation on Ash Surfaces
2. Adsorption by Carbon in Fly Ash
Low Fly Ash Loading and Carbon Content
3. Activated Carbon Injection
-------
Slide 15-6
PARTICULATE COLLECTION
EQUIPMENT
1. Venturi Scrubbers
2. Fabric Filters
3. Electrostatic Precipitators
4. Mechanical Collectors
Cyclone Separators
Gravimetric Settling Chambers
-------
Slide 15-7
VENTURI SCRUBBER WITH
WATER SPRAY NOZZLES
DIRTY FLUE GAS
SPRAY NOZZLES
LIQUID INLET
VENTURI THROAT-
CYCLONIC HIST
ELIMINATOR
-------
Slide 15-8
VENTURI SCRUBBER WITH
WATER FILM ATOMIZATION
Liquid
inlet
Liquid
inlet
Throat
-------
Slide 15-9
VENTURISCRUBBER WITH
VARIABLE THROAT AREA
HOT GAS
INLET
"THIMBLE* INLET
SCRUBBING UQUOR
TO THROAT
(60% OF LIQUID)
ALTERNATE OR SUPPLEMENTAL
NOZZLE LOCATION FOR VERY
HIGH TEMPERATURE GASES
TANGENTIAL LIQUID INLETS
(40% OF LIQUID)
CONVERGING INLET-WETTED
WITH TANGENTIAL LIQUID
SCRUBBING LIQUOR
TO THROAT
THROAT INSERT
THROAT-CROSS SECTION
VARIES WITH INSERT
POSITION
EXPANDER SECTION
WETTED ELBOW-FILLS
WITH LIQUID
HYDRAULIC OR MECHANICAL
ADJUSTMENT FOR THROAT
Courtesy of Andersen 2000,
-------
Slide 15-10
FLOODED ELBOW AND
CYCLONIC SEPARATOR
FEATURES
Flooded
elbow
Cyclonic
separator
-------
Slide 1541
IMPINGEMENT PLATE
SCRUBBER
dean |*a
Impingement
plate
* *.
-------
Slide 15-12
FABRIC FILTER COLLECTION
MECHANISMS
1. Inertial Impaction
2. Direct Interception
3. Diffusion
4. Electrostatic Attraction
-------
Slide 15-13
CLASSES OF FABRIC
FILTER SYSTEMS
1. Pulse-Jet
2. Reverse-Air
3. Shaker
-------
Slide 15-14
PULSE-JET FABRIC FILTER
Clean Air PI*
Blow Pipe
Bag Retainer.
xl//,.
'/ V Y
To Clean Air Outlet
and Exhauster
Dirty Air intet and Diffuser'.
Housing
Tubular Filter Bags
Dirty Air Plenum
Rotary Valve Air Lcc*
Courtesy of George A. Rolfes Company.
-------
Slide 15-15
REVERSE-AIR FABRIC
FILTER
-------
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-------
Slide 15-17
ELECTROSTATIC
PRECIPITATOR
Ducharge
-------
Slids 15-18
ELECTROSTATIC
COLLECTION PROCESS
• High Voltage lonization of Molecules
• Corona & Electric Fields Created
• Charges Transferred to Participates
• Migration of Participates to Plates
• Removal of Particulates
-------
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Slide 15-20
ESP DESIGN COMPONENTS
Step-Up Transformer
High Voltage Rectifier
Shell Enclosure for Support & Insulation
Vertical Wires - Discharge Electrode Wires
Vertical Plates - Collection Electrodes
Rappers
Hoppers
-------
Slide 15-21
ESP PARTICULATE
REMOVAL
Charged Particle Adheres to Plate
Dry Removal - Mechanical Rappers
Wet Removal - Water Sprays
Delivery to the Hopper
-------
LESSON PLAN NUMBER 16
FLUE GAS CLEANING II: ACID GAS REMOVAL
Goal: To provide information about the control of HC1 and SO2 acid gases.
Objectives: Upon completion of this unit, an operator should be able to:
1. Identify the two types of equipment most often used for acid gas
control in MWI units.
2. Describe the relative advantages and disadvantages of the wet
scrubber combination system of a venturi scrubber and packed tower.
3. Identify the two major chemical products formed when acid gases react
with the calcium hydroxide sorbent solution.
4. Contrast the design features of a spray dryer and fabric filter system
with those of dry sorbent injection and fabric filter system for acid gas
control.
5. Discuss the operational advantages of dry sorbent injection and fabric
filter systems relative to those of spray dryer and fabric filter systems.
6. Describe the function of a slaker.
7. Discuss the reasons for heating the fluid transfer lines from a slaker to
a spray atomizer.
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions
1. What is the general range of the amount of hydrated lime (calcium
hydroxide) which must be used in a spray dryer to achieve acceptable
acid gas removal from MWI flue gas?
2. Would a fine water spray by itself remove much HC1; much S02?
16-1
-------
Presentation
Outline: Flue Gas Cleaning II: Acid Gas Removal
Caustic Solutions & Wet Scrubbing Systems
Dry Sorbent Injection (DSI/FF)
Spray Dry Absorber (SDA/FF)
Projection
Slides:
See the following pages.
Source of
Graphics:
Slide 16-3
Slide 16-4
Slide 16-5
Slide 16-7
Slide 16-8
Slide 16-9
David S. Beachler and James A. Jahnke, APTI Course 413. Control of
Particulate Emissions. Student Manual. U. S. Environmental Protection
Agency, EPA-450/2-80-066, October 1981, p. 9-54.
"Emission Control Systems for Incinerators," Report Number TR-89-
900239, Andersen 2000 Inc., Peachtree City, Georgia, February 1989, pp.
2, 3, 15, and 16.
"Emission Control Systems for Incinerators," Report Number TR-89-
900239, Andersen 2000 Inc., Peachtree City, Georgia, February 1989, pp.
2, 3, 15, and 16.
Courtesy of AirPol, Inc., printed with permission, R. G, Barton, et al.,
"State-Of-The-Art Assessment of Medical Waste Thermal Treatment,"
Report to Risk Reduction Engineering Laboratory, USEPA, and California
Air Resources Board, June 15, 1990, pp. 97-108.
Robert G. Mclnnes, "Spray Dryers and Fabric Filters: State of the Art,"
Solid Waste & Power. April 1990, pp. 24-30.
Theodore G. Brna, "Cleaning of Flue Gases from Waste Combustors,"
Combustion Science and Technology. Vol. 74, 1990, pp. 83-98.
16-2
-------
Slide 16-1
ACID GAS REMOVAL
TECHNOLOGY
Wet Scrubbers
Dry Scrubbers
Venturi
Packed-Bed
Impingement Scrubber
Dry Sorbent Injection
Spray Dry Absorber
-------
Slide 16-2
EXAMPLE ACID GAS
NEUTRALIZATION REACTIONS
Caustic Soda:
NaOH + HC1
NaCl + H2O
Soda Ash:
Na2CO3
+ CO,
2HC1
2NaCl
H2O
Sodium Bicarbonate:
NaHCO3 + HC1
+ CO,
NaCl + H,O
Slaked Lime:
CA (OH)2 + 2HC1
+ 2H20
CaCl,
-------
Slide 16-3
PACKED-BED WET
SCRUBBER
Mist eliminator
Water iprays
:': \\Dirtygai
-------
Slide 16-4
COMBINED SYSTEM:
VENTURI AND PACKED-BED
LIQUID DISTRIBUTOR
LIQUID FEEDS
QUENCH SECTION
WETTED ELBOW
PACKING SUPPORT
COMBINATION CYCLONIC
SEPARATOR AND PACKED
TOHER ABSORBER
OUTLET
PACKING
IQUID DISCHARGE
Courtesy of Andersen 2000 Inc.
-------
Slide 16-5
COMBINED SYSTEM:
VENTURI / BAFFLE PLATE
SCRUBBER
Inlet
Quench Section
Liquid Feeds
Venturi
Chevron Mist
Eliminator
Liquid Feed
Wetted Eibow
Disc and Oonut
Battle Stages
Combination Cyclonic
Separator and Counter-
current Baffle-
Type Acid Gas Chamber
Outlet
Liquid
Flow
Liquid Discharge
Courtesy of Andersen 2000 Inc.
-------
Slide 16-6
WET SCRUBBER ACID GAS
APPLICATIONS
Advantage
Moderate Pressure Drop
No Special Start-Up Problems
Disadvantages
Corrosion and Erosion
Liquid Residue Produced
-------
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Slide 16-10
SPRAY DRYER ABSORBER
OPERATIONS
Slurry Atomized to Fine Droplets
Reaction Chamber Provides Residence Time for
Acid Absorption on Slurry Droplets
Slurry Droplets are Dried by Hot Flue Gas
Flue Gases are Cooled by Evaporation
Particulates Collected by a Fabric Filter
-------
LESSON PLAN NUMBER 17
TOXIC METAL CHARACTERISTICS AND EMISSIONS CONTROL
Goal: To provide information about the emission of heavy metals from MWI
units and the environmental concerns related to their disposal.
Objectives: Upon completion of this unit, an operator should be able to:
1. List four toxic metals found in medical waste.
2. Describe the environmental issues associated with emission of MWI
metals in the stack gases.
3. Describe the environmental issues associated with release of MWI
metals from the combustion residues disposed in landfills and
monofills.
4. List three elements in a control strategy for reducing metal air
pollutants.
5. Discuss the problems associated with proper sampling and laboratory
testing to determine a meaningful measurement of the potential for
ash leaching from a landfill or monofill.
6. Identify the names of two different laboratory procedures for
determining the toxic leaching characteristics of ash.
Lesson Time: Approximately 50 minutes
Suggested
Introductory
Questions:
1. How would you know if MWI ash is hazardous?
2. What options do you have if your ash fails a TCLP test?
17-1
-------
Presentation
Summary
Outline: Toxic Metal Characteristics and Emissions Control
Toxic Metals in Medical Waste
Changes in Metals During Incineration
Example Metal Compositions
Toxic Metal Air Pollutants
Control by Adsorption, Condensation, Activated Carbon
Ash Testing & Groundwater Contamination
Projection
Slides:
See the following pages.
17-2
-------
Slide 17-1
METALS IN MEDICAL WASTE
Medical Waste Composition:
Average of 8 to 10% Inorganic (Ash)
Up to 4% Metals
Non-Toxic Metals: Iron, Aluminum
Major Toxic Metals: Lead, Cadmium, Mercury
Other Trace Metals: Antimony, Arsenic, Barium,
Beryllium, Chromium, Nickel,
Silver, Selenium, Thallium
-------
Slide 17-2
CHANGES IN METALS
DURING INCINERATION
High Melting Point (Non-Volatile) Metals:
Form Oxides, Chlorides, Sulfides
Remain in the Solid Residue (Ash)
Low Melting Point (Volatile) Metals:
Form Liquids which Solidify when Cooled
Form Vapors which Condense when
Cooled, are Adsorbed onto Fly Ash, or
Remain as Vapor
-------
Slide 17-3
TOXIC METAL PATHWAYS
INTO ENVIRONMENT
1. Wet Scrubber Liquids - Waste Water
m 2. Bottom Ash - Leachate from Landfill
W
3. Collected Ry Ash - Leachate from Landfill
4. Stack Emissions - Gases & Particulates
-------
Slide 17-4
EXAMPLE COMPOSITIONS OF
METALS IN BOTTOM ASH
COMPONENT UNIT D
(mg/kg)
UNITE
UNITF
Arsenic
Cadmium
Chromium
Iron
Lead
Manganese
Mercury
Nickel
Total
Metals
11.7
5.6
180
6,200
<5.6
340.2
< 0.02
55
6,798
13.9
5.1
120
15,000
180
1,000
0.2
41
16,360
5.4
46.4
685
901
<9.8
86.8
-------
Slide 17-5
COMPARISON OF BOTTOM ASH
& BAGHOUSE ASH METALS
COMPONENT BOTTOM ASH BAGHOUSE ASH
(mg/kg)
Arsenic 13.9 12.5
Cadmium 5.1 94
Chromium 120 55
Iron
Lead
Manganese
Mercury
Nickel 41 12
Total 16,360 2,311
Metals
15,000
180
1,000
0.2
1,200
870
49
18
-------
Slide 17-6
MAJOR TOXIC METAL
AIR POLLUTANTS
Lead - Paniculate
Cadmium - Particulate
Mercury - Particulate & Vapor
-------
Slide 17-7
CONTROL STRATEGY FOR
METAL AIR POLLUTANTS
Provide for Condensation and Adsorption
by Controlling APCD Temperatures
Inject Activated Carbon Powder for
Enhanced Adsorption
Collect Metals as Particulates
-------
Slide 17-8
TOXIC METALS AS GROUND
WATER POLLUTANTS
Organic Decomposition to Form Acids
Acid Extraction of Heavy Metals from Ash
Ground Water Contamination by Heavy Metals
-------
Slide 17-9
IS ASH HAZARDOUS OR
NON-HAZARDOUS?
Answer Varies from State to State;
• Regulatory Definitions
• Toxicity Test Requirements
• Ash Sampling Procedures
-------
Slide 17-10
LABORATORY PROCEDURES
FOR TOXICS
EP - Extraction Procedure Toxicity Test
(an early procedure)
TCLP - Toxic Characteristic Leaching
Procedure (Method 1311)
EPA Method 1312 - Synthetic Precipitation
Leach Test for Soils
EPA Method 3050 - Acid Digestion of
Sediments, Sludgees & Soils
-------
Slide 17-11
ASH TREATMENT
BEFORE DISPOSAL
Chemical Extraction
Chemical Additives
Compaction
Vitrification
-------
-------
LESSON PLAN NUMBER 18
APCD PERFORMANCE & SYSTEM CONTROL FEATURES
Goal: To provide applied information about the performance and control
features of air pollution control devices.
Objectives: Upon completion of this unit, an operator should be able to:
1. Identify the ranges of acid gas removal efficiencies associated with
different acid gases and different types of scrubbers (e.g., wet or dry).
2. Describe the basic features of stack testing equipment for determining
the particulate emissions from a MWI stack.
3. List five different parameters which influence the performance of
APCD systems.
4. Describe why dew point considerations are important in ducts and air
pollution control equipment.
5. Identify typical operating temperatures which are selected to avoid
dew point problems.
^ 6. Identify key operating features and control variables of wet scrubber
systems for acid gas control.
7. Define the air to cloth ratio for a fabric filter.
8. Describe the typical types of operational problems associated with
fabric filter systems.
9. Describe normal procedures undertaken to prevent fabric filter systems
from operating at too high a temperature.
10. Characterize dry sorbent delivery systems and operational problems.
11. Describe the typical types of operational problems associated with
spray dryer systems.
Lesson Time: Approximately 40 minutes
18-1
-------
Suggested
Introductory
Question:
1.
Presentation
Summary
Outline:
How is one APCD system for particulates (or for acid gases) better than
another?
APCD Performance & System Control Features
Performance Indicators
Stack Testing Methods
APCD Control Considerations
Dew Point Considerations
Acid Gas Wet Scrubbing Operations
Venturi Scrubber Control Variables
Fabric Filter Performance Variables
Dry Scrubber & Spray Dryer Operational Features
Projection
Slides:
See the following pages.
18-2
-------
Slide 18-1
APCD PERFORMANCE
INDICATORS
€>
Operational Indicators
• Opacity or Visual Emissions
• Temperatures
• Pressure Drops
• Gas Concentrations
Stack Tests
• Particulate Emissions
• Dioxin/ Furan Emissions
-------
Slide 18-2
EXAMPLE ACID GAS
REMOVAL EFFICIENCIES
Equipment
HC1
SO
Wet Scrubbers
Dry Scrubbers
95 - 99.9
90 - 99
90 - 99
60 - 85
-------
Slide 18-3
TYPICAL CEMS USED AT
MWI UNITS
1. Combustion Temperatures
2. Opacity
3. Carbon Dioxide
4. Oxygen
5. Carbon Monoxide
6. Sulfur Dioxide
7. Hydrogen Chloride
-------
Slide 18-4
STACK TESTING METHODS
Particulates:
Hydrogen Chloride:
Multi-Metals:
Dioxin/Furan:
Methods 5 & 17
Method 26
Method 29
Method 23
-------
Slide 18-5
PARTICLE SAMPLING
TRAIN, METHOD 5
C-
Pitot Tube
-Temperature Sensor
Thermometer
Thermometer
ProDe
Temperature
Sensor
X
Reverse-Type
Pitot Tube
Stack Wall
Pitot Manometer
ri iP>V* ''PCTV,HFWi'I
'ill! !i' ft-' i
'u' 'LJ' 'u' 'u'
iHj LUJ iHj -ATJ
Thermometers
Orifice
Ice Bath Impingers
By-Pass
Valve
Dry-Gas Meter
Vacuum Gage
Main Valve
Air-Tight Pump
Courtesy of ABB Combustion Engineering, Inc.
-------
Slide 18-6
APCD CONTROL
CONSIDERATIONS
Flue Gas Temperature
Flue Gas Flow Rate
Pollutant Concentration
Pressure Drop
Reagent Flow
pH
Thermal Protection
Dew Point
-------
Slide 13-7
DEW POINT
CONSIDERATIONS
Threshold Condensation Temperature
Typically Values Range from 225 to 300° F
Dependent Upon the Mixture's Moisture
and Acid Concentrations
-------
Slide 18-8
ACID GAS WET SCRUBBER
OPERATIONS
Absorption and Chemical Reactions
Recirculation of Caustic Solution
Removal of Salts
Maintenance of Scrubber pH
Control Inlet Temperature
Provide Required Pressure Drop
-------
Slide 18-9
VENTURI SCRUBBER
CONTROL VARIABLES
Pressure Drop
Liquid/Gas Flow Rate Ratio
Scrubber pH
-------
Slide 18-10
DISADVANTAGES OF
VENTURI SCRUBBERS
• High Energy Requirements, Pressure Drop
• Liquid Waste Residue
• Corrosion and Erosion
-------
Slide 18-11
FABRIC FILTER
DESIGN FACTOR
AIR-TO-CLOTH RATIO
Total Air Flow/Filter Surface Area
Average Velocity Through Filter
Maximum Operating Temperature
-------
Slide 18-12
FABRIC FILTER
OPERATIONAL PROBLEMS
Low Pressure Drop:
• Holes in Bags
• Over Cleaning
High Pressure Drop:
• Blinding
• Under Cleaning
Fabric Deterioration or Fires:
• Improper Flue Gas Cooling
• Surge of Burning Flue Gas
Corrosion
Improper Insulation
Improper Air Dryer Operation
Improper Temperature Control
Leaking Gaskets
-------
Slide 18-13
DRY SORBENT
OPERATIONAL FEATURES
Sorbent Material Delivery Rate
Mixing of Sorbent Powder with Flue Gas
Optimum Temperature for Sorbent Reaction
Dew Point Considerations
-------
Slide 18-14
DRY SORBENT
OPERATIONAL PROBLEMS
Ash Removal from Collection Hopper
• Air Impactors
• Sonic Horns
* Vibrators
* Hopper Heaters & Insulation
• Maintenance of Air Seals
-------
Slide 18-15
SPRAY DRYER OPERATIONAL
CONSIDERATIONS
Slurry Flow Rate
Acid Gas Concentration
Adequate Drying of Slurry Droplets
Atomizer Maintenance
Overall Drying Conditions
Exit Dry Bulb Temperature
Exit Wet Bulb Temperature
Inlet-Exit Dry Bulb Difference
Slurry Water Content
Exit Dry Bulb Temperature
Air Leakage Prevention
Maintenance of Hopper Temperatures
-------
Slide 18-16
SPRAY DRYER
OPERATIONAL PROBLEMS
1. Slurry Droplets Sticking on Wall
2. Liquid Carryover
3. Caking of Solids on Fabric Filter
4. Ash Hopper & Removal System Plugging
-------
LESSON PLAN NUMBER 19
APCD OPERATIONAL AND SAFETY CONSIDERATIONS
Goal: To provide information about the operational and safety aspects of
APCD operations.
Objectives: Upon completion of this unit, an operator should be able to:
1. List the major ways of detecting APCD upsets.
2. Identify the some typical pollutant concentrations associated with
uncontrolled and controlled emissions from MWI systems.
3. Discuss the general features of starting up and shutting down an
APCD system.
4. Describe the function of a by-pass stack and why a "fail-safe" controller
is generally required.
5. Describe procedures undertaken to prevent blinding of fabric filter
systems during start-up.
6. List three routine operational problems which can cause dew point or
solidification problems in APCD systems.
7. Identify typical component systems which can fail and create a wet
scrubber upset conditions.
8. Identify typical component systems which can fail and create a wet
fabric filter upset conditions.
9. Describe the influence of an incinerator's upset influencing the APCD's
operation.
10. Describe the influence of an APCD's upset influencing the incinerator's
operation.
Lesson Time: Approximately 40 minutes
19-1
-------
Suggested
Introductory
Questions
What are the typical safety hazards which can occur associated with your
APCD system.
Ask the participants to describe the potential hazards and safety
requirements associated with entering a fabric filter bag house,
combustion chamber, or other confined space.
Presentation
Summary
Outline:
APCD Operational and Safety Considerations
Methods for Detecting APCD Upsets
Monitoring & Control Concerns
APCD Start-up and Shutdown
By-Pass Stack Operations
Routine Operational Concerns
Effect of Upsets on Other Systems
Wet Scrubber Operational Upsets
Fabric Filter Operational Upsets
APCD Safety Hazards
Projection
Slides:
See the following pages.
19-2
-------
Slide 1.9-1
OPERATOR REQUIREMENTS
1. Know the System Characteristics
2. Assess the Operating Conditions
3. Identify Potential Modifications
4. Make Timely Decisions
5. Keep Proper Records
-------
Slide 19-2
METHODS FOR DETECTING
APCD UPSETS
1. Observe Visual Emissions
2. Review Instrument Readings
3. Inspect APCD Equipment
4. Listen for Abnormal Sounds
5. Feel Unusual Vibrations/Hot Surfaces
6. Smell Unusual Odors
-------
Slide 19-3
EXAMPLE UNCONTROLLED
EMISSIONS AND PARAMETERS
PARAMETER LOW HIGH EXAMPLE
Opacity, % 0 10
Primary Temp., F 1,000 2,000
Secondary Temp., F 1,800 2,200
" Draft, in w.g. 0.03 0.15
Oxygen, % Dry Basis 11 15 13
CO2, % Dry Basis 5 10
CO,ppmat7%O2 0 100
Ha, ppm at 7% O2 935
SO2, ppm at 7% O2 207
PM, gr/dscf at 7% O, 0.211
-------
Slide 19-4
MONITORING & CONTROL
CONCERNS
Emissions Exceedance
Instrument Malfunction
Controller Malfunction
-------
Slide 19-5
APCD START-UP &
SHUTDOWN
Manufacturer's Recommendations
Sequence of Operations
Preheating
Maintaining Temperatures
-------
Slide 19-6
BY-PASS STACK OPERATIONS
APCD Start-up & Shutdown
Baghouse & Scrubber Protection
"Fail Safe" Provisions
-------
Slide 19-7
ROUTINE OPERATIONAL
CONCERNS
• Leakage Through Seals & Cracks
• Material Blockages
• Freeze Protection
it
-------
Slide 19-8
EFFECT OF UPSETS ON
OTHER SYSTEMS
Incinerator's Upset on APCD
Increased Emissions
Baghouse or Liner Fire
APCD's Upset on Incinerator
Puffing (Draft/Air Upsets)
-------
Slide 19-9
WET SCRUBBER
SYSTEM UPSETS
• Flue Gas Cooling System
• Water Spray Nozzle
• Thermocouple
• Control System
• Pump
• Fan or Damper
• Caustic Holding Tank
• Level Control Valve
• Corrosion
-------
Slide 19-10
FABRIC FILTER
OPERATIONAL UPSETS
Fabric Filter Blinding
Fabric Filter Rupture
Thermal Protection of Bags
Water Spray Nozzle Failure
-------
Slide 19-11
APCD SAFETY HAZARDS
Skin Puncture/Cuts
Thermal Injury
Chemical Burns
Confined Space Suffocation
Inhalation of Toxic Dust
-------
Slide 19-12
OPERATIONAL CONCERNS
ABOUT TOXIC METALS
Procedures to Prevent Exposure
Special Equipment (Suits, Aspirators)
Personal Monitors
-------
LESSON PLAN NUMBER 20
BOILERS AND OTHER HEAT RECOVERY EQUIPMENT
Goal: To provide descriptive information about boiler and heat recovery
applications.
Objectives: Upon completion of this unit, an operator should be able to:
1. List the major types of equipment used in heat recovery (including
boiler) applications.
2. Discuss the differences between unfired waste-heat boilers and integral
boilers and between fire-tube and water-tube boilers.
3. List three reasons that heat exchangers may be used in flue gas.
4. Discuss the heat exchanger aspects of a condenser where low pressure
steam condenses on the outside of tubes which contain cooling water.
5. Explain the problems associated with maintaining water level.
6. Describe the reason for having fins on the gas-side of economizers.
7. Discuss the influence that waterwall (membrane wall) surfaces have
on stoichiometric combustion conditions.
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Question:
1. Why are most of the boilers at MWI units waste-heat boilers?
Presentation
Summary
Outline: Boilers and Other Heat Recovery Equipment
Heat Recovery Equipment
Heat Exchangers
Boiler Applications
Fire-Tube Boilers
Water-Tube Boilers & Economizers
Waterwall Boilers
Condensers
20-1
-------
Projection
Slides:
Source of
Graphics:
Slide 20-3
Slide 20-4
Slide 20-6
See the following pages.
Slide 20-7
Slide 20-9
Slide 20-10
Slide 20-11
Slide 20-12
Slide 20-13
Slide 20-15
Gerald T. Joseph and David S. Beachler, APTI Course 415. Control of
Gaseous Emissions. Student Manual. U. S. Environmental Protection
Agency, EPA-450/2-81-005, December 1981, pp. 3-32 to 3-37.
Gerald T. Joseph and David S. Beachler, APTI Course 415. Control of
Gaseous Emissions. Student Manual. U. S. Environmental Protection
Agency, EPA-450/2-81-005, December 1981, pp. 3-32 to 3-37.
S. E. Sawell and T. W. Constable, "NITEP: Assessment of Contaminant
Leachability from MSW Incinerator Ash," Proceedings of an International
Workshop on Municipal Waste Incineration. Sponsored by Environment
Canada, Montreal, Quebec, October 1-2, 1987, p. 335-336.
David S. Beachler, APTI Course SI-428A. Introduction to Boiler
Operation. Self-instructional Guidebook. U. S. Environmental Protection
Agency, EPA-450/2-84-010, December 1984, pp. 1-3 to 1-13.
Joseph G. Singer, Combustion Fossil Power. 4th Edition, Combustion
Engineering, Inc, Windsor, CT, 1991, p. 8-32.
Deltak Corporation, Minneapolis, MN, Unpublished report, 1992.
David S. Beachler, APTI Course SI-428A. Introduction to Boiler
Operation. Self-instructional Guidebook. U. S. Environmental Protection
Agency, EPA-450/2-84-010, December 1984, pp. 1-3 to 1-13.
"Basic Environmental Engineering, Inc.," Basic Environmental
Engineering, Inc., Glen Ellyn, IL, Undated Brochure, Received: April
1992.
"Basic Environmental Engineering, Inc.," Basic Environmental
Engineering, Inc., Glen Ellyn, IL, Undated Brochure, Received: April
1992.
Frederick M. Steingress and Harold J. Frost, Stationary Engineering.
American Technical Publishers, Inc., Homewood, IL, 1991, pp. 227-275.
20-2
-------
Slide 20-1
HEAT RECOVERY
SYSTEM FEATURES
Raise Revenue through Steam Sales
Reduce Auxiliary Fuel Use
Reduce Electrical Energy Use
Lower Flue Gas Temperatures
-------
Slide 20-2
MWI HEAT RECOVERY
EQUIPMENT
Air-to-Air Heat Exchangers
Waste-Heat Boilers
Integral Waterwall Boilers
-------
Slide 20-3
RECUPERATIVE,
SHELL-AND-TUBE HEAT
EXCHANGER
To stack
exhaust
-------
Slide 20-4
HEAT EXCHANGER FOR
REHEATING FLUE GAS
Heat exchanger
-------
Slide 20-5
BOILER DESIGNS FOR MWI
APPLICATIONS
Unfired Waste-Heat Boiler Designs:
Fire-Tube Convection Unit or
Water-Tube Convection Unit
• Hot Water Boiler
• Saturated Steam Boiler
Integral Boiler Designs:
Waterwall Radiant Section
Water-Tube Convection Sections
• Saturated Steam Boiler
• Superheat Boiler
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Slide 20-9
WASTE-HEAT BOILER WITH
HORIZONTAL WATER TUBES
Economizer
Section
Evaporator
Sections
Superheater
Section
Courtesy of ABB Combustion Engineering. Inc.
-------
Slide 20-10
WATER-TUBE WASTE-HEAT
BOILER AND ECONOMIZER
Courtesy of Deliak Corporaiion, Minneapolis, MN.
-------
Slide 20-11
ECONOMIZER
Heated
Outlet header
Water inlet
Flue gas
-------
Slide 20-12
WATERWALL FURNACE
ENCLOSURE
Courtesy of Basic Environmental Engineering. Inc., Glen Ellyn. IL.
-------
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Slide 20-14
INTEGRAL BOILER SECTIONS
Radiant Section
• Feedwater Heating
• Evaporation
Convective Section
• Evaporator
• Superheater
• Economizer
-------
Slide 20-15
STEAM CONDENSER
SCHEMATIC
Exhaust Steam Inlet
Condenser
Tubes
• Cooling Water
Outlet
Baffle
Cooling Water
Inlet
Circulating
Pump
From F.M. Sieingress and HJ. Frost, Stationary Enpneeriny , American Technical Publishers, Inc.. Homewood, IL, 1991, printed with permission.
-------
-------
LESSON PLAN NUMBER 21
BOILER ENERGY PRINCIPLES
Goal: To provide an introduction of boiler energy principles and concepts
which are related to types of energy, steam production, energy
conversion, and heat transfer.
Objectives: Upon completion of this unit, an operator should be able to:
1. Describe the difference between sensible heat and latent heat and
their relationship to thermal energy.
2. Understand the basic energy unit of a Btu.
3. Describe the steam characteristics of saturated liquid, wet vapor,
quality, dry steam, and superheat steam.
4. Identify the three basic modes of heat transfer and give an example of
where each is the dominant form of heat transfer in a boiler system,
5. Describe the basic concept of an energy balance on a heat exchanger.
6. Describe the features of steam production in boilers.
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Question:
1. What is the difference between saturated steam and superheat steam?
Presentation
Summary
Outline: Boiler Energy Principles
Types of Energy in MWI Boilers
Categories of Thermal Energy
Steam Characteristics
Energy Conversion Examples & Heat Transfer
Energy Conservation (Energy Balance)
Features of Steam Production
Projection
Slides: See the following pages.
21-1
-------
Slide 21-1
BOILER ENERGY PRINCIPLES
Types of Energy
Units of Energy
Steam Characteristics
Energy Conversion
Heat Transfer
-------
Slide 21-2
TYPES OF ENERGY IN
MWI BOILERS
Chemical
Thermal
Mechanical
Potential
Kinetic
Electrical
- Heat of Combustion
- Sensible Heat & Latent Heat
- Work Related to Force x Distance
- Elevation Related Energy Storage
- Motion Related Energy Storage
- Electrical Power
-------
Slide 21-3
ENERGY UNITS
Btu
Calorie (kilogram-calorie)
Joule
Kilojoule
-------
Slide 21-4
CATEGORIES OF
THERMAL ENERGY
Sensible Heat
Latent Heat of Vaporization
Heat Content
Enthalpy
-------
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Slide 21-6
STEAM CHARACTERISTICS
Saturated Liquid (Water)
Saturated Vapor (Dry Steam)
Mixture of Liquid & Vapor
Quality (Vapor Fraction)
Superheat Steam
-------
Slide 21-7
ENERGY CONVERSION
EXAMPLES
Chemical Energy to Thermal Energy
Mechanical Energy to Potential Energy
Potential Energy to Kinetic Energy
Thermal Energy to Work of Automobile
Thermal Energy to Rotate a Turbine
Rotational Energy to Create Electricity
-------
Slide 21-8
MODES OF HEAT TRANSFER
Conduction
Convection
Radiation
-------
Slide 21-9
CONVECTION HEAT
TRANSFER
Natural or Free Convection
Forced Convection
Boiling
Condensation
-------
Slide 21-10
RADIATION HEAT TRANSFER
Electromagnetic Radiation
Solar Energy Example
• Ultraviolet
• Visible
• Infrared
Heat Transfer to Waterwalls
-------
Slide 21-11
ENERGY CONSERVATION
FOR A SYSTEM
Total Energy Input Rate
Must Equal
Total Energy Leaving Rate
-------
Slide 21-12
ENERGY LEAVING AN
INCINERATOR
• Sensible Heat Gain by Combustion Gases
• Latent Heat Gain by Combustion Gases
Water Formed in Combustion
A Water from Fuel Moisture
Water from Spray Nozzles
Moisture in Combustion Air
• Heat Loss through the Enclosure
• Energy Loss from Incomplete Combustion
-------
Slide 21-13
HEAT BALANCE ON A HEAT
EXCHANGER
Energy Extracted from the Hot Fluid
Must Equal
Energy Gained by the Heated Fluid
-------
Slide 2144
AIR PREHEATER IN
A COUNTERFLOW
CONFIGURATION
0.0 0.2 0.4 06 0.8
Relative Position Down The Unit
Cooled Flue Gas
Preheated Combustion Air
Ambient Air
Hot Flue Gas
-------
Slide 21-15
FEATURES OF STEAM
PRODUCTION IN BOILERS
Raise Water Temperature to Saturation
Vaporize Water (Make Steam)
Heat the Vapor to Form Superheated Steam
-------
LESSON PLAN NUMBER 22
BOILER WATER TREATMENT
Goal: To provide information about the important features of water
treatment in boiler applications.
Objectives: Upon completion of this unit, an operator should be able to:
1. List three general types of impurities found in water in boiler,
feedwater and steam.
2. List four parameters which are monitored to provide information about
feedwater conditions.
3. List two continuous operating instruments which can be used to
measure water quality in the boiler feedwater/steam system.
4. Define blowdown and discuss why it is required.
5. Discuss the general steps required for removal of gases in a deaerating
feedwater heater.
6. Identify two gaseous impurities removed in a deaerating feedwater
heater.
7. Contrast the water treatment required for cooling-water with that of
waste-water treatment.
8. Describe generally how an ion exchange process works to remove
hardness and minerals from water.
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Question:
1. Ask operator participants to discuss their knowledge of water treatment
problems at MWI units which resulted in major outages.
2. Ask them to describe the effective remedies which were used to overcome
the particular problems.
22-1
-------
Presentation
Summary
Outline:
Boiler Water Treatment
Boiler Water Impurities & Problems
Influence of Scale on Temperatures
Boiler Water Treatment Systems
Deaeration, Chemical Treatment & Blowdown
Indicators of Water Quality
Projection
Slides:
See the following pages.
Source
of
Graphics:
Slide 22-8
Slide 22-9
David F. Dyer and Glennon Maples, Boiler Efficiency Improvement.
Boiler Efficiency Institute, Auburn, AL, 1981, p. 8.28.
Frederick M. Steingress and Harold J. Frost, Stationary Engineering.
American Technical Publishers, Inc., Home wood, IL, 1991, p. 87.
22-2
-------
Slide 22-1
IMPURITIES OF RAW WATER
Composition Varies with Source
• Chemical Wastes
• Organic Wastes & Bacteria
• Oxygen & Dissolved Gases
• Dissolved or Suspended Minerals
• Suspended Solids
-------
Slide 22-2
CHEMICAL COMPOUNDS
Acids:
Bases:
Salts:
Hydrogen Ions in Solution
Metal-Hydroxyl Ions in Solution
Compounds of Acids & Bases
-------
Slide 22-3
BOILER WATER IMPURITIES
1. Dissolved Gases
2. Dissolved Minerals - Hardness
3. Dissolved & Suspended Solids
-------
Slide 22-4
BOILER WATER PROBLEMS
Corrosion & Pitting of Metal
Scale Build-Up Inside Tubes
-------
Slide 22-5
INFLUENCE OF SCALE ON
METAL TEMPERATURES
Scale
Tube Without
Scale
Tube With
Scale
-------
Slide 22-6
WATER TREATMENT FOR
A STEAM GENERATOR
MAKE-UP WATER
i
CLARIFIER
SOFTENER
DSAERATOR
VENT
STORAGE TANK
PUMP
FEEOWATER
BOILER
SLOWDOWN
STEAM
TURBINE
OR
CUSTOMER
SUPERHEATED STEAM
ELECTRICITY
LOW PRESSURE STEAM
CONDENSER
CONDENSATE
PUMP
PURIFICATION
-------
Slide 22-7
BOILER WATER PROBLEMS
& REMEDIES
1. Dissolved Gases Cause
Metal Corrosion & Pitting
Remedies:
Deaeration
Chemical Scavengers
-------
Slide 22-8
TRAY-TYPE DEAERATING
FEEDWATER HEATER
STEAM
INLET
WATER INLET
SPRAY
TRAY- SECTION
TO BOILER FEED PUMP
Courtesy of Boiler Efficiency Institute.
-------
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Slide 22-10
BOILER WATER PROBLEMS
& REMEDIES
2. Dissolved Minerals - Hardness
Increase Metal Corrosion
Form Scale & Sludge
Remedies:
Water Softeners
Condensate Purification
-------
Slide 22-11
BOILER WATER PROBLEMS
& REMEDIES
3. Dissolved & Suspended Solids
Causes Carry-Over of Impurities
Damages Superheater, Valves, Turbine
Remedy:
Boiler Water Blowdown
-------
Slide 22-12
INDICATORS OF WATER
QUALITY
1. pH - Indicates Acidic/Alkali Quality
<7: Acidic; 7: Neutral; >7: Basic
2. Conductivity of Steam & Feedwater
Microsiemens/cm
3. Total Dissolved Solids in Boiler Water
Microsiemens/cm
4. Alkalinity
Equivalent Calcium Carbonate, ppm
5. Hardness - Ability to Dissolve Soap
Calcium & Magnesium Salts, ppm
6. Silica - Silicon Dioxide, ppm
-------
LESSON PLAN NUMBER 23
BOILER SAFETY, CONTROL & OPERATIONAL FEATURES
Goal: To provide information about the proper operation of boilers, their
safety and control systems.
Objectives: Upon completion of this unit, an operator should be able to:
1. Discuss the operator's major responsibilities regarding safety.
2. Discuss three different types of operational upsets which can result in
a boiler explosion.
3. Describe an example set of events associated with a loss of water level
scenario.
4. Identify four water-side control parameters (manipulated variables).
5. Discuss the transient natures of three parameters used as water-side
control parameters (manipulated variables).
6. Discuss the general operator activities performed during a boiler start-
up and shutdown.
7. Discuss the general boiler operational activities of monitoring system
performance, detecting and repairing components, and removing soot
from tubes.
8. Discuss the parameters an operator would review in order to
determine if significant deposits were on a heat exchanger's surface.
9. List the general types of damage which can occur to MWI boilers, and
describe measures taken to reduce the potential damage.
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions:
1. Ask one of the participants to describe boiler start-up procedures.
23-1
-------
Presentation
Summary
Outline:
Boiler Operational, Control & Safety Considerations
Operating Responsibilities
Water-Side Control Parameters
Potential Major Hazards
Single, Two and Three Element Control Systems
Standard Operating Procedures
Inspection Check-List
Boiler Operational Activities
Boiler Start-Up and Shutdown
Excess-Air Waterwall Unit Operations
Projection
Slides:
See the following pages.
23-2
-------
Slide 23-1
OPERATING RESPONSIBILITIES
1. Maintain Safety of People
2. Maintain Safety of Equipment
3. Optimize Equipment Performance
-------
Slide 23-2
WATER-SIDE CONTROL
PARAMETERS
Steam Flow Rate
Feedwater How Rate
Steam Pressure
Steam Temperature
Drum Level
-------
Slide 23-3
POTENTIAL MAJOR HAZARDS
1. Explosive Mixture of Fuel/Air
2. High Pressure Steam Pipe Rupture
3. Loss of Water
-------
Slide 23-4
LOSS OF WATER LEVEL
SCENARIO
1. Boiler Runs Dry
2. Heat Extraction is Interrupted
3. Metal Overheats
4. Water Supply Causes Thermal Stresses
5. Tubes or Pressure Vessel Ruptures
-------
Slide 23-5
SINGLE-ELEMENT
CONTROL SYSTEM: DRUM
LEVEL
Steam drum
water level
SP
LC
Feedwater
Boiler
Courteiiy of the Instrumtiu Society of America.
-------
Slide 23-6
TWO-ELEMENT CONTROL
SYSTEM: DRUM LEVEL
Courtesy of the Instrument Society of America.
-------
Slide 23-7
THREE-ELEMENT CONTROL
SYSTEM: DRUM LEVEL
Stum
Bolter
Courtesy of the Instrument Society of America.
-------
Slide 23-8
BOILER PERFORMANCE
INDICATORS
• Steam Pressure
• Steam Temperature
• Steam Flow Rate
-------
Slide 23-9
STANDARD OPERATING
PROCEDURES
1. Safe Practices & Systems
2. General Operations
3. Start-Up and Shutdown
4. Routine & Major Maintenance
5. Emergency Procedures
-------
Slide 23-10
INSPECTION CHECK-LIST
1. Boiler Operating Conditions
2. Feedwater & Condenser System
3. Water & Oil Leaks (Valve Packing)
4. Steam Leaks (Safety Valve, Inspection Ports)
5. Equipment Noise
6. Tube Conditions
7. Soot-Blowers (Confirm Operation)
-------
Slide 23-11
BOILER OPERATIONAL
ACTIVITIES
Detect & Repair Tube Failures
Monitor Steam Production
Review Fluid Temperatures
Remove Soot from Boiler Tubes
-------
Slide 23-12
SOOT DEPOSITS
Soot on Heat Exchanger Surfaces
-------
Slide 23-13
OPERATOR-INITIATED
CHANGES
• Transmit Direct Signals
Motor, Pumps, Switches
• Transmit Signals to Controllers
Modify Set Points
Initiate Start-Up or Shutdown
• Request Maintenance
-------
Slide 23-14
PREPARATION FOR BOILER
START-UP
Inspect Boiler
Test Components
Fans, Pumps, Safety Valves
Clean Gas-Side of Boiler
Chemically Clean Water-Side
Fill Boiler with Water
Static Test Boiler at Pressure
Adjust Control System Settings
-------
Slide 23-15
BOILER START-UP
• Purge Air & Ignite Burner
• Maintain Minimum Air Flow
• Vent Air from Drum & Headers
Limit Thermal Stresses
• Vent Steam from Economizer
• Enable Automatic Controls
• Monitor Auxiliary Systems
-------
Slide 23-16
BOILER & COMBUSTION
SYSTEM SHUTDOWN
Stop Feeding Waste into MWI
Burn the Waste in the Primary Chamber
Operate Auxiliary Burners as Necessary
Let the Steam Pressure Decay
Limit the Cool Down Rate
-------
Slids 2347
EXCESS-AIR WATERWALL
UNIT OPERATIONS
Heat Transfer
From the Gas Side
To the Water/Steam Side
-------
Slide 23-18
METAL WASTAGE IN
EXCESS-AIR UNITS
Erosion (High Temperature)
• Temperature Control
• Velocity Control
• Rapping Rather than Soot Blowing
Corrosion
• Oxidation/Reduction Oscillations
• Chlorine (HC1) Reactions
• Metal Reactions
-------
ASME QMO EXAMINATION GUIDELINES'
Part I. Incineration and Monitoring
A. Basic principles:
1. Identification of different types of medical waste.
2. Recognition, separation, storage, and safe handling of medical
wastes.
3. Combustion process characteristics and control in relationship
to the types and compositional variation of wastes burned.
4. Gaseous products of combustion and their characteristics.
5. Solid residue from MWIs: ash composition and quality.
6. Fly ash versus bottom ash quantities and characteristics.
7. Heat release and need for auxiliary fuel firing.
8. Air pollutant emissions from MWIs.
9. Methods of monitoring air pollutants.
10. Methods of evaluating solid residue characteristics.
11. General principles of industrial hygiene and safety.
12. Environmental permitting conditions and standards (air
quality, residues, waste water, cooling water, solid waste).
13. Principles of operation of different types of emission monitors.
14. Temperature measurement methods.
B. Equipment:
1. Identification of different types of incinerator equipment.
2. Waste feeding hardware designs and operation.
3. Underfire air quantities and control.
4. Flame port air systems.
5. Solid fuel transport in incinerators.
6. Ash removal hardware options and implications.
7. Stack conditions and stack caps.
8. Temperature monitoring.
9. In-situ versus extractive continuous emission monitoring
systems (GEMS).
10. Flue gas sampling treatment equipment (dryers, permeation
tubes, dilution devices)
11. Automatic incinerator control systems.
12. Key failure modes for major equipment components and the
potential impact on the remainder of the operating systems.
1 ASME Standard for Qualification and Certification of Medical Waste
Incinerator Operators (ASME QMO-1), 1992
Appendix B-l
-------
Equipment Operation:
1. Procedures for acceptance and recording of waste received at
the facility.
2. Procedures for disposal of residue sent from facility.
3. Procedures for start-up and shut-down of incinerators and
CEMS.
4. Waste feed management systems - quantities, charging rates,
waste separation.
5. General housekeeping to maintain a healthy environment at
facility including control of noise, odors, and spillage.
6. Emergency action plans to respond safely and promptly to fire,
explosion, medical and environmental incidents.
7. Operation of manual and automatic ash removal equipment.
8. Operating permits and licenses.
9. Permit requirements for calibration, continuous monitoring,
and notification requirements for air quality control.
10. Implementation and maintenance of facility operational logs
and communications.
11. Periodic pollutant emission testing.
12. Ash disposal practices.
13. Identification of typical operating problems and solutions.
14 Inspections and testing procedures for all incinerator and
CEMS equipment.
Part II. Air Pollution Control Devices (APCDs)
A. Basic principles of APCDs:
1. Basic principles for collection of particulate matter in the
incinerator effluent including cyclones, fabric filtration, venturi
scrubbing, electrostatic precipitation.
2. Basic principles for collection of acid gases - wet and dry
methods.
3. Flue gas condensation.
4. Particle size distribution effects on APCD systems.
5. Typical control efficiencies as a function of key operating
system parameters.
6. Discharges from different types of APCDs.
7. Safety considerations for APCDs.
8. Federal air emission regulations.
9. Federal water quality regulations.
10. Federal solid waste regulation.
11. Trace metal emission from MWIs.
Appendix B-2
-------
12. Control of toxic air emissions including dioxins and furans.
13. Role of APCDs in formation of trace organics.
14. Impact of activated carbon on trace metal and trace organic air
emissions.
15. Methods for measuring APCD performance.
B. APCD Equipment:
1. Identification of major constituents in different types of APCDs
2. Identification of necessary ancillary equipment components
such as flue gas temperature control modules, induced draft
fans, and sorbent or reagent addition hardware.
3. Measurement of APCD control device efficiency.
4. Automatic control systems.
C, APCD Equipment Operation:
1. Identification of key parameters indicating APCD components
failure or the need for corrective action.
2. Appropriate procedures for handling and disposal of APCD
solid and liquid residues.
3. Procedures for start-up and shut-down of different classes of
APCDs.
4. Control of flue gas temperature entering the APCD.
5. Condensation of flue gas constituents.
6. Proper handling of reagents and sorbent materials.
7. Emergency action plans to respond safely and promptly to fire,
explosion, medical and environmental incidents associated with
APCDs.
8. Understanding the necessity of planned maintenance programs
for APCD components.
9. Understanding the impact of incinerator system failure on
operation of APCDs.
10. Understanding the impact of APCD system malfunction on
incinerator operations.
11. Inspection and testing procedures for all APCD and ancillary
equipment components.
Part III. Heat Recovery Systems
A. Basic principles:
1. Basic principles of thermodynamics.
2. Basic principles of heat transfer.
3. Tube surface fouling and corrective actions.
Appendix B-3
-------
4. Characteristics of hot water, saturated steam, and superheat
steam.
5. Basic principals of water chemistry in boiler operations.
6. Steam temperature and pressure measurements.
7. Safety practices associated with boiler operation.
8. Operating permits and licenses required of facility and
operators.
B. Equipment:
1. Identification of major components of hot water, saturated
steam, and superheated steam heat recovery boilers.
2. Soot blowing equipment.
3. Design of boiler feed water and cooling water treatment.
4. Safety and relief valves - design and operation.
C. Equipment Operation:
1. Overall operation of boiler hardware.
2. Processes and procedures for adjusting boiler feedwater and
cooling water chemistry to meet different facility design
specifications.
3. Procedures for start-up and shut-down of boiler systems and
ancillary components.
4. Identification of typical maintenance problems and required
operator actions.
5. Identification of typical operational problems and appropriate
interventions.
6. Understanding the interaction between boiler operation an
operation of both upstream and downstream components.
7. Inspection and testing of all boiler system components.
Additional Topics for Operator Supervisors:
1. Overall operation, maintenance and performance of integrated
MWI systems.
2. Understanding the job duties and responsibilities of
subordinates including certified operators and other non-
certified operational and support staff.
3. Formulation and updating of policies and procedures for proper
MWI facility operations.
4. Procedures for implementing and adherence with federal, state,
and local regulations and requirements.
Appendix B-4
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