United Statm
Environmental Protection
Agency
Industrial Environmental Research
Laboratory
Cincinnati OH 45268
EPA-600/9-79-044
December 1979
Research and Development
FY-80 Research
Plan for lERL-Ci
Activities at the
T&E Facility
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7 Interagency Energy-Environment Research and Development
8. "Special" Reports
9. Miscellaneous Reports
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
-------
EPA-600/9-79-044
December 1979
FY-80 RESEARCH PLAN FOR IERL-CI ACTIVITIES
AT THE T&E FACILITY
INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
-------
TABLE OF CONTENTS
Page
Introduction 1
Biological Treatment of Toxic Organic
Constituents of Wastewater 10
Quantification of VOC Emissions from
Cold Cleaning Degreasing Systems 14
Silicate Fixation of Metal Pollutants 17
Use of Carbon Adsorption to Remove
Toxic Organic Materials from Wastewater 20
Evaluation of Surfactant Scrubbing as
A Treatability Method 24
Evaluation of Steam Stripping to Remove
Toxic Organics from Wastewater 27
Leachability and Revegetation of Solid
Waste from Mining 31
Pilot-Scale Conversion of Mixed/Hazardous
Wastes to Energy 36
The Adsorptive Characteristics of Coal: Control
Technology for In-Situ Coal Gasification Effluents 41
Shakedown of Various Unit Processes for the
Treatment of Oil Shale Wastewaters 44
±i
-------
FIGURES
Number Page
1 Organizational Relationship of the Five
Facility Users ....................... 2
2 Vicinity Map of T£E Facility ................. 3
3 The T£E Facility as it Fits into the MSD Compound ...... 4
4 Architect's Rendering of the T&E Facility .......... 7
5 Floor Plan of the T§E Facility ................ 8
6 IERL Organizational Chart .................. 9
7 Project Schedule for Biological Treatment of
Toxic Organic Constituents of Wastewater .......... 12
8 Flow Diagram for Biological Treatment of Toxic
Organic Constituents of Wastewater ............. 13
9 Project Schedule for Quantification of VOC Emissions
from Cold Cleaning Degreasing Systems ........... 15
10 Flow Diagram for Quantification of VOC Emissions
from Cold Cleaning Degreasing Systems ........... 16
11 Project Schedule for Silicate Fixation of Metal
Pollutants ......................... 18
12 Flow Diagram for Silicate Fixation of Metal Pollutants .... 19
13 Project Schedule for Use of Carbon Adsorption to Remove
Toxic Organic Materials from Wastewater .......... 22
14 Flow Diagram for Use of Carbon Adsorption to Remove Toxic
Organic Materials from Wastewater ............. 23
15 Project Schedule for Evaluation of Surfactant Scrubbing
as a Treatability Method .................. 25
16 Flow Diagram for Evaluation of Surfactant Scrubbing
as a Treatability Method ................. 26
111
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Figures (continued)
Number Page
17 Project Schedule for Evaluation of Steam Stripping
to Remove Toxic Organics from Wastewater 29
18 Flow Diagram for Evaluation of Steam Stripping to
Remove Toxic Organics from Wastewater 30
19 Project Schedule for Leachability and Revegetation
of Solid Waste from Mining 34
20 Example Set-up for Leachability and Revegetation
of Solid Waste from Mining 35
21 Project Schedule for Pilot-Scale Conversion of Mixed/
Hazardous Waste to Energy 39
22 Flow Diagram for Pilot/Scale Conversion of Mixed/
Hazardous Waste to Energy 40
23 Project Schedule for the Adsorptive Characteristics of
Coal: Control Technology for In-Situ Coal Gasification
Effluents 42
24 Flow Diagram for the Adsorptive Characteristics of Coal:
Control Technology for In-Situ Coal Gasification Effluents . 43
25 Project Schedule for Shakedown of Various Unit Processes
for the Treatment of Oil Shale Wastewater 46
IV
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INTRODUCTION
The Office of Research and Development of the U. S. Environmental
Protection Agency has recently (March 1, 1979) begun operation of a new
facility in Cincinnati, Ohio known as the Test and Evaluation (T§E) Facility.
The purpose of this facility is to house a variety of bench- and pilot-
scale experiments in support of the various programs of the Cincinnati
Environmental Research Center and the Newtown Fish Toxicology Station (NFTS) .
However, the Industrial Environmental Research Laboratory (IERL) and the
Municipal Environmental Research Laboratory (MERL) manage the facility and
are its principal users. Other users are the Health Effects Research
Laboratory (HERL) and the Environmental Monitoring and Support Laboratory
(EMSL), and it is anticipated that NFTS, HERL, and EMSL needs can normally
be accommodated in activities as adjunct to MERL and IERL projects. Figure 1
shows the organizational relationship of the five (5) T§E Facility users.
The T£E Facility is located at the Mill Creek Sewage Treatment Plant
of the Metropolitan Sewer District (MSD) of Greater Cincinnati. (Figure 2
shows the general location of this installation, and Figure 3 shows the T£E
Facility as it fits into the MSD compound.) At this site, MSD operates a
conventional primary/secondary treatment system for municipal wastewater and
disposes of a variety of industrial wastes, some of which are incinerated.
Therefore, the T^E Facility has ready access to various municipal and indus-
trial wastewaters and sludges. The facility has approximately 24,000 ft^ of
usable pilot plant area which is highly flexible with regard to the types of
studies which can be accommodated and it is contemplated that work will be
performed in all areas of EPA's interests, viz., air pollution control, water
pollution control, solid waste management, and toxic substances.
-------
U.S. Environmental
Protection Agency
Office of Research & Development
(Stephen J. Gage)
Office of Monitoring
and Technical Support
(Matthew Bills,
Acting)
Environmental Monitoring
and Support Laboratory
(Dwight G. Ballinger)
Office of Environmental
Engineering and
Technology
(Steven Reznek)
Industrial Environmental
Research Laboratory
(David G. Stephan)
Municipal Environmental
Research Laboratory
(Francis Mayo)
Office of Environmental
Processes and Effects
(Courtney Riordan,
Acting)
Environmental Research
Laboratory
(J. David Yount,
Acting)
Newtown Fish
Toxicology Station
(William Horning)
Office of
Health Research
(Vilma Hunt)
Health Effects
Research Laboratory
(R. John Gamer)
Figure 1. Organizational Relationship of the Five T&E Facility Users
-------
Figure 2. Vicinity Map of T&E Facility
-------
B&O RAILROAD
Figure 3: The T&E Facility as it Fits Into the MSD Compound
-------
The building is a two-story metal structure composed of insulated metal
wall panels attached to a superstructure of rolled structural steel sections.
Figure 4 is an architect's rendering of this facility and Figure 5 shows the
floor plan. Other physical features include:
• Single high bay experimental area (200' x 123') which is extensively
equipped with services but has no permanent experimental apparatus
• Pipelines feeding various types of sewage and sludge from the Mill
Creek Sewage Treatment Plant
• Greenhouse
• Laboratories for analytical support, chemical storage areas, offices,
and building services (6,600 ft^)
• Two five-ton bridge cranes for ease of moving equipment in and out
• Machine Shop
This report describes those projects which the IERL plans to have active
through FY-80. The IERL is composed of three Divisions (Figure 6 provides
an organizational chart for IERL) and a summary of its planned T§E Facility
projects, sponsoring Divisions, and project officers follows:
Title Division Project Officer
1. Biological Treatment of Toxic Organic IPCD Brian Westfall
Constituents of Wastewater
2. Quantification of VOC Emissions from IPCD Charles Darvin
Cold Cleaning Degreasing Systems
3. Silicate Fixation of Metal Pollutants IPCD Fred Craig
4. Use of Carbon Adsorption to Remove IPCD Brian Westfall
Toxic Organic Materials from Waste-
water
5. Evaluation of Surfactant Scrubbing IPCD Charles Darvin
as a Treatability Method
-------
6. Evaluation of Steam Stripping to
Remove Toxic Organics from Waste-
water
7. Leachability and Revegetation of
Solid Waste from Mining
8. Pilot-Scale Conversion of Mixed
Hazardous Wastes to Energy
9. The Adsorptive Characteristics of
Coal: Control Technology for In-
Situ Coal Gasification Effluents
10. Shakedown of Various Unit Processes
for the Treatment of Oil Shale
Wastewaters
IPCD Brian Westfall
REHD John Martin
ESECD Walter Liberick
ESECD Robert Thurnau
ESECD Thomas Powers
-------
Figure 4. Architect's Rendering of the T&E Facility
-------
EXPERIMENTAL AREA
Figure 5. Floor Plan of the T&E Facility
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RESOURCE EXTRACTION
AND HANDLING DIVISION
DIRECTOR: Ronald D. Hill
OIL AND HAZARDOUS
MATERIALS SPILLS BRANCH
(Edison, N.J.)
Ira Wilder
EXTRACTION TECHNOLOGY
BRANCH
Eugene F. Harris
INDUSTRIAL ENVIRONMENTAL
RESEARCH LABORATORY-
CINCINNATI
DIRECTOR: David G. Stephan
DEPUTY DIR.: William A. Cawley
PROGRAM OPERATIONS OFFICE
PROGRAM MANAGEMENT
ADMINISTRATIVE MANAGEMENT
SPECIAL PROJECTS
DIRECTOR: Alden G. Christianson, Acting
INDUSTRIAL POLLUTION
CONTROL DIVISION
DIRECTOR: Eugene E. Berkau
METALS AND INORGANIC
CHEMICALS BRANCH
George S. Thompson, Jr.
ORGANIC CHEMICALS AND
PRODUCTS BRANCH
Irvin A. Jefcoat
FOOD AND WOOD
PRODUCTS BRANCH
Michael Strutz, Acting
_L
ENERGY SYSTEMS
ENVIRONMENTAL CONTROL
DIVISION
DIRECTOR: Clyde J. Dial. Acting
POWER TECHNOLOGY AND
CONSERVATION BRANCH
Victor Jelen, Acting
FUELS TECHNOLOGY
BRANCH
George L.Huffman
Figure 6: IERL Organizational Chart.
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BIOLOGICAL TREATMENT OF TOXIC ORGANIC CONSTITUENTS OF WASTEWATER
Objectives:
The objective of this project is to determine the effectiveness of the
activated sludge process, alone or in conjunction with powdered activated
carbon, to treat various industrial wastewaters which contain toxic pollu-
tants .
Fundamental Considerations:
Biological treatment has long been used as a treatment method for many
industrial wastewaters. However, additional data are required to determine
whether or not this type of treatment is applicable for wastewaters which
contain various toxic pollutants.
Conventionally available biological treatment methods include biological
filtration, activated sludge, oxidation ponds, RBC's, anaerobic digestion, etc.
However, activated sludge is the most versatile of these methods since it
can be tailored to handle a variety of wastes and to satisfy many different
effluent requirements. Therefore, this program will investigate the appli-
cation of the basic activated sludge system as a single unit process applied
to various clarified industrial wastewaters or synthesized industrial waste-
waters. The addition of powdered activated carbon directly into the aeration
unit of the system will also be evaluated.
Procedure:
Two activated sludge pilot units with required auxiliaries will be con-
structed. These units will be portable such that they may be tested at the
T§E Facility utilizing imported or synthesized industrial waste or at speci-
fic industrial plants utilizing a slip stream from the plant's effluent.
10
-------
Each of these units will have a capacity of 190 gpd and the flow sequence is
shown on Figure 8.
Specific industrial wastewaters will be selected for study based on
expected composition of the waste, likelihood of it being treated biologi-
cally; and specific needs enunciated by the Effluent Guidelines Division.
The initial phase of each test will require acclimating a sludge for the par-
ticular wastewater stream to be examined. Then samples from influent,
effluent, and wasted sludge will be analyzed for specific toxic pollutants
as well as for routine monitoring indicators such as BOD, COD, TOG, etc.
In addition, the effect of varying such parameters as MLSS, liquid detention
period, and carbon dosage will be evaluated.
11
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Pilot Plant
Design
Shakedown
Start 1st
Test
Start 2nd
Test
Start 3rd
Test
FY-79
AUG
il
L
SEPT
^
FY-80
OCT
L
IMOV
i
DEC
JAN
A
FEB
i
MAR
APRIL
MAY
L
JUNE
^
JULY
AUG
SEPT
Figure 7: Project Schedule for Biological Treatment of Toxic Organic
Constituents of Wastewater
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00
Imported or
Synthesized
Industrial
Wastewater
PAC
Ph Control
Nutrients
Primary
Clarifier
PS To
Waste
I
-*-Low Pressure Air
Aeration Basin
Recycled Sludge
Secondary
Clarifies
WAS to
Waste
Figure 8. Flow Diagram for Biological Treatment of Toxic Organic
Constituents of Wastewater.
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QUANTIFICATION OF VOC EMISSIONS
FROM COLD CLEANING DECREASING SYSTEMS
Objectives:
The objective of this project is to quantify the VOC emissions from
various cold cleaning degreasing systems and determine how these emissions
are affected by the use of remote solvent reservoirs and spray nozzles and
by varying freeboard height and ventilation.
Fundamental Considerations:
Degreasing operations employ various organic solvents and a certain amount
of this material escapes into the atmosphere which creates a major source of
air pollution. Preliminary information indicates that a significant amount
of these emissions can be eliminated by increasing the freeboard height, the
use of remote solvent reservoirs, controlled ventilation, solvent selection,
and other equipment modifications. However, additional information concern-
ing the amount of VOC emission reduction as a result of these measures is
required to properly assess the impact of this approach.
Procedure:
Solvent emissions from a remote solvent reservoir with spray nozzles and
a conventional cold cleaning degreaser system will be quantified. These
systems will be placed in an enclosure which will be maintained at a negative
pressure where a load of small parts will be automatically placed into the
degreaser system and removed according to a set cycle. The quantity of
solvent loss will be determined by weight loss and monitored with an infra-
red spectrometer. Freeboard ratios, ventilation and type of solvent (mineral
spirits and standard solvents) will be varied, and the temperature, humidity,
air flow and barometric pressure will be monitored.
14
-------
Fabricate and
Assemble Test
Apparatus
Shakedown
Complete
Collection of
Data
Data Reduction
and Analysis
FY-79
AUG
SEPT
L
FY-80
OCT
i
A
NOV
DEC
A
JAN
FEB
A
MAR
APRIL
MAY
JUNE
JULY
AUG
SEPT
Figure 9: Project Schedule for Quantification of VOC Emissions from Cold
Cleaning Degreasing Systems
-------
Load
Solvent \
Storage I ••
^ ^X
1
1" -
1 J
1
voc 1
Emissions
»/
Exhaust
Degreasing System
Figure 10. Flow Diagram for Quantification of VOC
Emissions from Cold Cleaning Degreasing
Systems
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SILICATE FIXATION OF METAL POLLUTANTS
Objectives:
The objective of this project is to determine the effectiveness of sili-
cate fixation of heavy metal waste as an alternative to disposing of hydroxide
sludges.
Fundamental Considerations:
Precipitation using lime or caustic has been the basic approach for pre-
cipitating metals as hydroxides from industrial plating and non-ferrous
wastewaters. Unfortunately, these sludges must be maintained at a pH near
their point of formation in order to prevent leaching of the hydroxides.
Further, the sludges must be dewatered to eliminate the bulkiness of the
sludge. Unfortunately., much of the sludge volume is excess material (calcium,
sodium, carbonates, etc.) carried into the precipitation process as materials
burden and serves no useful purpose.
Silicate fixation can be used as a substitute precipitation process for
removing heavy metals from acid wastewaters. The purpose of this test is to
consider fixation as part of the OSW approach to managing hazardous waste.
This study will be combined with the EPA/AES Sludge Characterization Study
to generate data on handling of metal finishing sludges.
Procedure:
Wastewater samples will be collected from industrial plating and non-
ferrous plants in the Cincinnati area and mixed with slag, cement, and lime
to form a solid material similar to concrete. The metal pollutants will be
fixed as silicates in this solid material which will be shipped to the Centec
Laboratories in Virginia for analyses. Elutriates from the extraction proce-
dure will be analyzed for metals.
17
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00
DESCRIPTION
Procure Equipment
Make or Obtain
Samples
Conduct Fixation
Tests
Analysis of /and
Elutriation of
Samples
Report Preparation
Promulgation of
RCRA
Regulations
FY-79
AUG
A
A
SEPT
A
A
FY-80
OCT
A
NOV
DEC
A
JAN
FEB
MAR
APRIL
MAY
JUNE
JULY
AUG
SEPT
Figure 11: Project Schedule for Silicate Fixation of Metal Pollutants
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Lime
Cement
Slag
oo
Wastewater
Storage
Reactor
Casting
Figure 12. Flow Diagram for Silicate Fixation of Metal
Pollutants
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USE OF CARBON ADSORPTION TO REMOVE
TOXIC ORGANIC MATERIALS FROM WASTEWATER
Objectives:
The objective of this project is to determine the effectiveness of car-
bon in removing organic compounds from industrial wastewaters.
Fundamental Considerations:
There are many existing examples which illustrate the feasibility of
carbon adsorption systems to handle toxic organic wastes. Carbon adsorption
has been shown to be an effective process in removing various and specific
organics in both industrial and municipal applications such as those organics
which affect the color, taste, odor, BOD, and COD of the wastewater. Carbon
adsorption is predominantly used as a polishing process at a tertiary level
of treatment.
Insufficient research exists concerning the efficiency of carbon adsorp-
tion in removing specifically the priority pollutants from actual industrial
wastewaters. Therefore, additional information is required to determine
whether activated carbon (powdered, granular, or both) can be utilized alone
or in conjunction with other processes for the purpose of removing toxic
organic pollutants from operating industrial plant wastewater streams.
Procedure:
Two skid-mounted multiple column carbon adsorption pilot units will be
constructed. The columns can be used in parallel or series to achieve a
range of flow up to 2,160 gpd.
The test program to evaluate the economic and technical feasibility of
an activated carbon wastewater treatment system will consist of two phases.
20
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These are, first, the development of batch isotherm data for determination of
the degree of treatment that can be obtained using one or more different car-
bons, and second, operation of continuous flow pilot carbon column tests. The
development of the isotherm data will be a laboratory bench test procedure
utilizing an average of six different tests per waste stream and type of
carbon tested. Each test series will be conducted for a minimum of one hour
at a constant temperature. The samples will then be analyzed for the removal
of a particular contaminant, TOG, and other applicable parameters.
The pilot plant dynamic flow column (Figure 14) tests will be conducted
utilizing data developed from the isotherms. Effluent samples will be with-
drawn from each sample port on either a time or throughput basis. The
sampling schedule should provide approximately 18 to 20 samples per day of
pilot plant operation. Five to six samples would be analyzed for the toxic
pollutants with the remainder analyzed for a particular contaminant such as
TOG, COD, and other applicable parameters.
Allowance will be made in the design and configuration of the system for
eventual field testing of the facility at specific industrial sites in the
manner described above. This will enable the testing of industrial waste
streams under actual conditions.
21
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Pilot Plant
Design
Start Purchase
of Materials
Start Pilot
Plant
Fabrication
Shakedown
Start 1st
Test
Start 2nd
Test
Start 3rd
Test
FY-79
AUG
L
SEPT
i
L
FY-80
OCT
i
NOV
DEC
L
JAN
i
FEB
L
MAR
i
L
APRIL
i
MAY
A
JUNE
JULY
L
AUG
i
SEPT
Figure 13: Project Schedule for use of Carbon Adsorption to Remove Toxic
Organic Materials from Wastewater
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N3
CXI
o^
f\^^^y|— ' rJ £•
U U STORAGE |AMPLE FE
TANK TRAILER TANK TAP pi
FOR WASTE FOR
WASTE
i
•ED
JMP
i . '
{"JW
FILTERS
SAMPLE rr
TAP I * L
ROTAMETERN
RATE SET T (•
ROTAMETER (A T
RATE SET T t
fn
r
1
fn1
r
1-
m
. CARBON
1 COLUMNS
T
I >. r^T™
* J.
CARBON -
COLUMNS '
1
m
r
T
-i
r
r
-4 JL WATER
T O METER
TO
' ^ 1A/AQTF
A WATER SAM PLE WA!> ' fc
T V METER TAP
Figure 14. Flow Diagram for Use of Carbon Adsorption to Remove
Toxic Organic Materials from Wastewater.
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EVALUATION OF SURFACTANT SCRUBBING AS A TREATABILITY METHOD
Objectives:
The objective is to determine the effectiveness of the surfactant
enhanced scrubbing system to remove volatile organic compound emissions from
metal finishing facilities.
Fundamental Considerations:
Metal painting spray booths utilize the evaporation of solvents into
the atmosphere as an integral part of the painting process. The ventilation
of the spray booth results in a high volume of low concentration VOC emissions.
They are largely insoluble in 1^0 but when a surfactant additive is used,
they become soluble and may be scrubbed from the gas stream.
Laboratory- and bench-scale investigations on the potential of the
surfactant scrubbing concept have been conducted and it is now time to design
a pilot system and enter an engineering development stage of this process.
Procedure:
Design and construction of the experimental apparatus will be performed
under contract by Ebon in Newark, New Jersey. It will be skid mounted and
easily transportable for evaluation at industrial sites. Initially, this
system will be shipped to the T&E Facility where it will be tested to assure
proper operation. It will then be taken to a metal finishing spray booth
operation in the Cincinnati area for a 9 to 12 month evaluation period.
24
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NJ
in
Award
Contract
Prepare Plans
and Specifications
Procure Materials
and Begin
Construction
Complete
Construction
Shakedown
@ T&E Facility
Ship to
Field Site
FY-79
AUG
SEPT
A
FY-80
OCT
NOV
A
DEC
JAN
A
FEB
MAR
A
APRIL
MAY
A
L
JUNE
1
JULY
AUG
SEPT
Figure 15: Project Schedule for Evaluation of Surfactant Scrubbing as a
Treatability Method
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N)
ON
Liquor
' Throttling
Valve
Resevoir
Clean Exft. Gas
Sample Port
&
•Full-Cone Spraying Nozzle
Section Packed With
Pall Rings
Packing Retention
'Plate
Flow Meter
Contaminated Gas
Input
Inlet Sample Port
Recycle to Resevoir
•Q-i
-&*$-
To
Drain
Figure 16. Flow Diagram for Evaluation of Surfactant Scrubbing as a
Treatability Method.
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EVALUATION OF STEAM STRIPPING TO
REMOVE TOXIC ORGANICS FROM WASTEWATERS
Objectives:
The objective of this project is to evaluate the use of steam stripping
as a method for removing organic chemicals from industrial wastewater streams.
Fundamental Considerations:
Many toxic pollutants are volatile chemicals, relatively insoluble in
water, and can be separated from wastewater by distillation with live steam.
Generally termed steam stripping, the process consists basically of heating
the full volume of wastewater to its boiling point and condensing a fraction-
ated portion of the resulting steam. Volatile chemicals will be selectively
concentrated in the condensate. Since the pollutant is relatively insoluble
in water, it will then separate as an immiscible liquid layer when the
condensate is cooled, and can be removed from the water by decantation.
Steam stripping is believed to be a feasible method for environmental control
of many tox.ic and priority pollutant chemicals.
Although extensive engineering data are known concerning steam stripping
of water/organic mixtures, these data are not applicable to low concentra-
tions of these chemicals. It is not possible to extrapolate data developed
for concentrated solutions to industrial waste streams, nor to predict
mathematically the degree to which this technique will be feasible in this
application. Most of all, it is not possible to establish the practical
level to which the various toxic chemicals can be removed from wastewater
through application of the steam stripping principle. Research is needed
to extend the scientific knowledge of this technique and to establish its
engineering feasibility.
27
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Procedure:
A detailed design of the proposed pilot plant test unit is shown in
Figure 18 which has a capacity of 720 gpd. A continuous small stream of
water containing one or more toxic pollutants will be pumped through a heat
exchanger and into the top of a sieve tray column. Steam from a boiler will
be added to the bottom of the column. A portion of the steam will condense
to supply sufficient heat to increase the temperature of all the water in
the column to 100°C. Excess steam will rise from the top of the column,
and be condensed and cooled with noncontact cooling water (once-through city
water). The condensate will drain into a decantation tank. The water layer
will be recycled continuously to the heat exchanger and the concentrated
pollutant chemical or mixture of chemicals will overflow into a drum to be
collected and recycled.
Bottoms from the column will flow by gravity through the shell of the
heat exchanger, then through a vented overflow pipe and into a hold tank.
After analysis, water from the hold tank will be pumped either into a waste
pretreatment unit or, if no priority pollutant is present, into the city
sewer.
Samples will be collected and analyzed and data will be obtained to
define the efficiency of operation. The principal program output will be
engineering data to permit specific design of similar units. A principal
criterion of performance will be the ratio of overhead mass flow to fresh
feed flow necessary to achieve acceptably low concentrations of toxic
pollutants in the discharge water. Another most important output of the
program will be the definition of the minimum practical effluent concentra-
tion of toxic pollutants achievable with this technique.
28
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Start Pilot
Plant Design
Start Purchase
of Materials
Start Pilot
Plant
Fabrication
Shakedown
Start 1st
Test
Start 2nd
Test
Start 3rd
Test
FY-79
AUG
L
SEPT
i
FY-80
OCT
L
NOV
1
DEC
JAN
L
FEB
i
MAR
APRIL
L
MAY
1
L
JUNE
^
JULY
L
AUG
^
SEPT
A
Figure 17: Project Schedule for Evaluation of Steam Stripping to Remove
Toxic Organics from Wastewater
-------
CITY
WATER RECORDING
PRESSURE TEMPERATURE
GAUGE FLOW SENSORS
Q QMETER NITROGEN ^(TYPICAL)
^ ^ " BLEED V
L
/STEAM
(GENERATOR
NONCONTACT
COOLING
LCONDENSER
\^-^\ DEMISTER/m
.VENT
SIEVE
"""TRAY
"COLUMN
SAMPLING
STATION,
ORGAN
WASTE
FEED
TANK
STEAM
SPARGERS
HEAT
EXCHANGER
O
VENT TO FLARE
OR OIL SCRUBBER
SAMPLING
STATION
.FLOW
'METER
HYDRAULIC
OVERFLOW
SAMPLING
' STATION
VARIABLE SPEED
GEAR PUMP
FLOW
METER
SAMPLING
STATION
HOLD
TANK
PORTABLE
TRANSFER
PUMP TQ SEWER
M (Ty RECYCLE, OR
^ OTHER WATER
TREATMENT
UNITS
Figure 18. Flow Diagram for Evaluation of Steam
Stripping to Remove Toxic Organics from
Wastewater.
30
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LEACHABILITY AND REVEGETATION OF SOLID WASTE FROM MINING
Objectives:
The objectives of this project are to determine the quality and quantity
of leachate generated by the disposal of mining waste under various layering
configurations, and to assess the vegetative uptake of potentially hazardous
materials from the solid waste.
Fundamental Considerations:
The Extraction Technology Branch is currently participating in a study
for the Office of Solid Waste to determine the environmental impact of solid
waste from the phosphate, uranium, and metallic ore mining industries. As
part of this study, the impact of these solid wastes on groundwater and sur-
face water will be investigated. The leachability of potentially hazardous
materials is of specific concern. To provide more detailed information, and
to support field observations concerning the movement of salts in the wastes,
pilot plant column studies will be conducted at the T§E Facility. Samples
of wastes that are being studied in the field will be shipped to the labora-
tory for physical and chemical characterization prior to being placed in
columns. Management practices similar to those used in the field will be
applied to the columns. Since revegetation of mining waste is a common
procedure for surface stabilization, grasses and legumes will be grown on
a number of the test columns. The survival of this vegetation, the uptake
of potentially hazardous materials by the plants, and the quality of leachate
moving through the columns will be studied. This information may help to
explain results obtained in the field studies, provide fundamental infor-
mation on chemical and physical reactions, and verify the validity of full
scale waste management practices.
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Procedure:
Columns of mining solid waste or waste covered with soil material will
be constructed in sections of pipe to simulate the conditions of reclaimed
and unreclaimed waste disposal sites. Drainage ports at the bottom of the
columns will allow for collection of leachate samples. A preliminary chemical
analysis of the waste and cover soil for physical (size, pore volume, etc.)
and chemical properties (nitrogen, phosphorus, potash, pH, SAR, heavy metals,
etc.) will be made. Based on these tests, the nutrients needed to support
plant growth will be identified. Fertilizer containing these nutrients and
sufficient lime to adjust the soil pH to values normal for the plant growth
will be added to the mine waste and will serve as a control column to demon-
strate the success of growing plants on supplemented mine waste only. An
additional control column will be composed of untreated mine waste with no
vegetation.
Columns containing mine waste which has been supplemented and covered
with up to four feet of soil material will demonstrate the usefulness of
special cover material for improving the growth of vegetation, reducing
leachate volume, improving leachate quality, and preventing the upward move-
ment of acid and salts. Subsequently, columns containing layers of absorb-
ing or non-absorbing materials such as charcoal, gravel, etc., will also be
investigated for prevention of metal salt and acid movement through the soil.
On a regular basis, leachate samples will be collected and analyzed for
critical parameters. Records of added water and leachate volumes will be
kept.
Periodically, samples of vegetation will be taken from each of the
columns. These will be analyzed to indicate the uptake of metal ions by the
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plants. At the conclusion of the study, analysis of the cover material and
waste at various depths will be made to determine chemical and physical
changes. Of special interest will be accumulation of salts and potentially
hazardous chemicals.
33
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DESCRIPTION
Pilot Plant
Design and
Fabrication
Obtain Solid
Waste, Characterize,
Load Columns-
Establish Grass
Execute First
Series of Tests
Data Analysis
and Setup for
Second Series Tests
Establish Second
Series of Tests
Data Analysis
and Preparation
of Report
FY-79
AUG
SEPT
L
FY-80
OCT
i
NOV
/
L
DEC | JAN
4
\
\
^
FEB | MAR
I
A
^
T
L
L
V
A
APRIL
MAV
JUNE
JULY
L
AUG
/
L
SEPT
V
1
t
!i
FY-81
OCT | NOV
T
I
A
M
'
L
»
k
^
DEC
JAN
FEB
MAR
APRIL
MAV
A
T
JUNE
JULY
AUG
A
SEPT
^
Figure 19: Project Schedule for Leachability and Revegetation of Solid Waste
from Mining
A
Start Task
A
Complete Task
®
series 1
®
series 2
-------
Distilled
Water
Meter'
Grass
and
Legumes
Soil
Control Material
X X
Solid _
Waste
Inert —
Gravel
Filter
V
V
V
<*>**«*
V
en
Inert
Gravel,
Charcoal,
etc.
Layer
Y
Leachate
Collection
System
Figure 20. Example set-up for Leachability and
Revegetation of Solid Waste from Mining
35
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PILOT-SCALE CONVERSION OF MIXED/HAZARDOUS WASTES TO ENERGY
Objectives:
The objective of this project is to develop a feasible alternative to
the improper disposal of hazardous and non-hazardous solid wastes by con-
verting them into usable forms of energy, utilizing an existing fluidized
bed combustion/pyrolysis test reactor.
Fundamental Considerations:
Laboratory, pilot-plant, and full-scale studies have been and are being
conducted to identify product yields from the pyrolysis, partial oxidation,
or combustion of various waste fuels. Specific waste fuels such as municipal
solid waste, rice hulls, rye grass straw, cattle manure, and wood bark have
been used in these studies, and the yields of various pyrolysis products at
various operating conditions have been identified. In addition, various
types of pyrolysis reactors, primarily affecting the time required to heat
the waste fuel to the desired reaction temperature, have been used in these
studies. Furthermore, various reaction products (gas, oil, char, etc.) have
been recycled to the reactor as either a fuel or as process heat to further
complicate the understanding of the pyrolysis process. As a result of these
uncoordinated studies, there exists a body of knowledge related to product
yields from specific waste fuels at specific operating conditions in specific
reactor types. The extrapolation of this information to other type waste
fuels at other operating conditions is difficult if not impossible. Further-
more, extrapolation to a mixture of waste fuels is even more difficult par-
ticularly with hazardous wastes.
A method is needed to predict product yields at various reaction condi-
tions (temperature, time, etc.) with various product recycle rates for any
36
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selected mixture of waste fuels. This method could be used by design engi-
neers to select near optimum reaction conditions to achieve the desired
product yields (based on local market conditions) from the waste fuels
available that exist in a given geographical area. The pyrolysis system
could be designed to use any or all of them depending on their impact on
product mix, system economics, the potential other uses for the various
waste fuels, etc.
To partially fulfill that need, a contract with Energy Resources Company
(ERG) was supported by EPA for three years. During that time an extensive
data base was established which led to the development of mathematical models
to predict product yields utilizing a fluid bed reactor. This reactor, now
at the T§E Facility, will continue such work with additional feedstocks/
combinations of feedstocks, particularly in the area of hazardous wastes.
The proposed project is designed to furnish a method to allow the
selection of near optimum pyrolysis reaction conditions of time, temperature,
reactor type, product recycle, etc., required to produce the most desirable
mix of products from a mixture of waste feedstocks, particularly in the area
of hazardous wastes, whose composition is known. The prediction method
further developed and verified by this contract will be made available to
the technical community for use in selecting pyrolysis, partial oxidation, or
combustion conditions to adequately destroy selected hazardous wastes and to
yield the most desirable product mix from the available mixture of waste
feedstocks.
Procedure:
This project will be accomplished through a contract effort which is
divided into the following four sub-parts:
37
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1) Preparation of a test plan directed at accomplishing the stated
objectives.
2) Modification and installation of the existing pyrolysis unit
(located at EPA's Cincinnati Testing and Evaluation Facility) in
such a manner as necessary to accomplish the stated objectives.
3) Conduct thermal destruction experiments.
4) Analyze collected samples, interpret the results, and provide con-
clusions, with supporting data, in a final report.
Modification and installation of the reactor will commence immediately
after an approved test plan is developed. This will be followed by a brief
shakedown period, all of which is scheduled to be completed five (5) months
after the contract is awarded. After this is completed, the first phase of
testing according to the test plan shall commence.
38
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DESCRIPTION
Contract Award
Work Plan
Completion
System Modification
Completion
Commence Phase 1
FY-79
AUG
SEPT
FY-80
OCT
NOV
DEC
L
JAN
^
FEB
L
MAR
^
APRIL
MAY
L
L
JUNE
^
i
JULY
AUG
SEPT
Figure 21: Project Schedule for Pilot—Scale Conversion of Mixed/Hazardous
Waste to Energy
-------
PROBES
TEMPERATURE Q
PRESSURE 0
SAMPLING ®
SPRAY NOZZLES •
DISENGAGING
SECTION
FLUIDIZED
BED
FEED
PYROLYSIS
j GASES
0.5m
0
O
__J L-.
O 00 .
YCLONE
TO
STACK
CHAR SCRUBBING
& SAND i OIL
VENT
1
FUEL
GAS
FLAME
SENSORToMBUS;OR
Oi
!o0®!
—i
AFTER BURNER
PEBBLE \/
,
SDISTRIBU
TOR PLATE
COOLING
WATER
m ^^ • • ii
t=:
TARS
TARS
AIR &
— GAS
Figure 22. Flow Diagram for Pilot/Scale Conversion of
Mixed/Hazardous Waste to Energy
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THE ADSORPTIVE CHARACTERISTICS OF COAL:
CONTROL TECHNOLOGY FOR IN-SITU COAL GASIFICATION EFFLUENTS
Objectives:
The objectives of this study are to evaluate the adsorptive characteris-
tics of coal in removing trace elements generated during in-situ coal
gasification.
Fundamental Considerations:
It has been stated many times that one of the chief concerns of in-situ
coal gasification is the potential for water pollution. Organics, especially
the polynuclear variety-, are generated during pyrolysis and on at least one
occasion have found their way into the groundwater. Inorganics, like ammonia,
hydrogen sulfide, etc., have been found to increase in water exposed to
gasified coal, char or ash. Trace elements like arsenic, mercury, lead,
selenium and cadmium can be volatilized during retorting and find their way
into the environment.
The study could address all of these considerations, but will be limited
initially to the study of trace elements adsorption on coal.
Procedure:
A testing manifold will be constructed in which the thickness of the
coal bed can be varied. Trace metals leached from a sample of gasified coal
will be allowed to pass through the coal beds and the concentrations- of the
trace elements will be monitored.
41
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DESCRIPTION
Complete
Literature
Survey
Design and
Laboratory Setup
Begin Testing
Complete Testing
FY-79
AUG
SEPT
FY-80
OCT
NOV
FY-81
A
DEC
A
JAN
FEB
MAR
A
APRIL
MAY
A
JUNE
JULY
AUG
SEPT
Figure 23: Project Schedule for the Adsorptive Characteristics of Coal:
Control Technology for In—situ Coal Gasification Effluents
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Water with
Trace
Elements
Coal
01
To Waste
Figure 24. Flow Diagram for the Adsorptive Characteristics
of Coal: Control Technology for In-Situ Coal
Gasification Effluents
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SHAKEDOWN OF VARIOUS UNIT PROCESSES
FOR THE TREATMENT OF OIL SHALE WASTEWATERS
Objectives:
The primary objective of this project is to shakedown various existing
devices or unit processes that have potential applicability to the treatment
of wastewaters from the emerging oil shale industry. A mobile van is being
equipped to house at least four such water pollution control pilot plants
(trains) which will be used for on-site treatment experiments at oil shale
operations in the West.
Fundamental Considerations:
The methods of pollutant removal from municipal and industrial waste-
waters have been extensively researched in the field by EPA and others. It
is necessary to develop the capability to evaluate various treatment methods
in the field for a new emerging "energy" industry—oil shale. The program
of which this T£E project is a small part will investigate all applicable
treatment control technologies for oil shale wastewaters. That program will
obtain testing equipment which is appropriate for field evaluation. Such
equipment will be obtained through: (1) specific design and fabrication;
(2) purchase of readily available, "off-the-shelf" units (5-10 gpm in size);
(3) loan of any such applicable and available units; or (4) use of EPA's
surplus lists.
Procedure:
Initially, two ion exchange units from the Crown, West Virginia, field
station will be delivered to the T§E Facility in August of 1979. Preliminary
information indicates that ion exchange, in combination with adequate primary
44
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and secondary treatment unit processes, will be effective in removing metals
and boron from some oil shale wastewaters. Consequently, these surplus units
will undergo brief shakedown tests at the T§E Facility to determine their use-
ability for subsequent field tests on oil shale wastewaters. Samples from
influent and effluent will be analyzed to determine removal capabilities of
these units for specific pollutants.
Project Schedule:
Determining the availability of mobile test equipment will be conducted
under FTB's overall water pollution control technology development program
and will continue through December of 1980. The shakedown of field equip-
ment made available may continue on an intermittent, as-needed basis. The
first specific wastewater field testing of oil shale effluents is scheduled
for July of 1980. Figure 25 indicates the four phases of this project, as it
blends with the schedule of the more comprehensive FTB program.
45
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FY-79
PHASE
I DEFINITION OF
AVAILABLE
EQUIPMENT
II EQUIPMENT
MODIFICATION*
III LABORATORY/
SHAKEDOWN
TESTING AT
THE T&E
IV FIELD TESTING
OF
EQUIPMENT**
AS
FY-80
O IN D J F MAM J J AS
FY-81
OlNlDlJ|FiMlAlMlJlJlAlS
FY-82
o|N|D|
Figure 25. Project Schedule for Shakedown of Various Unit
Processes for the Treatment of Oil Shale Wastewater.
'Done either at the T&E Facility or at Monsanto's Dayton, Ohio Laboratory
'Done elsewhere (not at the T&E Facility)
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-60Q/9-79-044
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
FY-80 Research Plan for lERL-Ci Activities at the
Facility
5. REPORT DATE
December 1979 issuing date
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Clyde R. Dempsey
Chief, T5E Facility
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
SAME AS BELOW
10. PROGRAM ELEMENT NO.
N/A
11. CONTRACT/GRANT NO.
In-house
12.
SPONSORING AGENCY NAME AND ADDRESS
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, OH 45268
13. TYPE OF REPORT AND PERIOD COVERED
Research Plan
14. SPONSORING AGENCY CODE
EPA/600/12
15. SUPPLEMENTARY NOTES
16. ABSTRACT
The Office of Research and Development of the U.S. Environmental Protection
Agency has recently begun (March 1, 1979) operation of a new facility in Cincinnati,
Ohio known as the Test and Evaluation (T§E) Facility. The purpose of this facility
is to house a variety of bench- and pilot-scale experiments in support of the various
programs of the Cincinnati Environmental Research Center and the Newtorn Fish
Toxicology Station. This report describes those projects the Industrial Environmental
Research Laboratory-Ci plans to have active at this facility during FY-80.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
Research, Planning, Pilot Plant
Control Technology
Research
13/B
18. DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (ThisReport)
Unclassified
21. NO. OF PAGES
51
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (Rev. 4-77) PREVIOUS EDITION is OBSOLETE
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