United States Control Technology EPA-450/3-89-010
Environmental Protection Center March 1989
Agency Research Triangle Park NC 27711
Hospital Incinerator Operator
Training Course: Volume III
Instructor Handbook
control * technology center
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EPA-450/3-89-010
HOSPITAL INCINERATOR OPERATOR
TRAINING COURSE:
VOLUME-III
INSTRUCTOR HANDBOOK
CONTROL TECHNOLOGY CENTER
SPONSORED BY:
Emission Standards Division
Office of Air Quality Planning and Standards
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
Air and Energy Engineering Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
Center for Environmental Research Information
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, OH 46268
March 1989
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EPA-450/3-89-010
March 1989
HOSPITAL INCINERATOR OPERATOR TRAINING COURSE:
VOLUME III
INSTRUCTOR HANDBOOK
EPA Contracts No. 68-02-4395
Work Assignment 16
Prepared by:
Midwest Research Institute
Suite 350
401 Harrison Oaks Boulevard
Gary, North Carolina 27513
Prepared for:
James A. Eddinger
Office of Air Quality Planning and Standards
U. S. Environmental Protection Agency
Research Triangle Park, North Carolina 27711
Control Technology Center
U. S. Environmental Protection Agency
Research Triangle Park, North Carolina 27711
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NOTICE
This training course is intended to provide the operator with a basic
understanding of the principles of incineration and air pollution control.
This training course is not a substitute for site-specific hands-on training
of the operator with the specific equipment to be operated.
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DISCLAIMER
This document generally describes the proper operation of a hospital
waste incinerator. It is based on EPA's review and assessment of various
scientific and technical sources. The EPA does not represent that this
document comprehensively sets forth procedures for incinerator operation, or
that it describes applicable legal requirements, which vary according to an
incinerator's location. Proper operation of an incinerator is the
responsibility of the owner and operator.
Mention of trade names or commercial products does not constitute
endorsement or recommendation for use.
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ACKNOWLEDGEMENT
This document was prepared by Midwest Research Institute located in Gary,
North Carolina. Principal authors were Roy Neulicht and Linda Chaput;
Dennis Wallace, Mark Turner, and Stacy Smith were contributing authors.
Participating on the project team for the EPA were Ken Durkee and James
Eddinger of the Office of Air Quality Planning and Standards, Charles Masser
of Air and Energy Engineering Research Laboratory, James Topsale of
Region III, Charles Pratt of the Air Pollution Training Institute, and Justice
Manning of the Center for Environmental Research Information. Also
participating on the project team were Carl York and William Paul of the
Maryland Air Management Administration.
Numerous persons were very helpful throughout this project and provided
information and comments for these course materials. Listed below are some
who deserve special acknowledgement for their assistance.
• Mr. Larry Doucet, Doucet and Mainka, who provided a thorough review of
the student handbook.
• The following persons and facilities who provided our staff access to
their facilities:
Messrs. Steve Shuler and Greg Swan, Joy Energy Systems; William Tice,
Rex Hospital; Dean Clark, B1o-Medical Services, Inc.; Gary Kamp,
Presbyterian—University Medical Center; Don Rust, Duke University
Medical Center; Chip Priester, Southland Exchange Joint Venture; and
Gregory Price, The Johns Hopkins Hospital.
• The following manufacturers who provided us with detailed operating
and maintenance information:
Joy Energy Systems, John Zink Company, Cleaver Brooks, and
Industronics.
• Mr. Charles Bollack and his staff, Mercy Medical Center, who hosted
the first trial run of this course and Mr. Robert J. Winterbottom,
R. J. Winterbottom, Inc., who assisted during the course at Mercy
Medical Center.
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PREFACE
The program for development of a training course for operators of
hospital medical waste incinerators was funded as a project of EPA's Control
Technology Center (CTC).
The CTC was established by EPA's Office of Research and Development (ORD)
and Office of Air Quality Planning and Standards (OAQPS) to provide technical
assistance to State and local air pollution control agencies. Three levels of
assistance can be accessed through the CTC. First, a CTC HOTLINE has been
established to provide telephone assistance on matters relating to air
pollution control technology. Second, more in-depth engineering assistance
can be provided when appropriate. Third, the CTC can provide technical
guidance through publication of technical guidance documents, development of
personal computer software, and presentation of workshops on control
technology matters. The technical guidance.projects, such as this one, focus
on topics of national or regional interest that are identified through contact
with State and local agencies.
The CTC became interested in developing a basic-training course for
operators of hospital waste incinerators with the idea that properly trained
operators can improve operating and maintenance procedures and, consequently,
minimize air emissions. This training course was prepared to provide the
operator with a basic understanding of the principles of incineration and air
pollution control and to identify, in a general sense, good operating
practices. The course is not intended as a substitute for site-specific
hands-on training of the operator with the specific equipment to be operated.
The course consists of three volumes:
Volume I—Student Handbook
Volume II—Presentation Slides
Volume III—Instructor Handbook
This document, Volume III, provides the basic materials for use by the
instructor teaching the training course. It includes the course description
and agenda; course goals; lesson plans; and pretest and posttest materials.
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TABLE OF CONTENTS
Page
INTRODUCTION v 11
REGISTRATION, INTRODUCTION, PRETEST 1
LESSON PLAN
SESSION 1. PROTECTING THE ENVIRONMENT: YOUR RESPONSIBILITY.. 1-1
SESSION 2. BASIC COMBUSTION PRINCIPLES 2-1
SESSION 3. BASIC INCINERATOR DESIGN 3-1
SESSION 4. AIR POLLUTION CONTROL EQUIPMENT DESIGN AND
FUNCTIONS 4-1
SESSION 5. MONITORING AND AUTOMATIC CONTROL SYSTEMS 5-1
SESSION 6. INCINERATOR OPERATION 6-1
SESSION 7. AIR POLLUTION CONTROL SYSTEMS OPERATION 7-1
SESSION 8. MAINTENANCE INSPECTION - A NECESSARY PART OF
YOUR JOB 8-1
SESSION 9. TYPICAL PROBLEMS 9-1
SESSION 10. STATE REGULATIONS 10-1
SESSION 11. SAFETY: AN IMPORTANT PART OF YOUR JOB 11-1
SESSION 12. HANDS-ON DEMONSTRATION 12-1
APPENDIX A. REGISTRATION FORM A-l
APPENDIX B. PRETEST, POSTTEST, ANSWER KEYS B-l
APPENDIX C. STUDENT WORKSHEETS C-l
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INTRODUCTION
This manual contains the basic materials for use by the course
instructors teaching'the Hospital Incinerator Operator Training Course. Among
the materials included are:
1. Course goals;
2. Instructional objectives;
3. Course description and agenda;
4. Course prerequisite skills;
5. Intended student population;
6. Discussion about course presentation;
7. List of course materials;
8. Lesson plans for each session;
9. Classroom worksheets; and
10. Pretest and posttest with answers;
The lesson plans include:
1. Session title, number, and the suggested time required;
2. Session goal and objectives;
3. List of support materials and equipment;
4. Special instructions (if any);
5. List of slides;
6. Session content outline and discussion keyed to slides and student
handbook;
7. List of key references; and
8. Review questions.
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GOALS FOR HOSPITAL INCINERATOR OPERATOR TRAINING COURSE
The goals for this course are: (1) to provide hospital waste incinerator
operators with the knowledge of basic principles of the proper operation and
maintenance of incinerators and air pollution control systems, (2) to give
them an appreciation for their role in minimizing air pollution, and (3) to
increase their awareness of regulatory requirements and safety concerns. The
knowledge gained in this course will improve the ability of the participants
to-perform their job responsibilities of properly operating and maintaining
hospital waste incinerators and their associated air pollution control
systems, monitoring key parameters indicative of performance of the equipment,
and doing their part to comply with applicable regulations.
At the conclusion of the course, the participants will understand the air
pollution problems associated with hospital waste incinerators and how they
can be minimized through proper operation and maintenance. They will be aware
of the key operating parameters for the incinerator and associated air
pollution control system. They will be aware of common operational problems
and safety hazards and possible solutions. Participants will learn how to use
monitoring and recordkeeping to improve operation and to aid in compliance
with regulatory requirements. Finally, participants will have an opportunity
to participate in a brief "hands-on" session at an actual incinerator to
further enhance their understanding of incinerator equipment and operation.
This course is intended as basic training and is not intended to be a
substitute for site-specific "hands-on" training with the specific equipment
to be operated.
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INSTRUCTIONAL OBJECTIVES FOR HOSPITAL INCINERATOR OPERATOR TRAINING COURSE
The following is a summary of the specific instructional objectives for
each of the 12 course sessions.
SESSION 1
Subject: Protecting the Environment: Your Responsibility
Objective: After completing this session, the students should be able
to:
1. Name the primary reasons that hospital wastes are incinerated;
2. Identify environmental concerns related to incineration;
3. List the types of air pollutants of concern that could be emitted to
the atmosphere from hospital waste incinerators; and
4. Recognize their role in preventing air pollution and improper ash
disposal.
SESSION 2
Subject: Basic Combustion Principles
Objective: After completing this session, the students should be able
to:
1. List the three factors that are needed for combustion to occur;
2. List the combustion products generated under good combustion and
poor combustion conditions;
3. Describe the relationship among fuel, air, and waste control;
4. Describe how combustion air requirements are affected by waste
characteristics;
5. Describe what happens when there is too much or too little
combustion air;
6. Estimate the heating value of different waste types;
7. Describe how the combustion gas oxygen level is related to
combustion air;
8. Define opacity and describe what happens to opacity under poor
combustion conditions; and
9. Recognize the definitions of these terms:
• Heating value
• Stoichiometric (theoretical) air
• Excess air
• Starved air
• Products of incomplete .combustion
SESSION 3
Subject: Basic Incinerator Design
Objective: After completing this session, the students should be able
to:
1. Understand the difference between multiple chamber, controlled-air
and rotary kiln incinerators;
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2. Identify the types of incinerators they operate—multiple chamber,
controlled air or rotary kiln;
3. Identify the types of waste charging systems they use; and
4. Identify the types of ash removal systems they use.
SESSION 4
Subject: Air Pollution Control Equipment Design and Functions
Objective: After completing this session, the students should be able
to:
1. Identify the types of air pollution control systems used on their
incinerators;
2. Name the air pollutants that their air pollution control systems are
intended to control;
3. Understand the basic principles that account for pollutant
collection and removal;
4. Identify the major components of their air pollution control
systems; and
5. List the functions of each major component.
SESSION 5
Subject: Monitoring and Automatic Control Systems
Objective: After completing this session, the students should be able
to:
1. List the operating parameters that may be controlled and/or
monitored;
2. Distinguish between a monitored and controlled parameter and a
parameter which is only monitored;
3. Identify the instruments used to monitor operating parameters;
4. Explain the basic types of control systems typically used on
incinerators; and
5. Identify the monitoring and control systems included on their
incinerators/air pollution control systems.
SESSION 6
Subject: Incinerator Operation
Objective: After completing this session, the students should be able
to:
1. Recognize the do's and don'ts of waste handling and charging;
2. Identify the key operating parameters for multiple-chamber and
control!ed-air incinerators;
3. State the operating range that is considered acceptable for each key
operating parameter;
4. Describe how to monitor each key operating parameter;
5. List the special actions required for startup and shutdown of the
incinerator;
6. Recognize the do's and don'ts of ash removal and handling.
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SESSION 7
Subject: Air Pollution Control Systems Operation
Objective: After completing this session, the students should be able
to:
1. Identify the key operational parameters for their air pollution
control systems;
2. Describe the operational ranges considered acceptable for these
parameters;
3. Describe how to monitor the key parameters; and
4. Name the steps to take to ensure proper operation of their air
pollution control systems during startup and shutdown.
SESSION 8
Subject: Maintenance Inspection - A Necessary Part of Your Job
Objective: After completing this session, the students should be able
to:
1. List the maintenance inspections that should be made on an hourly
basis;
. 2. List the maintenance inspections that should be made on a daily
basis;
3. List the maintenance inspections that should be made on a weekly
basis;
4. Identify and alert maintenance personnel of potential problems; and
5. Implement a recordkeeping system.
SESSION 9
Subject: Typical Problems
Objective: After completing this session, the students should be able
to:
1. Identify the most frequent operational problems with incinerators
and air pollution control systems;
2. Recognize the causes of operational problems; and
3. Describe the actions to take to correct and prevent operational
problems.
SESSION 10
Subject: State Regulations
Objective: After completing this session, the students should be able
to:
1. List the air pollutants from hospital waste incinerators that are
li.kely to be regulated by their State;
2. Recognize the types of requirements that may be included in
regulations;
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Describe how regulatory agencies determine whether their facilities
are complying with applicable regulations; and
Describe the State regulations applicable to their incinerators.
SESSION 11
Subject: Safety: An Important Part of Your Job
Objective: After completing this session, the students should be able
to:
1. Name the activities in their jobs that could expose them to
possible injury or disease if they do not take proper precautions;
2. Name the types of containers used for infectious waste;
3. Describe proper waste-handling procedures;
4. List the protective clothing and safety equipment they should wear
on the job; . •
5. Recognize the types of waste that must be discarded in red bags;
6. Name types of materials that should never be fed into an
incinerator;
7- Describe the safety precautions to take when charging the
incinerator;
8. Describe the safety precautions to take when removing the ash from
the incinerator ash compartment;
9. Describe the safety precautions to take when working around the
chamber of a mechanical ram feeder, ash conveyor, or incinerator;
10. Recognize the parts of the incinerator around which special
precautions are necessary;
11. Name the hazards associated with wet scrubber and fabric filter
operation and how to avoid them.
SESSION 12
Subject: Hands-On Demonstration
Objective: After completing of this session the students should be able
to:
1. Lorcate the major components of the incineration system;
2 Understand the operating principle of this incinerator's control
system; and
3. Point out potential problems or safety hazards.
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COURSE DESCRIPTION AND AGENDA
This training course is a 2 to 2*5 day course dealing with hospital waste
incineration. There-are 1% to 2 days of lecture presentations with time for
review and student interaction. One-half day is devoted to a hands-on
demonstration of operation of an incinerator and air pollution control
system. All sessions, including about a 2-hour hands-on session can be
completed in 2 full days, however. This requires long days and provides
limited time for discussion. Depending upon the size of the class, location
of the incinerator (i-e-» time needed for travel) and time desired for the
hands-on session, it may be desirable to present the course over a 2% day
period.
Two example course agendas are presented. The first agenda is a 2% day
agenda with the hands-on session on the last %-day. This agenda provides for
shorter lecture days. This agenda also would be more appropriate if (1) the
incinerator being used for the hands-on session is not conveniently located on
the premises where the class is being held, or (2) the class is very large
(larger than 15 persons) and the group must be split into two or more groups
for the demonstration, or (3) hands-on sessions are planned for more than one
facility to provide the opportunity to see more than one type of incinerator
in operation.
The second agenda is a shortened 2 day version. This agenda requires
longer days and provides little or no time for travel to a facility for the
hands-on session.
Depending upon the logistics of coordinating the hands-on session, it may
be appropriate to have the hands-on session at the beginning of the second
day. However, conducting the hands-on session prior to Session 6—Incinerator
Operation is not recommended.
The course should be taught at the high school level because it is
expected that most participants will have ended their formal education with
the 12th grade or lower. It is assumed that the average participant has not
received techrvf-cal or scientific instruction beyond high school. Therefore,
highly technical terminology, phrases, and acronyms commonly used in the air
pollution control community should be avoided unless they are explained.
The course agenda, which follows this section, is designed so that the
early sessions provide basic information on which the content of later
sessions is based. Therefore, it is not advisable to rearrange the sequence
of the sessions. However, the instructor may need to provide more time for
some sessions and less time for others or make the course longer or shorter,
depending on the training needs of the participants. For example, if no
attendees operate incinerators which have air pollution control devices, the
instructor may decide to delete or substantially shorten the sessions dealing
with air pollution control devices. This is acceptable as long as the basic
goal and objectives of each session are met and the participants receive the
information needed to meet the basic course goals.
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2%-DAY AGENDA FOR HOSPITAL INCINERATOR OPERATOR TRAINING COURSE
Day and time Session
Day 1
9:00-10:00 Registration, Introduction, and Pretest
10:00-10:30 Protecting The Environment— Your Responsibility
10:30-10:45 Break
10:45-11:45 Basic Combustion Principles
11:45-12:45 Lunch
12:45-2:00 Basic Incinerator Design
2:00-2:15 Break
2:15-3:00 . Air Pollution Control Equipment System Design and Functions
3:00-4:00 Monitoring and Automatic Control Systems
4:00 Adjourn for the Day
8:30-10:30 Incinerator Operation
10:30-10:45 Break
10:45-11:45 Air Pollution Control Systems Operation
11:45-12:45 Lunch
12:45-1:30 Maintenance Inspection—A Necessary Part of Your Job
1:30-2:30 Typical Problems
2:30-2:45 Break
2:45-3:15 State Regulations
3:15-3:45 Safety: An Important Part of Your Job
3:45-4:15 Posttest
4:15 Adjourn for the Day
Day 3
8:30-12:00 Hands-on Session
12:00 Adjourn
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2-DAY AGENDA FOR HOSPITAL INCINERATOR OPERATOR TRAINING COURSE
Day and time Session
Day 1
8:45-9:30 Registration, Introduction, and Pretest
9:30-10:00 Protecting The Environment—Your Responsibility
10:00-10:45 Basic Combustion Principles
10:45-11:00 Break
11:00-12:00 Basic Incinerator Design
12:00-1:00 Lunch
1:00-2:00 Air Pollution Control Equipment System Design and Functions
2:00-2:45 Monitoring and Automatic Control Systems
2:45-3:00 Break
3:00-5:00 Incinerator Operation
5:00 Adjourn for the Day
Day 2
8:30-9:30 Air Pollution Control Systems Operation
9:30-10:15 Maintenance Inspection—A Necessary Part of Your Job
10:15-10:30 Break
10:30-11:30 Typical Problems
11:30-12:30 Lunch
12:30-1:00 State Regulations
• 1:00-1:30 Safety: An Important Part of Your Job
1:30-2:00 Posttest
2:00-5:00 Hands-on Session
5:00 Adjourn
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COURSE PREREQUISITE SKILLS
There are no prerequisites for this course. However, participants with
less than a high school education and little previous incinerator operation
experience may find it difficult to comprehend the material and to
successfully complete the posttest.
INTENDED STUDENT POPULATION
This course is designed for student participation. Therefore, it is
desirable for participants to have some previous incinerator operation
experience so that they may better benefit from and contribute to the course
presented. It is expected that most participants will not have received
formal education beyond the high school level and will have little or no
knowledge of technical and scientific terminology. Ideally, the classes
should be made up of no more than 20 to 30 students to facilitate good
discussions and to apply the material presented to individual situations as
much as possible.
DISCUSSION ABOUT COURSE PRESENTATION
Instructor Qualifications and Responsibilities
The most important criteria in the selection of instructors for this
course are:
1. A knowledge of the current methods and procedures involving the
incineration of hospital wastes;
2. Relevant practical experience;
3. Knowledge of the kinds of jobs for which the training is designed;
4. Ability to instruct adults using appropriate methods, materials, and
techniques; and
5. A positive attitude toward air pollution control and infectious waste
management.
Prior to going before a class, instructors should be thoroughly briefed on the
overview of the course, course and session objectives, and the materials,
procedures, arid techniques to be used. If possible, they should attend an
early session or a previous presentation of the course to gain an appreciation
for the background and needs of typical students.
The instructor must allow adequate lead time for preparation. Thorough
familiarization with all the prepared materials is essential for even "expert"
instructors since the course is based upon specific learning objectives.
Preparation must include the study of the visual aids, student handbook, and
key references noted in the lesson content outline.
If possible, before the course begins the instructor should obtain and
become familiar with the operating permit for each incinerator operated by the
course attendees. This will enable the class discussions to better focus on
the particular types of equipment and permit requirements that apply to the
operators. The instructor also should coordinate the hands-on demonstration
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with the manager of the selected facility and schedule time before the
demonstration to become familiar with the equipment and operating procedures.
Session 10 of the course contains general information about State air
pollution control regulations governing the incineration of hospital waste.
The instructor will need to prepare more specific instructional material about
the applicable State and local regulations for the locale in which the course
is being presented. This material should focus on the requirements that apply
to-the operators in attendance and, as time permits, should include discussion
of the operating permit requirements for the individual incinerators.
Physical setting
The physical setting for this course must accommodate several special
requirements. Students will answer review questions in the student handbook
during each session, so desks or tables with comfortable chairs will be needed
and enough space should be provided to avoid crowding. Projection slides and
overhead transparencies will be used to illustrate lectures, so proper
projection equipment, screen, and room darkening will be required. A
chalkboard, erasers, and chalk also will be needed.
Lesson Plan Use
Each lesson plan is designed to serve as a:
1. Source of session objectives;
2. Content guide for the instructor;
3. Lecture outline;
4. Guide for use of visual aids; and
5. Guide to additional published information for instructor use.
Generally, each lesson plan parallels the material in the student handbook,
with keys to the visuals given in the right-hand margin.
Time ranges have been assigned to each session. Instructors should
"pace" lectures so that material is covered in the allotted time for the
course. If variations in format or content are believed to be beneficial, the
instructors should be sure to maintain the schedule so that session objectives
are met. They also should remember that the review questions and posttest
reflect the session objectives. To stray too far from the prescribed lesson
plan may require changes in the posttest.
Testing Process
Every student is required to take two tests—a pretest and a posttest.
The pretest is to be given during the first scheduled class session. It
is designed to test the student's knowledge of the subject matter before the
course begins. It is used only to estimate "learning gains" and to inform
course designers about the effectiveness of the instruction.
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The posttest is to be given at the end of the course. It is essential
a "final exam." The test is designed to measure how well the student has
mastered the stated objectives.
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Checklist
The following checklist is provided as an organizational aid.
1. Precourse responsibilities:
a. Reserve and confirm classroom, including size, "setup,"
location, and costs (if any).
b. Select, contact, and confirm all speakers for the
course. Forward materials to them.
c. Reserve hotel accommodations for speakers (if needed).
d. Arrange for food services (i.e., coffee breaks, water,
etc.)
e. Review and modify program curricula to recognize regional
interest, based on assessment of need.
f. Prepare and reproduce final ("revised" if appropriate)
copy of the agenda.
g. Reproduce final registration roster.
h. Prepare name badges and name "tents" for students and
speakers.
i. Identify, order, and confirm all A-V equipment needed.
j. Obtain sufficient copies of Student Handbooks, Pretest,
and Posttest, and other handouts.
k. Pack and ship supplies and materials to the course
location prior to beginning of course (if appropriate).
1. Obtain copies of operating permits for course attendees'
incinerators.
m. Arrange hands-on session with facility manager. Visit
site and become familiar with equipment and operating
procedures.
n. Prepare instructional materials for session on State and
local regulations that apply to course attendees.
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2. Onsite course responsibilities:
a. Determine and check on final room arrangements (i.e.,
tables, chairs, lectern, water, cups, etc.).
b. Setup A-V equipment required each day and brief operator
(if supplied).
c. Alert receptionist, watchmen, etc., of name, location, and
schedule of the program.
d. Set up and handle final registration check-in procedures.
e. Conduct a new speaker(s) briefing session on a daily
basis.
f. Verify and make final coffee arrangements (where
appropriate).
g. Make a final check on arrival of guest speakers
(instructors) for the day.
h. Collect student evaluation critiques at the end of the
course.
3. Postcourse responsibilities
a. Request expense statements from paid speakers; order and
process checks.
b. Write thank-you letters and send checks to paid speakers.
c. Write thank-you letters to nonpaid guest speakers.
d. Prepare evaluation on each course (including instructors,
content, facilities, etc.)
e. Make sure A-V equipment is returned.
f. Return unused materials to the appropriate office.
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COURSE MATERIALS
For instructor's use:
1. This Instructor Manual
2. Student Handbook
3. Presentation Slides Handout
4. Visuals slide package
5. Selected references
For distribution to students:
1. Registration form
2. Student Handbook
3. Presentation Slides
4. Pretest and posttest
5. Final registration roster
6. Student course critique forms
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Beachler, D. S. APTI Course SI:412, Baghouse Plan Review. U. S.
Environmental Protection Agency. EPA 450/2-82-005. April 1982.
U.- S. Environmental Protection Agency. Control Techniques for Particulate
Emissions from Stationary Sources, Volumes 1 and 2. EPA 450/3-81-005a,b.
(NTIS PB 83-127498). September 1982.
Air Pollution Control District of Los Angeles County. Air Pollution
Engineering Manual, AP-40. (NTIS PB 225132). U. S. Environmental Protection
Agency. May 1973.
U. S. Environmental Protection Agency. Municipal Waste Combustion Study:
Combustion Control of Organic Emissions. EPA 530/SW-87-021C. (NTIS
PB 87-206090). June 1987.
U. S. Environmental Protection Agency. Wet "Scrubber Inspection and Evaluation
Manual. EPA 340/1-83-022. (NTIS PB 85-149375).
U. S. Environmental Protection Agency. Fabric Filter Inspection and
Evaluation Manual. EPA 340/1-84-002. (NTIS PB 86-237716). February 1984.
Miscellaneous
U..S. Environmental Protection Agency. Continuous Air Pollution Source
Monitoring Systems Handbook. EPA 625/6-79-005. June 1979.
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REGISTRATION, INTRODUCTION, AND PRETEST
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LESSON PLAN
COURSE: HOSPITAL INCINERATOR OPERATOR TRAINING
COURSE
SESSION TITLE: REGISTRATION, INTRODUCTION, AND PRETEST
SESSION NO:
SESSION TIME: 60 MINUTES
GOAL
To familiarize students with the course structure and objectives; to have
them meet instructors and fellow students; to conduct the pretest; to present
pertinent logistical information; and to obtain registration information.
OBJECTIVES
At the end of this session, each student should know:
1. The name of the organization conducting the course; any other
contributing organization; the source of the course materials and any similar
information.
2. The name of all instructors and their affiliations.
3. Where to obtain the name and employer of each student in the class
(if roster list is already available).
4. The phone number where a student may receive messages during the
class offering.
5. The course goals and objectives.
6. The requirements for completing the course.
7. The teaching method used in the course.
8. The nature and uses of class materials.
9. The location of emergency exits, telephones, rest rooms,
refreshments, restaurants, transportation facilities.
SUPPORT MATERIALS AND EQUIPMEHT;
Blackboard; chalk; eraser.
Slide projector.
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SPECIAL INSTRUCTIONS:
Refer students to student handbook and handout including presentation
slides.
HANDOUTS:
1. Registration form (Appendix A)
2. Pretest (Appendix B)
SLIDE NO.
Title of Course
1 Course Goals
2 Upon Completing This Course You Should:
-------
INTRODUCTION AND REGISTRATION
IDENTIFY COURSE
1. Name of course
2. Name of organization presenting course
a. If EPA contractor, explain EPA/contractor relationship
b. Acknowledge source of training materials~U. S. EPA Control
Technology Center
INTRODUCE FACULTY
1. Introduction of course director
a. Name and affiliation
b. Experience
c. Areas of expertise
2. Introduce other instructor(s), if present
a. Name and affiliation
b. Experience
c. Areas of expertise
[NOTE: mention instructors who will arrive later]
3. Introduce local liaison persons, if present
4. Introduce host, if course is being held at a hospital facility
PRESENT LOGISTICAL INFORMATION
[NOTE: A simple floor plan on chalkboard or overhead is helpful]
1. Location of emergency exits and other pertinent information about
emergency procedures
2. "No smoking in classroom" rule
3. Location of restrooms, telephone
4. Procedures to obtain phone messages (include message phone number)
5. Location of vending machines, snack bars, and restaurants; plans for
lunches
6. Description of transportation and parking facilities
COURSE MATERIALS
Explain materials to be used; refer to:
Registration form
Student Handbook which includes presentation slides
Review worksheets for sessions
Agenda
-------
EXPLAIN SCHEDULE
[NOTE: refer students to agenda!
1. Number of days
2. Starting and adjourning times
3. Breaks, lunch
PRESENT COURSE REQUIREMENTS
1. Completed registration card
2. Pretest
3. 95 percent attendance - minimum
4. Posttest
REGISTRATION
1. Explain procedure for filling out registration cards
2. Have students fill out cards
3. Collect cards from students
HAVE STUDENTS INTRODUCE THEMSELVES
1. Give name, hometown, and employer
2. Describe their incineration experience; what their job involves
3. Explain what they expect to get from the course
-------
COURSE STRUCTURE AND OBJECTIVES
DESCRIBE TEACHING METHODS
1. Training
a. Interactive—each person has some experience to bring to course
2. Instructors
a. Will be there to help students become trained
b. Will add their, experience and expertise to the training
c. Will encourage questions and interaction; but avoid use of whole
class time for individual interests
3. Lecture sessions on basic topics followed by discussion
4. Review worksheets for some sessions; these are for students' use (not
to be handed 1n) to help apply information learned to their specific
situation. They will be handed out at appropriate times during the course.
5. Each section of the student handbook also has review exercises and an
answer key to aid the student.
PRESENT THE COURSE GOALS AND OBJECTIVES
1. COURSE GOALS
Intended as basic
introductory course
Objective is to
present a broad
perspective
— incineration
principles
— operation
— maintenance
~ safety
— pollution control
— regulatory
requirements
Provide an under-
standing of basic
principles so you can
better understand why
you do the things you
do during incinerator
operation
COURSE GOALS
Ta FMVIOI rou KITH »» UHOIUJTAHOIUS OF:
— BASIC PKIIICIFLCS OF [NCINMATIOM
— Pror«» OF t PUT ion «ND NAmTCNAiict
— RlWUTOItY «EOUI»E»tJ«TS mo SAFETY COHCEHMS
-------
2. COURSE OBJECTIVES
UPM COHPIET1H6 THIS COURSE YOU SHOULD:
KO >IK POLLUTtO» PWILIW >NO HOK TO MINIMIZE rHEM
UHOUSTMB me CAUSE or cannon optMnxc MOIWEHS «m>
S»FITT H»J*«OS AM) HO* TO HIHIMIZE THEM
(mm MOT ro KCNITOK OFEMTIOII ro «io IN CONPLTIKS KITH
KKULATOIT KEQUIKCMENTJ
Explain that the students
should:
a. Understand air
pollution problems and
how they can help
minimize them by
proper incinerator
operation
b. Understand the cause
of most common
operating problems and
safety hazards—how to
minimize the problems
and deal with them
when they do occur.
.c. Know how to monitor
operation to
understand what is
happening within the
incinerator and how to
control operation to
comply with
regulations
THE INSTRUCTOR SHOULD NOTE:
Each incinerator is different and has different monitoring and
control systems. Furthermore, regulations differ for specific
incinerators. This course is an introductory course to provide an
understanding of basic principles and a broad overview and is not a
substitute for site specific hands-on training at your facility. This
course is a supplement to such training; site specific hands-on training
by a qualified trainer with the particular equipment you will be operating
is strongly encouraged.
-------
PRETEST
EXPLAIN THE PRETEST
1. Test what they know as they enter the course;
2. Does not count In the final course grade;
• 3. Will be correlated to the posttest grade to measure actual
learning in the course and to help staff improve the course and the tests;
and
4. Students should not guess at answers on the pretest.
Tell students that each is to turn in his/her pretest as he/she
completes it and then take a break until (specified time).
Have students begin taking test.
[NOTE: Instructor is to grade the tests as promptly as possible and
record grades.]
8
-------
LESSON PLAN
COURSE: HOSPITAL INCINERATOR OPERATOR TRAINING
COURSE
SESSION TITLE: PROTECTING THE ENVIRONMENT - YOUR
RESPONSIBILITY
SESSION NO: 1
SESSION TIME: 30 MINUTES
GOAL
To familiarize students with
• Why hospital waste is incinerated
What the environmental concerns are related to incineration
• What air pollutants are important
OBJECTIVES
At the end of this session, each student should be able to:
1. Name the primary reasons that hospital wastes are incinerated;
2. Identify environmental concerns related to incineration;
3. List the types of air pollutants of concern that could be emitted to
the atmosphere from hospital waste incinerators; and
4. Recognize his/her role in preventing air pollution and improper ash
disposal.
SUPPORT MATERIALS AND EQUIPMENT:
Slide set for Session 1; slide projector
SPECIAL INSTRUCTIONS;
None
HANDOUTS:
None
1-1
-------
Slide No. Title
1-T Protecting the Environment—Your Responsibility
Picture-1 Picture of Beach Scene
1-1 Why Incinerate?
Picture-2 Picture of Ash and Smoke
1-2 Environmental Concerns
1-3 Environmental Concerns—Pictorial
Picture-3 Picture of Operator Doing Records
1-4 The Operator—Your Role
1-2
-------
INTRODUCTION
• Recently there has been much
concern about medical waste
washing up on our nation's
beaches
• Hospitals generate large
quantities of waste. Some
of the types of wastes that
are generated are infectious
wastes, others are general
rubbish.
• Historically, much of this
waste has been disposed of
in landfills. However, as
many landfills reach capa-
city and people become more
concerned with environmental
problems caused by improper
disposal of waste materials,
incineration has become an
even more attractive option
for handling wastes.
Furthermore, some landfills
are refusing to accept or
are banned from accepting
medical wastes.
WHY INCINERATE?
The primary advantages of
incineration (properly applied) are:
• It greatly reduces the
weight and volume of waste
material that must be
disposed of in landfills.
• -The incinerator sterilizes
the waste. That is, the
high temperatures in
incinerators can destroy any
pathogens that may be in
Infectious waste materials.
• It destroys organic
materials that may be
harmful or that may be
degradable to harmful
materials in landfills.
Picture
1-1
Wt INCINERATE?
UtUCIS HCIGMT MO VOLUKl OF «»STE
SrnuuzES mi «»srt
On rears DMAIIIC M»THI«LS rx«r »«r aicm
CI MJUBWUL ir-mroouCTS :» UMOFIILS
AtSTMITIC «USO«—OMTHOTS MSTCS SUCH «S 100T
nur nnuc MHOS outerlomiu
1-3
-------
• The incinerator destroys animal or human pathological wastes or other
hospital waste materials that the general public finds objectionable
to handle or see.
ENVIRONMENTAL CONCERNS
This photograph is a lead-in to
concerns about the environment Picture
1-2
• The general public will not
accept incineration as an
option for treating hospital
wastes if they do not
believe that it is safe
environmentally.
• Briefly, we will mention the
emissions of concern.
THE PRIMARY ENVIRONMENTAL CONCERNS ARE
• The pathogens are destroyed '-••* •-'
in the incinerator, avummaTAi.coreras
• Harmful air pollutants are . ?tnmu0£SI,UC,IM
not emitted from the
incinerator, and
• Ash residue is acceptable • A»««urT
and properly handled.
Explain concern about pathogens:
• The primary objective of
hospital waste incineration
is the destruction of
pathogens in infectious
wastes. Pathogens are those
biological components of the
waste that can cause an
infectious disease. Hence,
the term "infectious waste"
is used to refer to wastes
which may be suspected of
containing pathogens.
• The pathogens in Infectious waste can be destroyed by the high
temperatures achieved 1n hospital waste incinerators. Little
information 1s available on the incinerator conditions required to
destroy all pathogens, but temperature and time of exposure are known
to be important.
• Information on recommended incinerator operating temperatures will be
discussed later in the course.
• Concerns about ash quality and air emissions are depicted in the next
slide.
1-4
-------
POLLUTANTS OF CONCERN
SUDI i-3
In this figure an incinerator
and the main pollutants of concern
are shown. Explain what each
pollutant is and why it is of
concern. Begin with waste feed,
then air pollutants, then ash
residue.
WASTE FEED
• As previously noted, -,——
infectious waste may contain
pathogens. Proper Care in GNVMONMENTALCONCERNS
handling this waste should
be used to minimize exposure
to the operator.
AIR POLLUTANTS
Explain what each air pollutant is and why it is of concern. The major
air pollutants of concern are:
Particulate matter
Hydrochloric acid gas
Toxic metals
Organic compounds
Carbon monoxide
Particulate matter may be defined as fine liquid or solid matter such as
dust, smoke, mist, or fumes found in the gaseous emissions from the
incinerator.
• Particulate matter can be ash (material that does not burn) that is
part of the waste.
• Particulate matter can be soot—unburned carbon material.
• Particulate matter emissions may have a dark or light color.
• Particulate matter emissions can be described in terms of opacity.
Opacity is the degree to which light is obscured by a polluted gas—a
clear window has 0 percent opacity while black paper has 100 percent
opacity. Opacity will be further discussed later in the course.
• Particulate matter is a problem because it can cause or aggravate
respiratory problems in humans. It also creates aesthetic problems
since it is readily noticed and is a nuisance because of soiling of
exposed surfaces on houses and cars.
Hydrochloric (HCU acid is generated when polyvinylchloride (PVC) plastic
(usually clear plastic) material is burned in the incinerator.
• The appearance of a white plume or hazy cloud a short distance above
the stack can be an indication that HC1 is condensing.
1-5
-------
• The major concerns about HC1 are that it causes respiratory problems
in humans, contributes to acid rain problems, and causes material
damage to metals and concrete.
Toxic metals include cadmium, arsenic, beryllium, chromium, nickel, lead,
and mercury. These metals may be found in hospital wastes.
• Metals found in the waste will either end up in the air emissions or
the ash. These metals are known to be hazardous to human health.
• Chromium, beryllium, cadmium, and arsenic are suspected cancer causing
agents.
Organic compounds are compounds that contain primarily carbon and
hydrogen and may also contain other elements such as oxygen, nitrogen, and
chlorine in smaller amounts.
• Some organic compounds are known to cause or are suspected of causing
cancer and are considered hazardous air pollutants.
• Examples of compounds of concern are:
Benzene
Vinyl chloride
Oioxins
Carbon Monoxide (CO) also is generated during combustion if the combustor
is not operated properly (Your automobile generates some amount of CO).
• CO is toxic to humans if concentrations are high enough, and it also
is an indicator of combustion quality.
Pathogens
• Pathogens in the waste should be killed by the high temperatures, but
may be of concern if incinerator is not properly operated.
SOLID WASTE ASH QUALITY
One of the major objectives of incineration is to generate a high quality
ash for land disposal.
• All pathogens should be destroyed, i.e., sterile ash is the
objective.
• From an aesthetic standpoint, large pieces of medical waste that have
not been burned may be of concern to the public. Landfills may refuse
to accept waste not completely burned.
• Individual landfills may have requirements that must be followed in
order for your waste to be accepted. You should familiarize yourself
with these requirements to prevent refusal of the waste.
• Organic (carbon) levels in the ash also are of environmental
concern. High levels of organics or carbon may result in harmful
compounds leaching from landfills (moving from landfill into the water
supply).
1-6
-------
• A measure of ash quality is "burnout," which is the percentage of
organic material remaining in the waste. Some states may require a
certain level of burnout, e.g., a burnout of 95 percent, which means
that the ash-can contain only 5 percent organics.
• Similarly, the amount of metals in the ash can be of concern because
these metals can leach into the water supply.
• The ash should be stored in covered containers or kept wet prior to
transport to the landfill to prevent fugitive emissions.
THE OPERATOR - YOUR ROLE
This picture leads into role of
operator. It shows an operator
recording information as he operates Picture
the incinerator. Ask the 1_3
question: "What is your role in all
this?"
Snot l-«
THE OPERATOR— YOUR ROLE
It IS the Operator's rOle and IT t$ row HOLE »»o ntsponsiauirr ro »»OTECT -ME
responsibility to protect the M.IW-W.T .Y:
environment by:
• Immune i>OLLur»HT EMISSIONS THDOUGM »ROPE»
OMiunoit
• Minimizing emissions of
particulate matter, HC1 ,
toxic metals, carbon . fmmm HmMn mmM FW, .SM
monoxide, and organic HHUUM »«o STO/KGE
compounds through proper . ,D01Tim)Mi „.,„„„„ ,TO1L£M „,„„„,„„
incinerator and air
pollution control device
operation;
Operating the incinerator to generate high quality ash that is sterile
and can be disposed of in landfills;
Minimizing particulate matter emissions from ash handling (fugitive
dust) ;
Disposing of ash properly by sending it to appropriate disposal sites;
Performing the regular maintenance inspections to catch any problems
early which may later cause operating problems/emissions; and
Complying with all emission limits and operating practices specified
1n the permit to operate.
1-7
-------
Note that the remainder of the course is designed to:
• Provide you with an understanding of incineration and
• Describe good operating practices to help you achieve these objectives
1-8
-------
REFERENCES FOR SESSION 1
1. I). S. Environmental Protection Agency. EPA Guide for Infectious Waste
Management, EPA/530-SW-86-014. (NTIS PB86-199130). U. S. EPA Office of
Solid Waste. May 1986.
2. Ontario Ministry of the Environment. Incinerator Design and Operating
Criteria, Volume II-8iomedical Waste Incineration. October 1986.
3. Barbeito, M. S. and M. Shapiro. Microbiological Safety Evaluation of a
Solid and Liquid Pathological Incinerator. Journal of Medical
Primatology. pp. 264-273. 1977.
4. U. S. Environmental Protection Agency. Hospital Waste Combustion
Study: Data Gathering Phase. EPA 450/3-88-017. December 1988.
1-9
-------
LESSON PLAN
COURSE: HOSPITAL INCINERATOR OPERATOR TRAINING
COURSE
SESSION TITLE: BASIC COMBUSTION PRINCIPLES
SESSION NO: 2
SESSION TIME: 60 MINUTES
GOAL
To familiarize students with:
• Basic combustion terminology that will be used in the remainder of
the course.
How the combustion process works.
• Indicators of good combustion and poor combustion; and
How the combustion process affects air emissions.
OBJECTIVES
At the end of this session, each student should be able to:
1. List the three factors that are needed for combustion to occur;
2. List the combustion products generated under good combustion and poor
combustion conditions;
3. Describe the relationship among fuel, air, and waste control;
4. Describe how combustion air requirements are affected by waste
characteristics;
5. Describe what happens when there is too much or too little combustion
air;
6. Estimate the heating value of different waste types;
7. Describe how the combustion gas oxygen level is related to combustion
air;
8. Define opacity and describe what happens to opacity under poor
combustion conditions; and
9. Recognize the definitions of these terms:
Heating value
Sto1ch1ometric (theoretical) air
Excess air
Starved air
Products of incomplete combustion (PICS)
SUPPORT MATERIALS AND EQUIPMENT;
Slide set for Session 2; slide projector.
2-1
-------
SPECIAL INSTRUCTIONS:
None.
HANDOUTS:
None.
Slide No. Title
T Basic Combustion Principles
1 The Combustion Process
2 Fate of Combustion Air
3 Oxygen Reaction
4 Operating Factors Related to Combustion
5 Stoichiometric Air—Defined -
6 Substoichiometric air
7 Excess air
8 Control of Temperature as a Function of Excess Air
9 Characterization of Hospital Waste
10 Key Operating Parameters
11 Complete Combustion Products
12 Incomplete Combustion Products
13 Opacity
14 Stack Gas 02 and CO
Picture-1 Ash
15 Ash Quality
2-2
-------
BASIC COMBUSTION PRINCIPLES
Present the major goals of the
session to the class. To
familiarize them with:
• Basic combustion
terminology;
• How the combustion process
works; and
• Indicators of good
combustion and poor
combustion.
THE COMBUSTION REACTION
THE COMBUSTION PROCESS
• Combustion of hospital
wastes is a chemical
reaction. In the
incinerator, organic
materials and oxygen react
rapidly and violently to
• produce combustion gases and
energy in the form of heat
and light.
sssim 2.
BASIC OWUSTION PRINCIPLES
SLIDI 2-1
THE COMBUSTION PROCESS
Organic
Material + Oxygen *
Heat
Solid
Combustion Gas + Residue + Energy(Heat)
For the reaction to begin and to keep going, all three elements-
organic material, oxygen, and heat—must be present.
The organic material used in the reaction comes from two sources,
waste and auxiliary fuel. Some organic material is contained in most
hospital waste.
— Depending on the fraction of organics and the specific organic
composition, the waste may be adequate to sustain combustion.
— Auxiliary fuel may be used to maintain combustion if the waste
material does not contain enough organic material to maintain high
temperatures.
The combustion reaction between the organic material and oxygen that
causes the organics to burn will occur only after the temperature of
the organic material is raised to the point that combustion can
begin.
— Energy in the form of heat is required to raise the temperatures
of the incinerator chamber and organic material and 02.
— Initially, this energy usually is supplied by the pilot and
auxiliary fuel burners.
— After the system is in full operation, the energy released from
the burning waste often is adequate to maintain these high
temperatures.
2-3
-------
FATE OF COMBUSTION AIR
The oxygen needed for the
combustion reaction is
supplied by the ambient
combustion air. Combustion
air is supplied to the
combustion chambers through
air ports by a forced draft
fan, by an induced draft
fan, or by natural draft.
In general, this air
contains about 21 percent
oxygen (02) and 79 percent
nitrogen (N2), so about
21 percent of the total
combustion air fed to the
incinerator is oxygen that
is available to react with
the organic material in the
waste and fuel.
The nitrogen passes through
the chamber mostly
unreacted; some nitrogen
oxides are formed.
•uoi 1-2
OXYGEN REACTION
Hospital wastes contain two
types of organic materials—
volatile matter and fixed
carbon. These two types of
materials are involved in
distinct types of combustion
reactions, and the operating
variables that control the
two types of reaction are
different.
Volatile matter is that
portion of the waste that is
vaporized (or evaporated)
when the waste is heated.
— Combustion occurs after
the material becomes a
gas,
ConiBusoofl
An —
0,121%) -
Camon
ana
Orgiroc fna ana f
FATE OF COMBUSTION AIR
iune 2-3
OXYGEN REACTION
The combustion variables
that influence this
reaction are gas
temperature, residence
time, and mixing.
A minimum temperature is needed to start and sustain the chemical
reaction.
2-4
-------
— Residence time is the length of time, generally measured in
seconds, that the combustion gas spends in the high temperature
combustion chamber. The residence time must be long enough for
the reaction to be completed before it leaves the high temperature
zone.
— Turbulent mixing of the volatile matter and combustion air is
required to ensure that the organic material and oxygen are well
mixed.
Fixed carbon is the nonvolatile organic portion of the waste.
— The combustion reaction is a solid-phase reaction that occurs
primarily in the waste bed (although some materials may burn in
suspension).
— Key operating parameters are bed temperature, solids retention
time, and mechanical turbulence in the bed.
-- The solids retention time is the length of time that the waste bed
remains in the primary chamber.
— Mechanical turbulence of the bed is needed to expose all the solid
waste to oxygen for complete burnout.
•— Without mechanical turbulence, the ash formed during combustion
can cover the unburned waste and prevent the oxygen necessa-ry for
combustion from contacting the waste.
Products of complete combustion are:
— carbon dioxide
.— water
We will talk in more detail later about these combustion products
Provide some examples of volatile and nonvolatile waste. One example
is backyard charcoal grill with starting fluid.
— The starting fluid is highly volatile. When put on the charcoal
and ignited with a match, it rapidly volatilizes and burns.
— The charcoal contains less volatile matter and primarily burns
slowly as a fixed carbon bed.
OPERATING FACTORS RELATED TO COMBUSTION
Now that the combustion
process has been defined, ;uo«2-<
Some factors affecting OPEMTINS FACTQIS RELATED TO cnnaisnon
combustion will be '
dlSCUSSed. . COMMTKM MR
The three operating factors - '£££„„
that have the greatest
effects on the combustion • ^"^ '"«*•"»'"
reaction arei • *>*T« ««• CM»MCTEKISTKS
— Combustion airflow rate
and distribution,
— Operating temperatures,
and
— Waste feed rate and
characteristics.
These three factors are all
related.
2-5
-------
The combustion reaction is controlled by controlling them.
The two key questions about combustion air that we will address are:
— How much combustion air is needed to sustain the combustion
reaction?
— What happens if there is too much or too little combustion air?
STOICHIOMETRIC AIR
First let's
combustion air:
talk about
SLIDE 2-5
In the chemical reaction
between organic materials
and oxygen, the amount of
oxygen required under ideal
or "perfect" conditions to
burn all of the organic
materials with no oxygen
left over is calTed the
stoichiometric (or
theoretical) oxygen level.
— The amount of combustion
air associated with that
oxygen level is called
the stoichiometric air
level.
-- At stoichiometric air level the combustion gas would contain no
oxygen because it would all be used in the combustion reaction.
STOICHIOM6THIC AIH LEVEL
SUBSTOICHIOMETRIC AIR
Airflows less than those
required at stoichiometric
levels are called deficient
air or substoichiometric
starved-air levels.
— Under starved-air
conditions, the
combustion gas would
again contain no oxygen,
but organics also would
remain because
combustion is not
complete.
SUOE 2-6
AIR LEVEL BELOW STOICHKJMETHIC
-STAHVEO-AIH-
2-6
-------
EXCESS AIR
• A1r flows greater than those
required at stoichiometric
levels are called excess-air
levels. .^
— Typically a hospital
incinerator operates
with an overall 140 to
200 percent excess air
level. That is, the
incinerator operates
with one and one-half to
two tines more air than
required at stoichio-
metric levels.
-- -Excess air is used to
assure that enough
oxygen is available for
complete combustion.
CONTROL OF TEMPERATURE AS A FUNCTION OF AIR LEVEL
AIH LEVEL ABOVE STOICHIOMETHIC
•EXCESS AIR-
SUM 2-8
-EMP6RATIIB6 I
The air level affects
temperature—this is
graphically shown.
Maximum combustion
temperatures are always
attained at stoichiometric
conditions.
As the amount of excess air
is increased above the
stoichiometric point, the
temperature in the
incinerator drops because
energy is used to heat the
combustion air.
— If the amount of
combustion air is too
great, the temperature
drops below "good
combustion temperature,"
and undesirable
combustion products are
generated as a result of
incomplete combustion.
As the amount of excess air is decreased, the combustion temperature
increases until it becomes maximum at the stoichiometric point. Below
the stoichiometric point, the temperature decreases because complete
combustion has not occurred.
OffdEMTAlB
EXCESS Alfl
ComMi or roiTOUTuiii u > nnCTioa ar SXCHS •"»•
2-7
-------
Combustion temperature
• The relationship of how combustion air level can affect temperature
has just been shown.
• Temperature also plays an important role in the combustion of hospital
wastes.
• Temperatures need to be maintained at levels high enough to ensure
pathogen destruction and to sustain the combustion reaction.
• However, temperatures that are too high also cause problems.
Continuous exposure of the combustor refractory to high temperatures
is generally not desirable because it can cause the ash to fuse and
can cause damage to the refractory. The lower and upper limits for
"proper" temperature ranges are discussed in later sessions of this
course.
WASTE CHARACTERISTICS
iuot 2-9
• The primary characteristics mPmL,K^CHMACTESISTIC
of the waste that affect the
combustion reaction are: "'"tuV." «33° -:-a"-'z--=3
and
- The chlorine content. u$ms *Mwa w 1M™
• Different wastes have Hu"*" "•r°"'"1- a.000-12.aoo 7o-w soo-s.aoo
different heating values and
moisture contents. They
will affect the combustion
process. An example for a
few types of wastes is shown
so we can discuss.
• First explain the basic
terms of heating value and
moisture.
• The HEATING VALUE of a waste is a measure of the energy released when
the waste is burned.
— It 1s measured in units of Btu/lb (J/kq)..
-- The higher the heating value, the more energy released when
burned.
-- A heating value of about 5,000 Btu/lb (11.6xlO~6 J/kg) or greater
is needed to sustain combustion. (Wastes with lower heating
values can be burned but they will not maintain adequate
temperature without the addition of auxiliary fuel.
• The heating value of the waste can be used to calculate total heat
input to the incinerator where:
Heat Input (Btu/h) = Feed Rate (Ib/h) x Heating Value (Btu/lb)
• Heat input to the incinerator will affect temperature
— More heat input yields higher temperature
• Heat input also will affect air requirements; more air is required
(1 SCF/100 Btu)
2-8
-------
• Moisture is evaporated from the waste as the temperature of the waste
is raised in the combustion chamber;
— It passes through the incinerator, unchanged, as water vapor.
— Evaporation of moisture uses energy and reduces the temperature in
the combustion chamber.
• Chlorine in plastics or solvents in the waste feed will react to form
hydrochloric acid (HC1).
— This HC1 can be an emission problem.
— It can create corrosion problems of the equipment downstream from
the incinerator.
Point out how the Btu value and moisture varies widely.
— Compare plastics (high Btu, no moisture) to
— Beddings, shavings, etc. to
— Anatomical
SUMMARY OF KEY OPERATING FACTORS AFFECTING COMBUSTION
• Key factors are interrelated
• A1r quality/distribution
— Sufficient air for 2u"2-10
complete reaction
— Distributed to promote
mixing
3
• Mixing
— Assure contact of oxygen
and organics
• Temperature . *„„ CH,,,,CTER.ST.CS
— High enough to sustain - HHT.NSV.LUE
•*. . * — XOISTUHE CONTENT
COmOUStlOn - Cm-amnE CCMTENT
— High enough to have
complete reaction
• Residence/retention time
— Sufficient time to allow
reaction to complete
Waste characteristics also are important
• Heating value
— Measure of energy released
— Heat Input determines air required
• Moisture content
— Requires energy to vaporize water
• Chlorine content
— Affects HC1 emissions
This summarizes the key parameters affecting combustion. What happens if
combustion is not complete?
2-9
-------
PRODUCTS OF THE COMBUSTION REACTION
SLIDE 2-11
X,
COMPLETE COMBUSTION
COMPLETE COMBUSTION
Explain the combustion products
in the gas stream and ash when
complete combustion occurs and
incomplete combustion occurs.
• The primary products of
hospital waste incineration
are:
-- combustion gases,
— solid residue (ash), and
-- energy.
• The primary objectives of
the combustion process are
to
— generate an ash residue
that is sterile (free of
pathogens) and does not
contain unburned,
recognizable medical
wastes; and
-- to minimize air
pollutants in the
combustion gas stream.
Complete combustion
• The organic materials that enter the incinerator with the waste and
fuel are primarily made up of carbon, hydrogen, and oxygen.
• Ideally, these organic materials react with oxygen in the combustion
gas to form carbon dioxide and water vapor.
• The chemical reaction for-this ideal situation is
Organics + 02 + Heat * CO, + H,0 + Heat
(C, H, 0)
• This ideal reaction represents complete combustion.
2-10
-------
INCOMPLETE COMBUSTION
• However, this ideal reaction SLlof
does not occur in operating
waste combustion systems.
• Factors that lead to a less
than ideal reaction are poor
mixing, too little
combustion air, and low
temperatures.
• Under those conditions
products of incomplete
combustion are emitted with
the stack gases.
• The most common product of
incomplete combustion is CO.
• Another product of
incomplete combustion that
often is emitted under poor
mixing conditions or high
temperature, low excess air
conditions, is elemental
carbon (or soot).
— The soot particles are very fine and generally result in high
opacity at the combustion stack.
• Other products of incomplete combustion that cause concern because of
their health impacts are hazardous organic compounds such as benzene,
dioxins, and furans. Although these compounds are not found in the
waste, under incomplete combustion conditions they can be formed as
intermediate combustion products.
Explain fate of metals and HC1.
• Whether combustion is complete or not does not significantly affect
these emissions.
Identify how complete/incomplete combustion can affect ash.
• The waste feed also includes inorganic materials.
— Generally, they are not involved in the combustion reaction.
~ The inorganic materials in the waste feed (ash) are either
retained in the ash or are emitted as particulate matter in the
combustion gas.
— Air velocities in the combustion bed are controlled to reduce the
amount of inorganic material entrained (picked up by) the
combustion gas and emitted with the combustion gas.
• If combustion is not complete, organics will remain in ash; this is
typical . . . it is atypical to have 100 percent combustion of ash
bed.
• Under poor conditions (low temperature, low turbulence in ash bed) may
have pathogens remaining 1n ash; i.e., may not sterilize ash.
2-11
-------
OPACITY
Obviously, complete combustion is the goal to minimize air emissions and
prevent poor ash quality. What are some of the indicators of
complete/incomplete combustion?
COMBUSTION INDICATORS
The information presented in the above section suggests that the
following indicators can be used to monitor combustion quality.
Stjai 2-15
OPACITY
The opacity of the combustion
gas stream is a measure of the
degree to which the stack gas plume
blocks light.
• High opacities indicate high
emissions.
• Opacity is primarily caused
by noncombustible ash or
uncombusted carbon (soot) in
the flue gas.
• High opacities can indicate ;
poor mixing or low levels of '
combustion air. /
• High opacities also may be '
generated by high levels of
HC1 emissions or poor burner
operation in the secondary
chamber.
• If a large amount of water vapor is present in the combustion gas, the
water can condense when it cools as it leaves the stack forming a
dense white "steam plume." This is not an indicator of poor
combustion and should not be confused with a black or white smoke
plume caused by soot or acid gases.
• Opacity can be visually determined by a person or measured by an
instrument.
• Opacity levels will be discussed in more detail in the regulatory
session.
Other indicators which provide information about combustion conditions
are measurements of the combustion gas oxygen and CO levels. However, these
measurements require instruments and most facilities do not have those
instruments.
• PoorMcong
• Sama-Au Conooons
2-12
-------
STAQ US P. A»O CO
LOU 0,
-- INSUFFICIENT tIR
HIGH 0,
-- TOO MICH EXCESS AID COOLS CAS
HIGH CO "EMS 1*00* coNiusrtoH
STACK GAS OXYGEN AND CARBON MONOXIDE
Stack Gas 0, concentration. SLI(« 2-11
• The stack gas 02
concentration provides a
measure of excess air.
Hospital waste incinerators
typically operate at 140 to
200 percent excess air,
which roughly corresponds to
12 to 14 percent 02 in the
stack gas.
• High 02 means too much
excess air (cools gases).
• Low 02 means insufficient
air (incomplete combustion).
Stack Gas CO concentration.
• Each combustion system has a "typical operating range" for CO. If the
stack gas CO concentration goes above this typical range, combustion
problems are likely. Typically <100 ppm.
ASH QUALITY
Picture 2-1 is a picture of a
barrel of ash and is used as a lead
in to discussing ash quality. The
ash in the picture is a fine gray
ash.
Picture
2-1
2-13
-------
Visual appearance of ash can
be an indicator of SUOCMS
combustion problems. *?"wfl
If an incinerator is
operating properly, little • '«*<>*<• "«*""«
organic material will remain . No «ECOG»IZAILE-EDKAL .ASTES
in the ash. . SU««T-««.».£»....««
Is the ash whitish gray or - «ITISH G«Y .s iu.«
jet black?
— Whitish gray indicates
better burnout and less
carbon than black.
The extent of organics
combustion can be measured
by the quantity of
combustible materials
remaining in the ash.
Noted increases in ash combustibles indicate a combustion problem
which may include bed temperatures that are too low, improper
distribution of combustion air in the bed, or waste retention times
than are "too short.
2-14
-------
REFERENCES FOR SESSION 2
1. McRee, R. Operation and Maintenance of Controlled Air Incinerators.
Ecolaire Environmental Control Products. Undated.
2. U. S. Environmental Protection Agency. EPA Guide for Infectious Waste
Management, EPA/530-SW-86-014. (NTIS PB86-199130). U. S. EPA Office of
Solid Waste. May 1986.
3. Ontario Ministry of the Environment. Incinerator Design and Operating
Criteria, Volume II-Biomedical Waste Incineration. October 1986.
4. Beard, J. T., F. A. lachetta, and L. V. Lillelehet. APTI Course 427,
Combustion Evaluation, Student Manual. EPA 450/2-80-063. U. S. EPA Air
Pollution Training Institute. February 1980.
5. Beachler, D. S. APTI Course SI:428A, Introduction to Boiler Operation,
Self Instructional Guidebook. EPA 450/2-84-010. U. S. EPA. December
1984.
6. Brunner, C. R. Incineration Systems. Van Nostrand Reinhold. 1984.
7. U. S. Environmental Protection Agency. Municipal Waste Combustion
Study: Combustion Control. EPA 530-SW-87-021C. (NTIS PB 87-206090).
June 1987.
8. Air Pollution Control District of Los Angeles County. Air Pollution
Engineering Manual, 2nd Edition AP-40. (NTIS PB 225132) U. S.
EPA. May 1973.
2-15
-------
LESSON PLAN
COURSE: HOSPITAL INCINERATOR OPERATOR TRAINING
COURSE
SESSION TITLE: BASIC INCINERATOR DESIGN
SESSION NO: 3
SESSION TIME: 1 HOUR 15 MINUTES
GOAL
To familiarize the operators with
• The key components of an incineration system
• The-different types of incineration systems
• The operating principles of multiple chamber excess-air and controlled
(starved)-air incinerators
OBJECTIVES
At the end of this session, each student should be able to:
1. Understand the difference between multiple chamber, controlled-air
and rotary kiln incinerators;
2. Identify the type of incinerator he/she operates—multiple chamber,
controlled air or rotary kiln;
3. Identify the type of waste charging system he/she uses; and
4. Identify the type of ash removal system he/she uses.
SUPPORT MATERIALS AND EQUIPMENT:
Slide set for Session 3; slide projector
SPECIAL INSTRUCTIONS;
None
HANDOUTS:
Appendix C—Worksheet 1: "Incinerator System Information"
3-1
-------
Slide No.
Title
T
1-
2
3
4
5
P1cture-3-l
P1cture-3-2
6
7
8
9
P1cture-3-3
Picture-3-4
Picture-3-5
Picture-3-6
10
11
12
13
Picture-3-7
14
15
Picture-3-8
Picture-3-9
Picture-3-10
16
Picture-3-11
17
18
Picture-3-12
Picture-3-13
19
20
21
Title Slide
Major Components of an Incineration System
Incinerator Types
Multiple-Chamber Incinerators
In-Line Multiple-Chamber, Excess-Air Incinerator
Retort Multiple-Chamber, Excess-Air Incinerator
Multiple Chamber Incinerator
Multiple Chamber Incinerator
Controlled-Air Incineration
Principle of Controlled-Air Incineration
Control of Temperature as a Function of Excess Air
Major Components of a Controlled-Air Incinerator
Controlled Air Incinerator
Controlled Air Incinerator
Controlled Air Incinerator
Controlled Air Incinerator
Rotary Kilns
Rotary Kiln with Auger Feed
Operating Mode
Waste Feed Loading/Charging Systems
Manual Load
Hopper Ram Assembly
Hopper Ram Charging Sequence
Manual Load/Ram Feed
Cart Dumper
Ash
Ash Discharge and Removal Systems
Manual Ash Removal
Mechanical Ash Removal
Incinerator with Staged Hearth and Automatic Ash Removal
Ash Sump
Ash Container
Combustion Gas Handling Systems
Major Components of Burner System
Incinerator with Waste Heat Boiler and Bypass Stack
3-2
-------
INTRODUCTION
During this session the
following will be discussed:
1. The major components of an
incineration system;
2. The three major types of
incinerators used for hospital
wastes; and
3. Their principle of
operation.
Upon completion of this
session, each operator should know
what type system they operate, be
able to identify its key components,
and understand its operating
principle.
MAJOR PARTS OF
SYSTEM
AN INCINERATION
SESSION 3.
BASIC INCINERATOR DESIGN
Sum 3-1
OOO I
!3ooc:::::-
The major parts of an
incineration system to be discussed
in this session are shown in this
slide. These are
• The waste charging system,
• The incinerator, and
• The ash removal system.
• Add-on air pollution control
systems will be discussed in
Session 4.
• Control and monitoring
systems will be discussed
separately in Session 5.
• It is important to think of
the incinerator as a system
because the design, opera-
tion, and maintenance of
each part of the system
affects the performance of
the other parts.(Give an
example of how each part of
the system is inter-
related.) For example,
let's consider the waste
charging system:
— The design of the waste charging system will affect how the
incinerator can be operated. If the charging system is a
mechanical system, the size of the system can limit operation of
the incinerator.
M«JM
i»c!»«»«naK SYSTEM
3-3
-------
— The operation of the waste charging system affects the performance
of the incinerator; if waste is fed to the incinerator too fast,
incomplete combustion and air pollution may result.
-- The maintenance of the waste charging system affects the operation
of the incinerator; if the charging system breaks down, the
incinerator cannot be operated.
• Throughout this course, and when you operate your incinerator, you
should think about all the system parts and how operation of each part
affects operation and performance of the entire system.
INCINERATOR TYPES
• The "heart" of the system is
the incinerator, and there
are three basic types of su« 3-2
incinerators used for HOTOTOR TYPES
medical wastes:
~ Multiple chamber; . „„,.„,« O...IH--XCESS *,»
-- Controlled air; and
„ . , . -, • '.3«rilOLL£D '. SriHVEDI »IH
— Rotary kilns.
• 'QTiftY <||.N
Point out that different names
are used by different people . . .
do get hung up on names.
-- Multiple chamber, also
called excess air; often
used for pathological
waste
— Controlled air, also
called "starved air" or
pyrolytic.
— Note that controlled air, by design, are also "multiple chamber"
units.
During this session we will briefly discuss the principle of operation for
each type incinerator and identify:fcey components.
3-4
-------
MULTIPLE-CHAMBER INCINERATORS
5-5
MILTlPlE-tHAHBER INCINERATORS
COKIUSTIOK OCCURS 111 mo o* noac CHAMIERS
PHIIURY AMD SECONDARY CHAKIEK OPERATE HITH ll» LEVELS
IIOVI STOICHIOMTRIC
USl OVIRFIRE COmuSTION MR
IN-LINI AM DITORT DESIGNS
INTRODUCTION
Prior to 1950's "single
chamber" incinerators were used;
crudest type of single chamber
incinerator is a 55-gallon drum with
ho-les drilled in sides near the
bottom.
In multiple-chamber
incinerators, combustion
occurs in two or more
combustion chambers
— The primary chamber for
solid phase combustion, and
— The secondary chamber for gas phase combustion.
These incinerators are often referred to as excess-air
incinerators because they operate with excess air
levels well above stoichiometric in both the primary
and secondary combustion chambers.
Primarily use overfire combustion air.
The traditional designs that are used for multiple-chamber
incinerators are
the "in-line" hearth, and
the "retort" hearth.
IN-LINE HEARTH
This slide depicts the in-line
hearth design. Explain the
components and the principles of
operation.
• Flow of the combustion gases
is straight through the
incinerator with turns in
the vertical direction only
(as depicted by the
arrows).
The coabustion process involves
two chambers. Both the primary and
secondary combustion chambers are
operated above stoichiometric oxygen
levels.
[»-l.l« •Hll.nrt.l-CHAMM. EXCESS-AIR INCINERATOR
Ref. 3-1
3-5
-------
Primary chamber can have a grate (as shown here) or solid hearth.
— Grate is not recommended for infectious waste because
sharps/liquids can fall through
In the primary chamber, the waste is ignited using the primary
burner. Once the waste has started burning, the burner usually shuts
off because it is no longer needed.
Moisture and the volatile part of the waste are vaporized.
As the burning proceeds, combustion of the nonvolatile portion (fixed
carbon) of the waste occurs in the primary chamber. The incinerator
is designed for surface combustion of the waste. Surface combustion
requires mostly overfire combustion air, rather than underfire air.
The combustion products and vaporized gases pass from the primary
chamber through the flame port to the mixing chamber.
Secondary combustion air is added in the flame port. The design of
the flame port and mixing chamber, as well as the addition of
secondary air, promotes mixing.
Mote changes in direction enhance mixing and turbulence.
A secondary burner located in the mixing chamber provides additional
heat to maintain sufficient combustion temperatures.
The combustion of the gases begun in the mixing chamber continues as
the gases pass through a port in the wall to the secondary or
"combustion" chamber.
Sum 5-5
RETORT HEARTH
This slide depicts the retort
design. The combustion gases turn
in the vertical direction (upward
and downward) as in the in-line
incinerator, but also turn sideways
as they flow through the
incinerator. Because the secondary
chamber is adjacent to the primary
chamber (they share a wall) and the
gases turn in the shape of a U, the
design of the incinerator is more
compact.
In-line incinerators perform
better in the capacity range
greater than 750 Ib/h
(340 kg/h). The retort
design performs more effi-
ciently than the in-line
design in the capacity range
of less than 750 Ib/h
(340 kg/h).
The retort design is more typically used in hospital waste
applications.
Note that this slide shows the fixed solid hearth (rather than the
grate as shown in the previous slide).
Point out primary, secondary chambers, etc.
RITWT miLrm.E-CHMiin. EXCESS-*n
Ref. 3-1
3-6
-------
• Multiple-chamber retort incinerators are frequently designed and used
specifically for incinerating pathological wastes.
• Multiple-chamber incinerators designed specifically for pathological
wastes incorporate the following two design features:
1. The hearth in the primary chamber is solid instead of a grate.
Pathological waste is moist and contains liquids. To assure that fluids are
retained in the incineration chamber, a solid hearth is used. A raised "lip"
at-the door often is designed into the hearth to prevent liquids from spilling
out the door during charging.
2. The auxiliary burners in the primary chamber are intended for
continuous operation. Because the heating value of pathological waste is low
and is not sufficient to sustain combustion, additional auxiliary burners are
provided in the primary chamber to provide the heat necessary for
incineration.
This slide is a picture of the
charging door for a multiple
chamber, retort incinerator. Mote Picture
the natural draft secondary air 3-1
damper in the lower door. Note the
secondary air burner assembly in the
left lower corner.
This slide shows the interior
of a chamber for a small retort Picture
multiple chamber incinerator used 3~z
for pathological wastes. Mote:
• Draft openings in door
• Primary burner assembly to
right side
• Ash on hearth
3-7
-------
CONTROLLED-AIR INCINERATION
• The control!ed-air
incinerator also is a
multiple chamber
incinerator. Combustion suacs-o
occurs in two or more
chambers.
• In a control!ed-air
incinerator the amount and
distribution of air to each . ^^^ OCCUJIS ,„ „„ OR „„„ CH,HIERS
combustion chamber is
t ^ ^ i • AMUIITS INO DISTRIBUTION or coHiusno* »m
COn urO I I 60 . T0 uot CHAMCX »«t cm«nioLi.ED
• THIS tVDe incinerator iS ~ MI«««T CHMIC* ULO» STOICHKWETSIC
-. <- . .. " SECONO*«T CHMieR J«OVE STOICHIOIIETIIIC
often referred to as a
"starved-air" incinerator.
• The term "starved-air" is
derived from the principle
of combustion most
frequently used in this type
of incinerator.
— The combustion air to the chamber into which the waste is fed (the
primary chamber) is strictly controlled so that the amount of air
present in this chamber is less than that needed for complete
combustion, i.e., the chamber is "starved" for air.
~ The secondary chamber operates at excess-air levels (above
stoichiometric).
First we will discuss the operating principle of controlled-air
incineration in more detail; then we will identify the major components of a
controlled-air incinerator.
3-8
-------
PRINCIPLE OF CONTROLLED-AIR INCINERATION
,;z 5-7
PRINCIPLE OP CONTROLLED-** tNCINEHAr
Ref. 3-2
This slide 1s a simplified
drawing of an incinerator that
operates using the control!ed-air
principle. The principle of
controlled-air combustion is
summarized as follows:
• The system consists of two
combustion chambers:
— the primary chamber
(also referred to as the
ignition chamber), and
— the secondary chamber
(also referred to as the
combustion chamber).
• The primary chamber accepts
the waste, and the
combustion process begins.
An auxiliary burner is used
to ignite the waste. Once
the waste has started
burning, the burner usually
shuts off because it is no
longer needed (unless
pathological wastes are
being incinerated).
• The air distributed to the primary chamber is controlled so that the
chamber is starved for oxygen, in other words, the chamber is operated
below stoichiometric levels.
• The combustion air usually is fed to the primary chamber as underfire
air—underfire air is directed "under" or through the waste bed
through air inlets located near the floor or hearth of the primary
chamber.
• Three processes occur in the primary chamber.
~ First - the moisture in the waste is vaporized; boiling a pot of
water on the stove is an example of the vaporization of water.
— Second - the volatile fraction of the waste is vaporized; when an
open can of gasoline sits in the sun, the gasoline vaporizes.
— Third - the fixed carbon remaining in the waste is burned. Fixed
carbon is the nonvolatile portion of the waste. To achieve
complete combustion, the fixed carbon must be burned in the
primary chamber at higher temperatures and for longer times then
the volatile fraction. Charcoal briquettes burning in your
charcoal grill are an example of fixed carbon burning.
• The combustion gases containing the moisture and the volatile
combustible materials from the primary chamber are directed to the
secondary chamber.
• As the gases enter the secondary combustion chamber, more air—the
secondary combustion air—is added through the main "flameport". The
air is added.with enough force to cause mixing of the air and the
combustion gases.
3-9
-------
• Enough air is added to the secondary chamber so that an "excess" of
oxygen is available for the combu-stion process.
• The gas/air mixture is burned in the secondary chamber at high
temperatures to promote complete combustion.
• An auxiliary fuel burner is used, as needed, in the secondary chamber
to ensure that the high temperature is maintained.
CONTROL OF TEMPERATURE AS A FUNCTION OF EXCESS AIR
Control of the incinerator.
This slide illustrates how the
amount of air supplied to each
chamber of the incinerator is used
to control the combustion chamber
temperature.
SLIOI 3-3
PflMAKY
CHAMBCT OPERATING I
AAMQE I
CHAMBER OPESATING
3AM3E
The primary chamber operates
in a starved-air
condition. Adding more air
allows more combustion and
therefore increases the
temperature (up to the point
of maximum temperature at
the stoichiometric air
level).
The secondary chamber
operates in an excess-air
condition. Adding more
excess air (which is cold)
dilutes and cools the gases
and decreases the tempera-
ture.
sxcsss /us
D»r*OL of
tt A FUNCMoi or excess
Ref. 3-3
Thus:
• The amount of air supplied to the primary chamber controls the
combustion rate of the waste and the temperature of this chamber; and
• The amount of air supplied to the secondary chamber controls the
temperature of this chamber and the combustion rate of the combustion
gases from the primary chamber.
The control system for a controlled-air incinerator is based upon controlling
the temperatures in each chamber by controlling the amount of air to each
chamber. Control systems will be discussed in more detail during Session 5.
3-10
-------
COMPONENTS OF A CONTROLLED-AIR INCINERATOR
3-9
MAJOR COMPONENTS OF 1 CCNTBOUSD-AlB INCINERATOR
This slide presents a schematic
of a controlled-air incinerator.
Identify and discuss the major
components:
1. Primary Chamber. The
chamber where the waste is fed and
combustion begins. The primary
chamber operates with a "starved-
air" atmosphere.
2. Primary Chamber -
Combustion Air Blower. Forced air
blower for providing underfire
combustion air to the primary
chamber.
3. Primary (Ignition)
Burner. Fuel burner for preheating
combustion chamber, igniting waste,
and maintaining temperature in the
primary chamber.
4. Charge Door. Door through which waste is loaded.
5. Ash Removal Door. Door through which ash is removed.
6. Secondary Combustion Chamber. Chamber where combustion of volatile
gases is completed. The secondary chamber operates with an excess-air
atmosphere.
7. Secondary Combustion Air Blower. Forced air blower for providing
combustion air to the secondary chamber.
8. Secondary Combustion Chamber Air Port. Port through which
combustion air enters chamber and causes mixing.
9. Secondary Combustion Chamber Burner. Auxiliary fuel burner for
maintaining high temperature in secondary chamber.
10. Cleanout/Inspection Doors. Doors in the secondary and primary
chambers which can be opened when the incinerator is shut down to remove ash
and inspect the refractory.
11. Primary Chamber Water Spray. Some manufacturers include a spray
system'to inject a fine water spray (mist) into the primary chamber to assist
in temperature control.
12. Primary Chamber Underfire Steam Injection. Some manufacturers
include systems for injecting steam into the ash bed to reduce clinker
formation and promote good ash burnout.
13. Stack. Natural draft stack for venting combustion gases to the
atmosphere. Because gases are hot, they rise up the stack causing a "draft"
(pulling air) through the system.
14. Thermocouples. Two thermocouples located at the exit to each
chamber to measure the temperature of the combustion gases.
15. View Ports. Sealed glass view ports for observing the combustion
chamber during operation.
16. Control Panel. Instrument panel where the controls and the
instruments for controlling and monitoring the operation are located.
3-11
-------
• The incinerator depicted in this figure has a hopper/ram assembly for
automatically feeding the waste to the incinerator but no mechanical
device for continuously removing the ash from the system. Waste feed
charging systems and ash removal systems will be discussed later
during this session.
Controlled-air units come in all
sizes and shapes. This is a photo- Picture
graph of a controlled-air unit. Note 3-3
the
• Primary chamber and burner
• Underfire air ports in primary
chamber
• Secondary chamber with burner
coming in from left end
• Combustion air blower; top left
• Stack
• Hopper feed system
This is a schematic of another
(smaller) controlled-air unit. It Picture
has a small vertical primary chamber 3-4
and a small horizontal secondary
chamber. This drawing does not show
any automatic waste feed system
(charge door is on the left). How-
ever, the manufacturer of this unit
does sell mechanical hopper/ram feed
systems sized to go with this unit.
Note: Ref. 3-9
• Primary burner (left front)
• Secondary burner (right upper)
• Combustion air blower and
distribution plenum (mounted
on front of secondary
chamber); large vertical tube
on center is air line for
underfire air in primary
• "Flame port" between chambers
• Control system
This is a large control!ed-air
unit. Note: Picture
3-5
• Primary chamber
• Underfire air ports
• Secondary chamber
• Secondary burner assembly
and blower
• Mechanical feed system
3-12
-------
This is a picture of a batch-
type control!ed-air unit. Note:
• Rectangular "shape of
primary/secondary chamber
• Secondary sits above
primary—separated
internally
• charging door
ROTARY KILN
The use of a rotary kiln for
hospital wastes is not as common as
the use of a typical controlled-air
unit; less than one dozen in use
(frequently used for hazardous
wastes). A rotary kiln also uses
the concept of two-stage combustion
and has two combustion chambers.
The primary chamber is a horizontal
cylindrical chamber which is
slightly inclined and rotates, hence
the name "rotary kiln." The
rotation of the kiln tumbles the
waste resulting in turbulence. The
secondary chamber is usually
cylindrical in shape—much like the
secondary chambers described for
control!ed-air incinerators—or is
box-like.
ROTARY KILN—KEY COMPONENTS
Describe the principle of
operation and the key components of
a rotary kiln.
A rotary kiln is designed to
operate continuously. The
incinerator must include a system
for continuous or semicontinuous
waste feed to the kiln and
continuous ash removal. The
principle of operation of a kiln is
summarized as follows:
• The rotating kiln is
inclined. Waste is fed into
the higher end of the kiln
by the mechanical feed
system.
Picture
3-6
Ref. 3-16
Sum 3-10
mm tims
• CoNiusrtoit OCCURS m MULTIPLE CHJKIIPIS
• a*INUT CH«»ie« IS ROTATING OTLINOEK
--•tooucts rumuLENCE ;x «»srt JED
JLIOI 5-U
flOTAHY KILN WITH AUGER FEED'
Ref. 3-4
3-13
-------
• Inside the kiln, moisture and volatiles are vaporized from the waste,
and the waste is ignited. The volatile gases pass into the secondary
chamber.
• Air and heat"are added in the secondary chamber to promote complete
combustion.
• As the kiln rotates, the solids are tumbled within the kiln and slowly
move down the incline toward the discharge end. Tumbling of the waste
within the kiln provides exposure of the waste to the air. Combustion
of the solids occurs within the kiln, and the ash is discharged into
the ash removal system.
• The residence time of the solids within the kiln can be controlled by
the kiln's speed of rotation (revolutions per minute [rpm]). The
faster the kiln rotates, the faster the solids will move through the
kiln.
The key parts of a rotary kiln are:
Charging System. Mechanical waste feed charging system for continuously
feeding waste to the kiln.
Kiln. The rotating kiln is the primary combustion chamber. The waste is
fed into this kiln and ignited. The kiln traditionally operates with an
excess-air atmosphere; however, some manufacturers are now designing kilns to
operate in a starved air condition. This requires the use of special kiln
seals and air injection schemes.
Kiln Drive. The kiln is rotated by a drive motor and gear system.
Primary Burner. The primary burner ignites the waste and provides
additional heat input to the primary chamber, as necessary.
Primary Combustion Air Blower. Provides combustion air for the primary
chamber.
Kiln Seals.. Sealing rings to minimize air in-leakage between the
rotating kiln and the kiln end plates.
Secondary Chamber. Chamber where final combustion of gases occurs.
Secondary Burner. Auxiliary fuel burner to maintain temperature of the
secondary combustion chamber.
Secondary Combustion Air Blower. Provides combustion air for the
secondary chamber.
Ash Container. Container for collecting ash exiting the lower end of the
kiln.
Stack. Vent for discharge of combustion gases to the atmosphere.
3-14
-------
MODE OF INCINERATOR OPERATION
• We have talked about the
basic designs of the
incinerator
• The design of the
incinerator and associated
equipment
— such as waste feed
charging and ash removal Su" 3"12
systems—must be
consistent with how the
incinerator will be
operated. The opposite • imi»im»T mm
also is true-how you . ^.^OUTY
operate your incinerator
must be consistent with
the design features.
• For the purposes of
discussion, we can define
three basic modes of
incinerator operation.
1. Single batch;
2. Intermittent duty; and
3. Continuous duty.
Single Batch Operation. Single batch operation means the incinerator is
loaded with a batch of waste, sealed, and turned on. After combustion is
completed, the incinerator is allowed to cool and the ash is removed.
Usually, ash is not removed until the next day. Essentially a 24-h cycle for
a batch.
Intermittent Duty. Intermittent duty means that the incinerator is
intermittently loaded with batches of waste, one after another, over a period
of time, usually one to two work shifts. The batches might be fed at routine
intervals—such as every 5 minutes for 8 hours or might be fed at uneven
intervals, whenever waste is available. In any event, the incinerator must be
shut down to remove ash from the system; thus, its operation is intermittent.
Continuous Duty. Continuous duty means the incinerator can be
continuously operated 24 hours per day. The system 1s designed so that ash is
removed while the Incinerator 1s 1n operation and the incinerator does not
have to be shut down. The waste feed charging system and ash removal system
are very important parts of this incineration system.
3-15
-------
'.-.at 3-13
HASTE FEED IQADIHG/CHAKSINC SYSTD1S
CONSISTENT KITH INCIUCRATO* CIMCITT
COISISTCNT KITH OMMMNG "OOC
MtMMI. VS KeCH/KIOU. VS iUTOMTEO
HASTE FEED CHARGING SYSTEM
There are many different ways
to "feed" the Incinerator.
, • The incinerator should be
fitted with a waste feed
charging system that is:
~ Consistent with its mode
of operation, and
-- Consistent with its
capacity.
• Manual and mechanical waste
feed systems will be
discussed.
Manual Feed. This means you
load the waste directly into the
incinerator. This approach is
applicable only for single batch
units or smaller intermittent feed
units. A safety hazard exists when
waste is fed manually into an
operating incinerator.
Mechanical Feed. When mechanical feed is employed, some type of
mechanical device is used to charge the waste to the incinerator. The
mechanical device can be manually activated or fully automated.
Mechanical charging systems have several advantages over manual handling
and charging:
• They provide added safety to the operating personnel by preventing
heat, flames, and combustion products from escaping the incinerator
during charging.
• They limit ambient air infiltration when charging a controlled-air
incinerator, thus, there is little impact on the combustion rate.
• They enable incinerators to be automatically charged with smaller
batches of waste at regulated time intervals; this improves operation
and combustion efficiency.
This slide shows the manual feed system.
Picture
3-7
3-16
-------
HOPPER RAM FEED SYSTEM
This slide shows a hopper/ram
feed system. It is the most common
..-_, TO-J
mechanical feed system. It is
frequently referred to as simply a
ram "feeder." In a mechanical
hopper/ram feed system:
• Waste is manually placed
into a charging hopper, and
the hopper cover is
closed.
• A fire door isolating the
hopper from the incinerator
opens.
• The ram moves forward to
push the waste into the
incinerator.
• The ram reverses to a
location behind the fire
door.
• After the fire door closes, a water spray cools the ram, and the ram
retracts to the starting position.
• The system is ready to accept another charge.
HOPPER RAM CHARGE SEQUENCE
*Ut ASSEXILT
Ref. 3-5
This slide depicts the charging
sequence. The entire hopper/ram
charging sequence normally is timed
and controlled by an automatic
sequence. The sequence can be
activated by the operator (push
start button) or for larger, fully
automated incinerators may be
activated at preset intervals by an
automatic timer.
iuoi 3-15
HOPPER RAM CHARGING SEQUENCE '
Ref. 3-6
3-17
-------
The simplest hopper ram Picture
assembly requires the operator to 3-8
manually load the waste into the
hopper. This photograph shows
manual loading/automatic charging.
However, some systems are Picture
designed to make loading the hopper 3~9
easier. An example of a way to make
hopper loading easier is a system
where the hopper is located low
enough so that all the operator has
to do is tilt a cart containing the
waste so that the waste falls into
the hopper. One fully automated
system uses a "cart dumper" which
automatically picks up a cart full
of waste and dumps the waste into
the hopper.
3-18
-------
ASH REMOVAL SYSTEMS
The ash remaining from the
combustion process must be removed
from the Incinerator and disposed of
in an acceptable manner.
Picture
3-10
SYSTEM CRITERIA
The ash removal system must be
consistent with:
• Operating mode; for batch
operation batch removal is
acceptable; continuous duty
incinerator must have
continuous ash removal
• Capacity
The ash is removed either
manually or mechanically.
• Manual removal 1s typical
for smaller units.
• Manual or mechanical removal
1s practiced for medium-
sized, intermittent-duty
Incinerators.
• Mechanical semlcontinuous
removal of ash is necessary
for continuous-duty
incinerators.
SLIDI 3-16
ASH DISCHARGE ADD REMOVAL SYSTEMS
• ConisrnT KITH. QI>CMTIM Mat
• COMSISTUT WITH CAMCITT
• HIM*!. VS NIOUIICAL
3-19
-------
Manual Ash Removal. Manual ash
removal means that you remove the
ash from the incinerator using a
rake or shovel.
• Manual ash removal is used
for most multiple-chamber
incinerators.
Picture
3-11
Snot 3-17
SEDWIICAL ASH REHOVM.
Tunfu if ISH ro END ar
COLLECTION conn IKE*
TftUSfC* F*(M COLLECT I OH HUNT
MECHANICAL ASH REMOVAL
Continuous operation" of an
incinerator requires some type of
mechanical system for removing the
ash while the incinerator is
operating. The mechanical system
includes three major components:
1. A means of moving the ash
to the end of the incinerator hearth
• Usually an ash transfer ram
or series of transfer rams;
2. A collection device or
container for the ash as it is
discharged from the hearth
• Gate and dump cart
• Water sump
3. A transfer system to move the ash from the collection point.
• Rake or conveyor
For controlled-air incinerators using mechanical ash removal, the ram
used for waste charging often is used for pushing the ash to the discharge end
of the hearth. As each new waste charge is pushed into the incinerator, it
pushes the waste bed on the hearth forward towards the discharge end. Each
repetitive charge continues to push a portion of the waste bed towards the
discharge end where it falls into a drop chute or water quench pit.
3-20
-------
Sum 3-13
INCINERATOR WITH STAGED HEARTH AND
AUTOMATIC ASH REMOVAL r
Ref. 3-7
STEPPED HEARTHS
This slide depicts an
incinerator that has' stepped hearths
and several individual ash transfer
rams. This system is often used in
larger incinerators. Each hearth
has its own ash ram and the waste is
pushed from one hearth to the other
by activating each ram in series,
starting at the discharge end of the
hearth. In other words:
• The ash on the last hearth
(3) is discharged by ram
No. 3.
• Ram No: 2 activates and
pushes the waste on hearth
No. 2 to hearth No. 3.
• Ash ram. No. 1 activates and
pushes the waste on hearth
No. 1 to hearth No. 2.
• Finally, a new charge is added to hearth No. 1.
A major advantage to this type of system is that when the waste is pushed
from one hearth to the next, the waste bed is mildly disturbed and
redistributed which provides some degree of "mixing" of the waste and promotes
more complete combustion. Another advantage is that the underfire air to each
hearth usually can be controlled separately, which allows for greater
combustion control.
After the ash drops from the hearth, some means of collecting and
transporting the ash is required.
• One type of collection system uses an ash bin sealed d-irectly to the
discharge chute or positioned within an air-sealed chamber below the
hearth. A door or gate which seals the chute is opened at regular
intervals to allow the ash to drop into the collection bin. When the
bin is filled, the seal-gate is closed and the bin is removed and
replaced with an empty bin.
3-21
-------
In the second method, the
ash is discharged into a
water pit. The ash
discharge chute is extended
into the water pit so that
an air seal is maintained. R - , 17
The water bath quenches the er< J"i/
ash as the ash is col-
lected. A mechanical
device, either a rake or
drag conveyor system, is
used to intermittently or
continuously remove the ash
from the quench pit. The Picture
excess water is allowed to 3_jj
drain from the ash as it is
removed from the pit, and
the wetted ash is discharged
into a collection container.
3-22
-------
COMBUSTION GAS HANDLING
SYSTEM
All Incinerators must have a
system for moving combustion air and
combustion gases through the
incinerator system and for
controlling the air flow.
• Three basic types of systems
are typically used for SUM5-19
hOSpital WaSte OMISTiai 6AS HANDLING SYSTEMS
incinerators.
• These are: • *»WUL O««T
— Natural draft; . lmmimT
— Induced draft; and
- Balanced draft (a ' *"— °*"T
combination of induced
draft and forced draft)
• "Draff is the difference
between the pressure within
the incinerator and the
pressure in the
atmosphere. When the
pressure inside the
incinerator is lower than
the outside air pressure
(i.e., negative pressure),
air tends to flow into the
incinerator.
• Incinerators are equipped with stacks to produce the "draft" necessary
to move combustion air into the incinerator and to discharge the
combustion gases'to the atmosphere.
Natural draft. The height of the stack and the difference in temperature
between the combustion gases and the outside air creates a natural draft.
Because the incinerator is at a lower pressure than the outside air,
combustion air is pulled into the incinerator. Your fireplace operates on the
principle of natural draft.
Induced draft. Incinerators that have heat recovery boilers or air
pollution control (ARC) systems usually use an induced draft system. When a
boiler or ARC system is added to the incinerator, the resistance to airflow is
increased (that 1s, airflow is "blocked") and natural draft 1s no longer
sufficient to move air through the system. A fan is added at the end of the
system to "induce" a draft, or pull the gases through the system.
Balanced draft. Many incinerators use forced draft fans or "combustion
air blowers" to push the combustion air into the incinerator. In a balanced
draft system, a forced draft fan is used to push (or blow) combustion air into
the incinerator and an induced draft fan (or the natural draft stack) is used
to pull the combustion gas through the incinerator and exit from the stack.
3-23
-------
The draft is balanced so that the incinerator is maintained at a slightly
negative pressure. This negative pressure prevents emissions from leaking
from the combustion chamber.
Mechanisms for controlling incinerator draft will be discussed in
Session 5—Control Systems.
BURNERS
The burners on a hospital waste
incinerator provide the heat needed
to sustain sustain combustion of the
waste charged. The burners may be
either oil-fired or gas-fired
(natural gas or propane) and are
designed to provide a rated heat
input expressed in BTU/h. The heat
input rate for the burners on your
incinerator will depend on:
• The type of incinerator at
your facility;
• The number of burners, and;
• The heating value of the
waste burned.
SLIDE 3-20
MJOR OmHEHTS OF BURNER SYSTEM
• FfluctD im ILO»CII(SJ
• ni£L rrm»
• 'ILOT >»o Mm sunnEft
• H.AHE SlfE 3UAHD SrSTE.1
Most incinerators have a single burner in the secondary chamber that
burns the combustion gases from the primary chambers. However, the primary
chamber may have more than one burner, especially if the incinerator has been
designed to burn pathological waste only.
The components of a burner system include:
• A forced-air blower;
• A fuel train;
• Pilot and main burners; and
• Most importantly a flame safeguard system.
FORCED AIR BLOWER
The forced-air blower provides the combustion air needed to burn the oil
or gas fuel and, if oil is used, the atomizing air. A single forced-air
blower in conjunction with regulation valves may be used to supply air to the
different burners or each burner may have a separate air blower. When the
burner is first turned on, the blower comes on and purges the burner of any
volatile gas or oil residues that may have built up since the last burn. This
is a safety feature.
3-24
-------
FUEL TRAIN
The fuel train is the series of components that controls the flow of fuel
to the burner. The fuel train set up for gas and oil burners is basically the
same. Each fuel train has a pressure gauge, a manual shut-off valve, and a
solenoid shut-off valve. The only difference between the gas and oil fuel
trains is the device used to control fuel flow; the oil fuel train utilizes a
needle flow valve while the gas fuel train utilizes a gas orifice union. The
manual shut-off valves must be open before the burners are turned on. The
solenoid valves are safety valves which close off the fuel supply if the
burners do not light or if the air supply for combustion is lost.
PILOT AND MAIN BURNERS
Each burner is equipped with both a pilot and main burner. The pilot is
lit first and once a flame is detected the fuel supply to the main burner is
opened allowing the pilot to light the main burner. Proper operation of the
burners is best achieved by looking at the burner flame pattern through the
viewports in the incinerator wall or in the burner itself. Some burners are
equipped with an observation port to view the main flame and another to view
the pilot flame. Gas-fired burners have a blue flame while oil-fired burners
have a luminous yellow flame. The flame pattern will likely vary with the
type of burner. However, the length of the flame should be such that the
flame touches the waste but does not impinge directly on the refractory floor
or wall.
FLAME SAFEGUARD
The device which controls the burner ignition process is called the flame
safeguard. When the burner is first started, the burner blower starts and
when it reaches full speed, a purge timer starts. When the purge timer times
out, the flame safeguard energizes the pilot relay that opens the pilot fuel
supply and ignitor. When the pilot lights, a flame detector (either an
ultraviolet scanner [gas or oil] or flame rod circuit [gas only]) detects the
pilot flame and causes the main flame relay to activate the fuel supply to the
main burner. The pilot then ignites the main burner. The flame detector
continues to operate and shuts the burner down if the main burner fails.
Additionally, if the air supply is lost, both pilot and flame relays shut off
the fuel supply. The pilot usually is ignited for no more than 15 seconds
(interrupted pilot). If the main burner does not ignite during the pilot
ignition period, the flame safeguard system shuts the entire system down by
closing the solenoid shut-off valve and turning off the burner blower.
3-25
-------
WASTE HEAT BOILERS
:..!£ 3-21
»CIHt«»rO« >ITH »STC NE»T 10ILE* «»0 SrUSS 171CK
The heat generated during
Incineration can be recovered and
used to generate hot water or steam
in a waste heat boiler. This slide
is a schematic of an incinerator
with a waste heat boiler added.
Addition of a waste heat boiler to
an incinerator has several impacts
on the incineration system:
• One impact of adding a
boiler to the system is that
an induced draft fan must be
added to the system in order
to move air through the
system.
• An emergency bypass stack is
another feature that
normally would be added to
an incinerator when a waste Ref. 3-2
heat boiler (or air
pollution control system) is
added to the incinerator
system.
• Since the boiler causes a resistance (blockage to airflow) in the
system if the induced draft fan stops, pressure will build up in the
incinerator because the hot gases cannot escape quickly enough. The
bypass stack is added to allow a route for the hot gases to escape
should the fan fail. In other words, it allows the incinerator to go
back to a natural draft system.
• The bypass stack also is used in cases where the boiler must be
bypassed for some reason (for example, loss of water flow to the
boiler causing heat buildup).
• The bypass stack usually contains a damper valve in the stack to -
control direction of the gas flow or a cap on top of the stack to
prevent air from being pulled into the system when the fan is
operating. When the "bypass" must be activated, the damper, or cap,
is opened. The bypass is usually activated automatically by some type
of sensor; for example, if the fan speed falls below a preset level,
the bypass opens.
Worksheet. Appendix C includes a worksheet which is to be used by the
operators to summarize information on their incinerator systems. The
objective is for the operators to be able to determine the types of
incinerator systems they have. The worksheet is for their use and is not to
be turned in to the instructor. After the worksheet is completed, it should
be discussed to determined if there is any confusion or problems.
3-26
-------
REFERENCES FOR SESSION 3
1. A1r Pollution Control District of Los Angeles County. Air Pollution
Engineering Manual, 2nd Edition AP-40. (NTIS PB 225132). U. S. EPA.
May 1973.
2. Ecolaire Combustion Products, Inc., Technical Article: Principles of
Controlled Air Incineration. Undated.
3. McRee, R. Operation and Maintenance of Controlled Air Incinerators.
Ecolaire Environmental Control Products. Undated.
4. Consertherm® Systems Technical Data Form for Rotary Kiln. Industronics,
Inc. Undated.
5. Doucet, I. Waste Handling Systems and-Equipment. Fire Protection
Handbook, 16th Edition. National Fire Protection Association.
6. Consumat Systems, Inc. Technical Data Form for Waste Feed System.
Undated.
7. U. S. Environmental Protection Agency. Source Category Survey:
Industrial Incinerators. EPA 450/3-80-013 (NTIS PB 80-193303). May
1980.
8. Ashworth R. Batch Incinerators—Count Them In; Technical Paper Prepared
for the National Symposium of Infectious Waste. Washington, D.C.
May 1988.
9. Ecolaire Combustion Products, Inc., Technical Data Sheet for E Series
Incinerator. Undated.
10. Doucet, L. C. Controlled Air Incineration: Design, Procurement and
Operational Considerations. Prepared for the American Society of
Hospital Engineering, Technical Document No. 55872. January. 1986.
11. U. S. Environmental Protection Agency. Hospital Waste Combustion
Study: Data Gathering Phase. EPA 450/3-88-017. December 1988.
12. Brunner, C. R. Incineration Systems. Van Nostrand Relnhold. 1984.
13. Personal conversation with Larry Doucet, Doucet & Malnka Consulting
Engineers. November 28, 1988.
14. Cleaver Brooks*. Operation, Maintenance, and Parts Manual for the
Pyrolytic Incinerator. Publication No. CBL-6826. September 1988.
15. Letter from K. Wright, John Zink Company, to J. Eddinger, EPA.
January 25, 1989.
16. Simonds Manufacturing Corporation. Product Brochure, Model 2151B
Incinerator. Undated.
3-27
-------
17. Ecolaire Combustion Products, Inc. Product Brochure for Model Types TO
and TES.
3-28
-------
LESSON PLAN
COURSE: TRAINING COURSE FOR OPERATORS OF HOSPITAL
WASTE INCINERATORS
SESSION TITLE: AIR POLLUTION CONTROL EQUIPMENT DESIGN AND
FUNCTIONS
SESSION NO: 4
SESSION TIME: 45 MINUTES
GOAL
To familiarize students with the components and the functions of the
various types of air pollution control systems that are found on hospital
incinerators.
OBJECTIVES
At the end of this session, each student should be able to:
1. Identify the type of air pollution control system used on his/her
incinerator;
2. Name the air pollutants that their air pollution control system is
intended to control;
3. Understand the basic principles that account for pollutant collection
and removal;
4. Identify the major components of his/her air pollution control
system; and
5. List the functions of each major component.
SUPPORT MATERIALS AND EQUIPMENT:
Slide set for Session 4; slide projector
SPECIAL INSTRUCTIONS:
Depending on the instructional objectives, it may be appropriate to
discuss only those APC devices used on the incinerators of the operators
taking the course.
HANDOUTS;
None
4-1
-------
Slide No. Title
T Title
1 Control Strategies for Air Pollutants
2 Air Pollution Control Systems for Hospital Waste Incinerators
3 Spray Towers
4 Countercurrent-Flow Spray Tower
5 Spray Tower System
Pieture-1 Spray Tower
Picture-2 Spray Tower (Interior)
6 Venturi Scrubbers
7 Spray Venturi with Rectangular Throat
8 Cyclonic Mist Eliminator
9 Venturi Scrubber System
10 Packed Bed Scrubbers
11 Countercurrent-Flow Packed-Bed Scrubber
12 Venturi Scrubber/Packed Bed
13 Fabric Filters
14 Pulse Jet Baghouse
15 Dry Scrubbers
16A Components of a Dry Injection Absorption System
16B Components of a Dry Injection Absorption System
17 Spray Dryer Absorber Vessel
18 Components of a Spray Dryer Absorber System
19 Electrostatic Precipitators
20 Components of an ESP
21 Gas Flow Through a Plate Precipitator
4-2
-------
INTRODUCTION
The objective of this session
is to familiarize you with the
various types of ARCS currently used
or expected to be extensively us.ed
in the future on hospital waste
incinerators. The components of the
systems and how they work are
discussed.
SESSION 1,
AIR POLLUTION CONTROL EQUlPHtNT
DESIGN AND FUNCTIONS
CONTROL STRATEGIES
This slide presents a table
summarizing control strategies for
air pollutants from hospital waste
incinerators. Note that three basic
strategies are presented:
• Control of feed material.
For example, not charging
PVC plastics to the
incinerator will control HC1
emissions . . . reducing the
chlorine in reduces the
chlorine out. •'"'
• Combustion control.
Controlling the combustion
process—through proper
design and operation-
minimizes emissions of
particular matter, organics,
carbon monoxide; some
control of metals (e.g.,
operating with insufficient
air will produce black smoke
[soot]).
Sum o-i
CONTROL STRATEGIES FOR AIR POLLUTANTS
MIC
ironlcl
Controlling
CoMltlon
control
i oo Hut (on
control
Sorojr i
foric rntip
on (unction3
Or, i
Vf
I'MtM control: rm OMIOAM for moit tfflcuncy.
oy ntojMfffctoney oartteuuu control.
4-3
-------
• Add-on pollution control systems. Pollution control systems can be
added on after the incinerator to reduce emissions. The pollution
control devices we will discuss include:
— Wet scrubbers
- spray towers
- Venturis
- packed beds
-- Fabric filters
— Dry scrubbers
- dry injection
- spray dryers
• The pollutants controlled by the air pollution control devices include
particulate matter and the acid gases (HC1 and S02).
• Because of the variations in design some units are more effective for
particulate matter while others are primarily intended for acid gas
control.
• Some of the control devices also achieve limited control of organic
compounds and metals
Air Pollution Control Systems for
MWI - -•« '-2
AIR POILUTIOH CONTROL SY5TOS FOR
• We will discuss the key **™, "** '"""^"^
components of each of these
types of ARCS and will ' ?l™'™m
briefly describe how they ~ vwni« SOHIHMS
. — PACXCD-ICD SCRUUCRS
• FAIRIC'MLTERS
First we will discuss wet • DRY
scrubbers, including:
• Spray towers
• Venturi scrubbers
• Packed beds
-- OUT INJCCTIOH
-- SfHAr OUTERS
ELECTROSTATIC P«CIMTATORS
4-4
-------
SPRAY TOWERS
POLLUTANTS CONTROLLED
Spray towers are low-energy
scrubbers used to control
large-particle emissions.
itiot 1-3
SPRAY TOWER
ION
LIMITED MUTICJUITE CONTROL
LlNITU HO. 4C10 GAS CONTKOL
• Spray towers are only
effective for relatively
large particles and,
therefore, are practically
limited in application to
controlling large particles
that may be emitted by
multiple chamber incin-
erators.
• Controlled-air incinerators
have inherently lower
particulate mass emission
rates and fine particle size
distributions; because spray
towers are low efficiency
scrubbers, they do not
effectively provide
additional control.
• Spray towers will result in some scrubbing of the acid gases.
DESCRIPTION OF SPRAY TOWER SCRUBBER
This slide shows a schematic of .-UDI..-*
a countercurrent spray tower.
Explain:
• Its application and the
pollutants controlled
- The major components
• How it works
Spray towers are relatively
simple scrubbers consisting of:
• A hollow cylindrical steel
vessel; and
• Spray nozzles for injecting
the scrubbing liquid.
Caon exnaust Gas
COUNTERCURRENT-R.OW SPRAY TOWEH'
Ref. 4-1
4-5
-------
HOW DOES A SPRAY TOWER SCRUBBER WORK?
Spray towers are designed to use many spray nozzles to create i large
amount of fine liquid droplets for impacting and capturing particulate matter.
• The dirty exhaust gas enters the bottom of the scrubber and travels
upward.
• Water droplets are sprayed downward by a series of spray nozzles
designed to cover the entire cross-sectional area of the scrubber.
Particulate matter is impacted (hit) by the droplets. The water with
the particulate matter drains out the bottom.
• Some collection of gases occurs. Gas collection occurs by
absorption. The gases are absorbed (gas molecules are mixed with
water molecules) by the water.
• For both particulate and gaseous control the water must contact the
particulate or gas molecules. Since contact is limited, control is
limited.
• The cleaned exhaust gas exits out the top of the scrubber.
SPRAY TOWER SYSTEM
The spray tower system is
relatively simple. It includes the
tower itself and an ID fan. The
water is sprayed into the tower and
typically drains out to a sewer
discharge.
3uo( t-5
This photograph shows a spray
tower on a multiple chamber, excess-
air pathological incinerator. Note:
Spray Tower System
Picture
4-1
The water outlet to the
floor drain
The ID fan
This photograph shows the
inside of the same spray tower.
Picture
4-2
4-6
-------
VENTURI SCRUBBERS
POLLUTANTS CONTROLLED
Venturi scrubbers are high-
energy scrubbers used for the
control of fine particulate
emissions. Hydrochloric acid gas,
if present, also is controlled to
some degree by a venturi scrubber.
Sum 1-6
'/BITURI SCRUBBER
HIGH ENERGY
•IIOH EFFICIENCY P««riCUUrE C3Nr»OL
LIMITED ltd ACID 5« CON mot.
DESCRIPTION OF VENTURI SCRUBBER
This slide is a schematic of a
venturi scrubber. Describe the
pollutants controlled, key
components, and the principle of
operation.
• A venturi scrubber consists
of:
— A constriction in the
ductwork referred to as
a venturi throat;
— Spray nozzles at the
entrance to the venturi
throat that supply the
scrubbing liquid;
— A device for removing
entrained water
droplets, typically a
cyclonic mist
eliminator; and
Sum «-7
SM«T »t»njf»i KITH IECTMGUU* THTOITI
Ref. 4-1
— An Induced draft fan for moving the flue gas through the scrubber.
Some venturi scrubbers have an adjustable throat that can be used to
vary the size of the opening.
4-7
-------
HOW DOES A VENTURI SCRUBBER WORK?
Venturi scrubbers are designed to maximize turbulence and mixing of water
droplets and dirty flue gas to improve pollutant capture efficiency.
• The venturi throat has the smallest cross-sectional area in the
ductwork and consequently the gas has the highest speed at this
location.
• As the flue gases speed up at the entrance to the venturi section,
water is injected into the flue gas stream through spray nozzles or
through the force of the high speed gases passing over water running
down on the sides of the venturi.
• The high gas speeds through the constricting throat create turbulence
which breaks the water droplets into smaller fine droplets and causes
mixing.
• Collection efficiency increases with higher gas speeds and turbulence;
however, higher gas speeds require more energy. The amount of energy
is measured as the change in pressure across the venturi or.the
pressure drop (A?) in inches.of water column. For scrubbers with
adjustable throats, decreasing the size of the throat opening
increases pressure drop and collection efficiency.
• Higher pressure drops require more fan energy and result in higher
operating costs, but also higher collection efficiency.
• Some acid gases are absorbed by the water in the venturi. However, a
venturi is not a highly efficient acid gas scrubber.
MIST ELIMINATOR
SLIDI t-3
The water droplets,
containing the captured
particulate matter must be
separated from the clean gas
stream. A cyclonic mist
eliminator which uses
centrifugal force to
separate the water droplets
often is used. This slide
shows a cyclonic mist
eliminator.
The dirty scrubber water is
sent to wastewater
treatment.
CTCLONIC iisr ELINIHATOH-
Ref. 4-1
4-8
-------
VENTURI SCRUBBER SYSTEM
1-9
vemjRISCBUB8S» SYSTEM WITH
HeORCUATED SCRUBBER UOUOH
Sometimes the scrubbing —
liquid is "once through" ~=
water. That is, the water
passes through the scrubber
once and is sent to the
sewer or treatment plant. *
Other times the scrubbing
liquid is recirculated.
When the liquid is
recirculated, particulate
matter and acid gases
concentrate (build up) in
the liquid. Some of the
dirty liquid must be
discharged and some fresh
liquid must be added to
prevent the liquid from
getting too dirty. The
discharged liquid is called "blowdown". The fresh liquid added is
called "makeup." When recycled scrubber liquid is used, an alkaline
liquid (rather than plain water) is often used to prevent the
scrubbing liquid from becoming acidic as it collects acid gases from
the combustion gases. The amount of alkaline "caustic" added is
controlled so that the scrubber liquid can be maintained in a
"neutral" condition, i.e., not acidic and not alkaline. A measure
called pH is used to determine if the liquid is acidic or alkaline.
We will discuss this more later. The main reason for controlling pH
is to prevent damage to the equipment and to meet restrictions on the
wastewater discharge.
PACKED-BED SCRUBBERS
POLLUTANTS CONTROLLED
Packed-bed scrubbers are
used primarily for acid gas
control.
While packed-bed scrubbers
remove some particulate
matter, they have a low
collection efficiency for
fine particulates; they are
also susceptible to plugging
under conditions of high
particulate concentration.
SUOi 4-10
PACKED TOMER
• UM uatsr
• Him cMtctuor »cto us co»r«ot
4-9
-------
DESCRIPTION OF PACKED-BED SCRUBBER
This slide is a schematic of a
packed-bed scrubber. Explain the
polluants controlled, key
components, and how it operates.
3UOE 4-11
OMMIST
Packed-bed scrubbers consist
of:
:HTY OH/MOT
Ref. 4-1
COUNTERCURRENT-FLOW
PACKED-BED SCRUBBER1
• A cylindrical shell to house
the scrubbing media
• Packing media and supporting
plates
— The packing media is
composed of 1- to 3-inch
(2.5-7.6 cm) diameter
plastic shapes that are
intended to maximize the
surface area.
• Liquid spray nozzles to distribute the scrubbing liquid
• Demister pads to remove liquid droplets from the clean flue gas
• An induced draft fan for moving the flue gas through the scrubber
HOW DOES A PACKED-BED SCRUBBER WORK?
The scrubbing liquid used is important.
• With water as the scrubbing liquid there is removal of soluble
gases. HC1 is highly soluble in water and is efficiently captured in
wet scrubbers. HC1 is of primary concern.
• Addition of alkaline materials is needed to achieve significant
reductions of acid gases, such as S02, which are less soluble in water
than is HC1.
• However, as already described for venturi scrubbers, alkaline
(caustic)^materials often are added to the water to neutralize the
acids collected in the scrubbing liquid. The liquid is neutralized:
— 'To reduce corrosion of equipment when the scrubbing liquid is
recycled, and
— To keep the pH (a measure of the water's acidity) of the water
discharge within acceptable ranges required by wastewater
treatment facilities.
• Example caustic materials used are:
— Lime (CaO)
— Sodium hydroxide (NaOH)
— Sodium carbonate (Na2C03)
Packed-bed scrubbers are designed to maximize the liquid/gas interface to
increase opportunities for absorption of the acid gases at low fan energy
costs. This is done by using the packing media to provide a large surface
area for the contact to occur.
4-10
-------
Scrubbing liquid is sprayed onto the packing media from the top.
The liquid passes downward due to gravity, wetting the surface of the
packing media.
The dirty flue gases enter the bottom of the scrubber and travel
countercurrent (opposite) to the flow of the liquid.
The wet surface of the packing media creates a large surface area of
liquid/gas interface for absorption.
The acid gases are absorbed and captured in the liquid.
The acid gases react with the alkaline materials in the scrubbing
liquid and are neutralized.
Particulate matter also is collected in the scrubbing liquid through
impaction. However, gas streams containing a lot of particulate
matter may cause plugging of the packing media.
The flue gases pass out the top of the scrubber unit through the
demister pads which remove any entrained droplets of liquid that may
contain absorbed acid gases and particulate matter. Demisting is very
important, since'any droplets passing out of the system will contain
the pollutants.
The dirty scrubbing liquid containing the collected particulate, acid
gas/sorbent reaction products, and the unreacted sorbent materials
passes out the bottom of the scrubber and is recycled or sent to
wastewater treatment.
VENTURI SCRUBBER, PACKED BED SYSTEM
This schematic shows a
combination venturi scrubber
(particulate control) packed bed
(acid gas control) system. Note the
recirculated scrubber liquor,
demister section (with clean water
spray for flushing) and the ID fan.
SLIDE t-12
—^i ^aaa >—• ,*•
scnuaeen WITH PACKED e&>
4-11
-------
FABRIC FILTERS
POLLUTANTS CONTROLLED
Fabric filter systems—often
referred to as "baghouses"—are
designed to remove solid participate
matter from the flue gas stream by
fi-ltering the flue gas through
fabric bags.
• Fabric filters are
especially effective at
removing fine particulate
matter.
SLID* »-l3
FABRIC FILTER
OTU CAIXU '
PtxrioiUTC coat-not
emcnvt FO« FIME M«TICULATE
ACID 5»S CMTMI.
— IP USED III CmuuNCTIOK KITH OUT SCRUBBER
Sum t-U
POLLUTANT COLLECTION PRINCIPLES
This slide shows a schematic of
a pulse jet baghouse. Explain the
pollutants controlled, the key
components and the principle of
operation.
• Particulate - the dirty flue
gases are passed through
fabric bags which filter out
the particulate matter
creating a "cake" (i.e., a
coating) of collected
particulate matter on the
bag that further increases
filtration. The principle
is very similar to that of a
household vacuum cleaner.
JCT lAGMQUSt
-Ref. 4-2
Acid gases - when used with dry scrubbers which we will discuss next,
the alkaline material injected by the scrubber is collected in the
filter bag along with the pollutants. As the acid gases pass through
the cake they react with the alkaline material, form solid salts, and
are captured.
4-12
-------
DESCRIPTION OF A PULSE-JET FABRIC FILTER
• Pulse jets are one of three fabric filter types classified by bag
cleaning technique. Pulse-jet fabric filters are used on hospital
waste incinerators.
• A pulse-jet fabric filter consists of:
— Dirty air inlet and a plate (diffuser) with holes in it that
uniformly distributes the flue gas
— A dirty air chamber or plenum which contains the fabric bags
~ A tube sheet, with holes for each bag, which supports the bags and
separates the dirty air plenum from the clean air plenum
— The tubular filter bags with supporting wire frame bag retainers
— The bag cups and venturi's to which the individual bags are
attached and which inject the pulse of cleaning air into the bags
-- The air compressor which supplies the compressed air for cleaning
the bags
-- The ash hopper which holds the collected particulate after it is
cleaned from the bag
— A valve system (e.g., rotary valve air lock) for discharging the
ash from the hopper and a system for collecting the discharged
ash.
HOW DOES A PULSE-JET FABRIC FILTER WORK?
The openings in the mesh weave of a fabric filter bag are relatively
large and can only capture large particles. Actual filtration of fine
particles is performed by the cake of filtered-out material that builds up on
the bag surface.
• The dirty flue gas enters through the air inlet at the bottom of the
unit and is distributed through the diffuser.
• The dust-laden gas flows upward through the dirty air plenum on the
outside of the cylindrical bags and is filtered through the bags with
the filtered-out dust cake forming on the outside of the bags.
• On a timed frequency or at a pre-determined pressure drop, the bags
are cleaned.
• The bags are cleaned by a blast of compressed air injected inside the
bag tube -at the top of the bag.
• The air blast creates a shock wave that travels down the bag,
fracturing the filter cake.
• The filter cake falls into the ash hopper at the bottom of the unit
and is then removed from the hopper by the discharge system.
Mention operating concern about temperature and moisture.
4-13
-------
DRY SCRUBBERS - GENERAL
POLLUTANTS CONTROLLED
Dry scrubbers remove acid
gases, primarily HC1 and S02.
POLLUTANT COLLECTION PRINCIPLES
• Dry scrubbers inject
alkaline sorbent materials
into the dirty flue gas.
The acid gases begin to
react with the alkaline
sorbents to produce solid
particulate salts that are
collected by a particulate
control device, usually a
fabric filter (see previous
-section), that follows the
dry scrubber. The unreacted
sorbent is also captured on
the fabric filter cake where
additional acid gas reacts
with the sorbent and is
captured.
Suot '-15
OUT SCRUBBERS
• ACID 5*S CONTROL
• III COIUUIICTI OK KITH PMTICULAU COP1T»OL
— f«l«IC MUM
— ELtCKOSTATIC P«tCIW»TOR
DRY INJECTION
DESCRIPTION OF DRY INJECTION
Dry injection systems
consist of:
— Dry sorbent storage tank
— Blower and pneumatic
line for transfer of the
sorbent
— Reactor vessel (venturi
contactor or retention
chamber)
— Particulate control
system (fabric filter or
ESP) for collection of
the dry sorbent
4-14
-------
SLIDE «-l6»
OUT IUCCTIOII «iso«*rta« SYSTEH
HOW DOES DRY INJECTION WORK?
This slide is a schematic of e
dry injection system: In dry
injection systems the sorbent
material is injected into the flue
gases as a dry powder. The acid
gases are absorbed by the alkaline
sorbent.
The dry injection system
uses finely divided alkaline
sorbent material, usually
calcium hydroxide or sodium
bicarbonate, with the
approximate consistency of
talcum powder.
There are several variations
on how and where the dry
sorbent is injected.
In this schematic, the
sorbent is injected directly
into the duct between the
boiler and particulate
control device. An
expansion/retention chamber
is included in the system
downstream of the injection
point; the expansion chamber
increases the residence time
of the sorbent/gas mixture
in the duct which provides
more time for absorption/
reaction to occur. The
expansion chamber may be
deleted from the system.
The unreacted sorbent and reaction products are carried by the flue
gas to the particulate control device where they are collected. The
particulate control devices used are fabric filters and ESPs. When a
fabric filter is used, acid gas removal may be further enhanced by
reaction with the sorbent collected in the filter cake.
4-15
-------
This schematic shows a slightly
different system. Here the dry
absorbent is injected directly into
a .contactor/reaction -vessel to
induce mixing and reaction.
Otherwise the system is the same.
JLIOC 4-l6l
_ ^ _±; rJih __]
ORY WJCCTION ABSORPTION SYSTEM
Suoe 4-17
SPRAY DRYERS
HOW DOES A SPRAY DRYER WORK?
• Spray dryers are designed to
spray an alkaline slurry of
sorbent material into the
hot flue gases where the
acid gases are absorbed into
the slurry droplets and
reacted with the alkaline
material to form solid
particle reaction
products.
• The atomizers produce small
droplets of slurry that are
•injected into the absorber
reaction vessel.
• The alkaline sorbents in the
slurry react with the acid
gases producing CaCl2 and
CaSO\ solid salts. •
• The hot flue gases dry the moisture from the slurry and the reacted
and unreacted sorbent either is entrained in the flue gas stream or
drops to the bottom of the reaction vessel.
• The entrained sorbent and reaction products are carried to the
particulate control where they are captured on the bags.
• Because the absorbent is added to the system wet, it is more efficient
than the dry injection system and requires less sorbent to be used.
However, the system is more complicated.
SPRAY DRYEH ABSORBER VESSEL
4-16
-------
COMPONENTS OF A SPRAY DRYER ABSORBER
• The primary components of a
spray dryer system are: SUOH-H
— Lime slaker, if pebble
lime is purchased
— Sorbent mixing tank
~ Sorbent feed tank
— Atomizer feed tank
— Rotary atomizers or air
atomizing nozzles
— Spray dryer absorber
reaction vessel
— Particulate control
system
• Spray dryer facilities •=>
usually purchase pebble lime
llaU; "Or USc. Catmniin at t S«»T o«rw nsomtn srsroi
• The pebble lime is converted
to calcium hydroxide
[Ca(OH)2] by the addition of
water in the slaker.
• The calcium hydroxide is mixed with water in the mixing tank to
produce a slurry containing 5 to 20 percent solids.
• The slurry is stored in the feed tank and is transferred to the
atomizer feed tank immediately prior to use.
ELECTROSTATIC PRECIPITATORS
POLLUTANTS CONTROLLED
Electrostatic precipitators :w-n
(ESP's) are used to remove
particulate matter from flue gas **""'"" "M"™*
streams. They have been used for
__ . , . . -, • Ponnoiure COITIHI.
over 50 years on many industrial
processes. For hospital ' u~tt mi
-------
• Once the particles or liquid aerosols that make up the particulate
matter are charged, they move towards an oppositely charged surface
because of electrostatic attraction (opposite charges attract each
other, the same charges repel each other).
• The collected particles are removed by rapping or washing the
collecting surface.
• This charging, collecting, and removal process is commonly referred to
as precipitation.
DESCRIPTION OF A SINGLE-STAGE, HOT-SIDE, PLATE ESP
• ESP's can be classified according to a number of design features.
These features include:
— The method of charging (single-stage or two-stage)
— The method of particle removal from collection surfaces (wet or
dry)
-- The temperature of operation (cold-side or hot side), and;
— The structural design and operation of the discharge electrodes
(tubular or plate).
• The ESP's likely to be used on medical waste incinerators are single-
stage, hot-side, plate ESP's and are discussed here.
• Most ESP's used to reduce particulate matter emissions from boilers
and other industrial processes are single-stage ESP's. These units
use very high voltage to charge particles. The particles, once
charged, move in a direction perpendicular to the gas flow and are
collected on the oppositely charged collection surface. Because
particle charging and collection occurs in the same stage, these ESP's
are called single stage ESP's.
• Collected particles are removed from the unit by rapping the
collection electrodes or by spraying water on the electrodes to wash
the particles away.
• ESP's are grouped according to the temperature of the flue gas
entering the unit. Therefore, the ESP's used on medical waste
Incinerators are likely to be hot-side units. These ESP's are larger
than cold-side ESP's because the higher gas. temperature makes the
volume of gas treated larger.
• ESP's use either flat plates or cylindrical tubes to collect
particulate matter. Most ESP's use plates as collection electrodes.
4-18
-------
MAJOR COMPONENTS OF A SINGLE-STAGE HOTSIDE ESP
This slide is a schematic of a
s-ingle-stage, hot-side plate ESP;
the major components are:
SLIOI 4-20
— Discharge electrodes
(wires) that hang
between the collection
plate electrodes and
that provide the
electrical energy
required to charge the
particles and liquid
aerosols in the dirty
gas
— Collection -electrodes
that are placed parallel
to each other and
collect the charged
particulate matter
-- High-voltage equipment including a step-up transformer, a
CWWMHTS or »» ESP >
Ref. 4-3
high-
voltage rectifier, and automatic circuitry that controls the
electric field between the discharge and collection electrodes.
Rappers that remove collected particulate matter that has
accumulated on the collection electrodes
A hopper that is used to store the collected particulate matter
temporarily prior to disposal
A hopper discharge device that removes the collected material from
the hopper
A shell structure that encloses the electrodes and supports the
precipitator components in a rigid frame to promote electrode
alignment and configuration
4-19
-------
HOW DOES AN ESP WORK?
SLIDI 4-21
G»S PLOT rxKOUSH » 'UTE f«CIf ITATim '
This slide depicts the gas flow
through a plate predpitator. In
this arrangement, dirty gas flows
into a chamber consisting of a
series of small diameter discharge
electrodes (wires) especially spaced
between rows of plates. Discharge
electrodes are approximately 0.05 to
0.15 inches in diameter. Collection
plates are usually between 20 and
40 feet high and spaced from 4 to
12 inches apart.
The following steps in sequence
describe how an ESP works:
A high-voltage, pulsating,
direct current is applied to
the discharge electrodes and
the collection electrodes
with the discharge electrode
being negatively charged and R6f. 4-3
the collection electrode
being grounded. The applied
voltage creates an electric
field and is increased until
it produces a Corona
discharge, which can be seen
as a luminous blue glow
around the discharge
electrode.
The dirty exhaust gas enters the ESP such that the gas flows between
the collection plate electrodes.
As the dirty gas comes into contact with the corona, the gas particles
become negatively charged.
The negatively charged particles migrate to the collection electrode
because they are repelled from the negatively charged discharge
electrodes (like charges) and attracted to the collection electrodes
(opposite charges).
When the charged particles reach the collection plate, the charge on
the particle is only partially discharged. The charge is slowly
leaked to the grounded collections electrode. A portion of the charge
is retained and allows the particle to adhere to the plate and
promotes cohesion of other particles to the collected particles on the
plate.
The collection plates are rapped periodically to remove the collected
particles. Plates are rapped when the accumulated dust layer is
4-20
-------
relatively thick (0.03 to 0.5 inches). This procedure allows large
sheets of dust to fall off the plates and helps eliminate dust
reentrainment.
• The dislodged dust falls into the hopper where it is removed with a
hopper discharge device such as a slide gate or drawer (manual dust
removal) or a trickle valve, rotary airlock valve, screw conveyor, or
pneumatic conveyor (automatic dust removal).
SUWARY
These describe the major types of pollution control systems likely to be
found on hospital waste incinerators. Other types of control systems,
especially, other types of wet scrubbers, also may be used. Examples of other
types of wet scrubbers are:
• Tray towers
• Ionizing wet scrubbers
• Hydrosonic scrubbers
• Collision scrubbers
4-21
-------
REFERENCES FOR SESSION 4
1. Joseph, J. and D. Beachler. APTI Course SI:412C, Wet Scrubber Plan
Review - Self Instructional Guidebook. EPA 450/2-82-020. U. S.
Environmental Protection Agency. March 1984.
2. U. S. Environmental Protection Agency. Control Techniques for Particulate
Emissions from Stationary Sources, Volumes 1 and 2.
EPA 450/3-8l-005a,b. (PB83-127498). U. S. Environmental Protection
Agency. September 1982.
3. U. S. Environmental Protection Agency. APTI Course SI:412B, Electrostatic
Precipitator Plan Review—Self Instructional Guidebook. EPA 450/2-82-019.
July 1983.
4. Beachler, 0. and M. Peterson. APTI Course SI:412A, Baghouse Plan Review -
Student Guidebook. EPA 450/2-82-005. U. S. Environmental Protection
Agency. April 1982.
5. Sedman, C. and T. Brna. Municipal Waste Combustion Study: Flue Gas
Cleaning Technology. EPA/530-SW-87-021d (NTIS PB 87-206108)
U. S. Environmental Protection Agency. June 1987.
6. Richards Engineering, Air Pollution Source Field Inspection Notebook;
Revision 2. Prepared for the U. S. Environmental Protection Agency, Air
Pollution Training Institute. June 1988.
7. U. S. Environmental Protection Agency. Operation and Maintenance Manual
for Electrostatic Precipitators. EPA 625/1-85/017. September 1985.
8. U. S. Environmental Protection Agency. Hospital Waste Combustion Study:
Data Gathering Phase. EPA 450/3-88-017. December 1988.
4-22
-------
LESSON PLAN
COURSE: HOSPITAL INCINERATOR OPERATOR TRAINING
COURSE
SESSION TITLE: MONITORING AND AUTOMATIC CONTROL SYSTEMS
SESSION NO: 5
SESSION TIME: 60 MINUTES
GOAL
To familiarize students with:
The difference between a parameter that is controlled and a parameter
that is simply monitored
The types of operating parameters that may be controlled or monitored
The basic types of automatic control systems used on incinerators
The types of monitors that may be included on their incinerator/air
pollution control systems
OBJECTIVES
At the end of this session, each student should be able to:
1. List the operating parameters that may be controlled and/or
monitored;
2. Distinguish between a control parameter and a parameter which is only
monitored;
3. Identify the instruments used to monitor operating parameters;
4. Explain the basic types of control systems typically used on
incinerators; and
5. Identify the monitoring and control systems included on his/her
incinerator/air pollution control system.
SUPPORT MATERIALS AND EQUIPMENT:
Slide set for Session 5; slide projector
SPECIAL INSTRUCTIONS;
None
HANDOUTS:
Appendix C: Worksheet No. 2 "Incinerator System Information—Monitoring
and Control Systems"
5-1
-------
Slide No.
Tit7e
T Title Slide
1 Monitored vs Controlled Process Parameters
2 Temperature Monitoring System
Picture-1 Temperature Recorder
3 Thermostat with Setpoint
4 Schematic of Temperature Control Loop
5 • Temperature Controller/Meter with Low/High Setpoints
6 Digital Temperature Controller/Meter with Low/High Setpoints
7 Basic Types of Incinerator Control Systems
8 Automatic Timer Sequence
9 Automatic Modulated Control
10 Monitored and Controlled Parameters for Incinerators
11 Monitored and Controlled Parameters for Scrubbers
12 Monitored and Controlled Parameters for Fabric Filters
13 Monitored and Controlled Parameters for ESP's
14 Temperature
15 Schematic of TC Placement
Picture-2 Example TC Placement in Primary Chamber
16 Incinerator Draft and APC Pressure Drop.
17 Schematic of Draft Gauge
P1cture-3 Picture of Draft Gauge
18 Automatic Damper
19 ID Fan Damper Control
20 Damper Control with Motor
21 Oxygen and CO Monitors
22 In Situ vs Extractive CEMS
P1cture-4 In Situ Oxygen Monitor
23 Extractive Monitoring System
P1cture-5 CEMS Control Panel/Cal Gases
24 Opacity Monitoring System
P1cture-6 Transmissometer
25 Charge Rate
Picture-7 Manual Charge Weighing.
P1cture-8 Automatic Weigh Scale
26 APC Monitors
P1cture-9 Venturi Meter
Picture-10 pH Meter
5-2
-------
INTRODUCTION
._,_. .
SESSIONS.
MONITORING AND AUTOMATIC aanvssL
The objective of this session
is to familiarize you with:
— Basic terminology
— The difference between
monitored and controlled
parameters
-ru j-ff a. j.
The different parameters
which may be controlled
and/or monitored, and
— The basic types of
control systems used
• The type of control system
and the operating parameters
that are monitored will be
different for each
incinerator.
• Control systems can be very complex; control systems for some newer
incinerators are becoming more and more automated. Once the system is
properly set up, typically it does not need constant adjustment; in
fact, you may not be able to adjust and should only adjust if you have
been properly trained. Nonetheless, it is helpful and important to
have a basic understanding of how the control system works.
• The parameters most likely to be monitored and/or controlled are
briefly discussed to provide basic familiarity.
MONITORED VERSUS CONTROLLED PROCESS PARAMETERS
It is important to make a
distinction between
• A parameter that is
monitored and
• A parameter that is used for
automatic control.
• Monitored parameter. When a
parameter is monitored, it
means that information is
obtained by a sensing device
in the incinerator and the
information 1s transmitted
tO a receiver SUCh aS a
display meter or recorder
for you to view. However,
the information from the
sensor does not
automatically control any
operations.
P»«»TH
- ««««*«• •«««»
CMTMUU «««•«»
- ^,£"^
» Mimii emnm. M«««T« mrm* LIMITS
5-3
-------
• Controlled parameter. When a parameter is used for control, the
Information transmitted from the sensor is used to adjust some
function(s) within the incineration system in order to maintain the
controlled parameter within certain limits.
TEMPERATURE MONITORING SYSTEM
This slide shows a simplified
schematic of a monitored
parameter. It includes
• A sensor for measuring
temperature
• A recorder for displaying
temperature
SUBI 5-2
COKTKXBOOM
CMIKMT
TEMPERATURE MONITORING SYSTEM
This slide is a picture of a
circular chart typical of the type
used to monitor and record
temperatures.
Picture
5-1
5-4
-------
SETPOINTS
A control system includes a
controller to send a-signal to the
operating system which is
adjusted.
• Control systems use
setpoints for the
monitored/controlled
parameter to determine when
action will be initiated for
the adjusted parameter.
• A simple control system
which you are all familiar
with that uses a setpoint is
the household thermostat.
The desired temperature of
the room is set, and the
furnace automatically turns
on and off in order to main-
tain this temperature. A
temperature dial is provided
so you can monitor the room
temperature.
TEMPERATURE CONTROL LOOP
This slide is a simplified
schematic of a temperature control
loop which adjusts the primary
chamber combustion air blower and
burner operations to control the
temperature.
• The control system includes:
— A sensor for measuring
temperature
— A recorder for
displaying temperature
— A signal processor for
controlling adjustments
or initiating the alarm
— One or more controllers
which receive signals
from the processor
SLIOI 5-5
Ac* H«nng tin Cootnq
THERMOSTAT WITH TEMPERATURE "SET POINT"
SLIM 5-1
CONTROL ROOM
SCHEMATIC OF TEMPERATURE CONTROL LOOP
In this case:
— A controller for starting/stopping the burner and
— A controller for adjusting the combustion air blower
5-5
-------
— "Proportional" controllers which send a proportional output over a
wide operating range. This type control is often called a
modulated control
In this case:
— An on/off relay would typically be used for the alarm; for
example, when a high temperature setpoint is reached the alarm is
turned on
— An on/off relay might also be used for the burner; for example,
when a low temperature setpoint is reached the burner is turned
on; when a high temperature setpoint is reached the burner is
turned off
— A proportional controller might be used for the combustion air
blower. As the temperature drops below the control setpoint, the
blower proportionally increases to provide more combustion air and
raise the temperature. The further the actual temperature is from
the control temperature, the more air the blower provides—until
maximum is reached. As the temperature moves back towards the
control setpoint, the blower air proportionally decreases to
maintain the temperature. The blower air "modulates" back and
forth.
TEMPERATURE CONTROLLER/METER
An example of a temperature
monitor/control display which is
used on an incinerator is presented
in this slide. This controller has
low and high setpoints. Two
pointers are used for setting the
high and low setpoints, and the
third pointer indicates the actual
temperature.
Sum 5-5
TEMPERATURE CONTROLLER/METER
WITH LOW/HIGH SETPOINTS '
Ref. 5-1
5-6
-------
Snot 5-6
TEMPERATURE CONTROLLER
WITH DIGITAL DISPLAY'
Ref. 5-1
TEMPERATURE CONTROLLER/METER—
DIGITAL
This slide is another example
of a temperature controller with low
and high setpoints; this controller
has a digital display.
So that you can fully
appreciate how your incinerator
operates, you should know
• Which parameters are
monitored and how the
monitored value is
displayed; and
• Which of the parameters are
automatic control parameters
and what incinerator
operating functions they
adjust.
Now, we will briefly discuss the most frequently monitored/controlled
parameters and the operating functions that they may be used to adjust. As
previously mentioned, each incinerator will use different monitoring and
control systems and you must refer to your operating manual to determine how
your system operates.
TYPES OF INCINERATOR AUTOMATIC CONTROL SYSTEMS
• The control systems used for
incinerators vary from
manually controlled units to
highly sophisticated
electronically controlled
units.
• We will briefly discuss
three basic levels of
control systems, as an
introduction to the typical
control systems used on
hospital waste
Incinerators. These are:
— Manual control
— Automatic timer sequence
— Automatic modulated
control
MANUAL CONTROL
• With a totally manual control system, you make all adjustments
including turning burners on or off, adjusting combustion air dampers,
and adjusting stack dampers.
SLIDI 5-7
INCINERATOR TOOCESS CONTROL STSTBg
NtMUL
AUTOMATIC TIKI* siauwci
AUTOMATIC NODULATED
5-7
-------
The on/off cycling of auxiliary burners to control combustion chamber
temperatures between low and high setpoints is a simple automatic
control which is a step up from full manual control.
Also, the use of a barometric damper will automatically control
incinerator draft.
SHOE 5-3
AUTOMATIC TIHffi SEQUfflCE
PKESET TIHtK SEQUENCE
— *CTIV>TES OH/OFF OK HIGH/LOU SETTINGS
- COHIUST10N UK
- CH»«6l FEEDER
SETPOINT LIMITS OVERRIDE TIMER SEQUENCE
AUTOMATIC TIMER SEQUENCE
• A preset timer sequence may
be used for controlling an
incinerator. With this type
control system, a timed
sequence is activated when
the incinerator is turned
on.
• The timed sequence activates
on/off or low/high settings.
• A typical timer sequence
controls combustion air and
burner operations in
conjunction with low/high
temperature setpoints.
For example, the primary
combustion air blower may start off
in the "low" air setting and
continue to supply air at a low rate
until 1 hour into the cycle; at this
time, the control time causes the
blower to shift to the "high"
combustion air rate.
• The auxiliary burners also are turned on/off or shifted from low to
high fire rates based on the timer sequence.
• Low and high temperature setpoints are provided to override the timer
control sequence if the low/high temperature setpoints are exceeded;
that is, if the high temperature setpoint is exceeded, the burner will
cycle back to low fire even though the burner would normally be
operating at a high fire based on the timer sequence.
5-8
-------
AUTOMATIC MODULATED CONTROL
• With a fully modulated
control system:
— A setpoint for the
parameter to be suoes-9
Controlled is Chosen AUTOMATIC HODUUTED coma
(e.g., temperature)
— Selected Operating • $€THH»T rm com-nou-to M«»«TE» is CHOSEN
rUnCtlOnS ^S.y . , . o^riHG MOMCTEDS »« coxrimiouSLr ADJUSTED ro
combustion air) are «'•"'» «TTOI"T
continuously adjusted -«-«,«„.
(modulated) over a range
to maintain the control
setpoint
— On/off relays also are
used with the system
(e.g., low/high
setpoints'for auxi1iary
burners)
• Control system typically is
complicated.
MONITORED/CONTROLLED PARAMETERS
MONITORED/CONTROLLED PARAMETERS:
INCINERATORS Su" ™
IQHTORED AM OimgXL£D PROCESS PAHMCTERS
_.,.,.., . FOR INCIHEHATDRS
Briefly, the key parameters
that typically are monitored or
controlled and the incinerator P.M.ITO.
operating functions used to achieve TD^UTWI O»UST.O..,«
control are discussed:
auutn)
Primary and secondary „„„
chamber temperatures are ior«»«««
usually the main control
parameters. Om"
— Combustion air rate and
auxiliary burners are
the operating functions
used to maintain the *„„»„ „,,,„„ rm Imugt
temperatures at the
control setpoint
Incinerator draft also is an important control parameter.
— Either a barometric damper (natural draft systems) or a fan damper
(induced draft systems) is used to control draft
Oxygen is used as a control parameter in addition to temperature for
some systems.
— Combustion air levels are adjusted to maintain setpoints
Other parameters which are sometimes monitored are carbon monoxide and
opacity. These are not used as control parameters.
5-9
-------
• Charge rate often is monitored. It can also be automatically
controlled using a timer sequence.
MONITORED /CONTROLLED PARAMETERS : SCRUBBERS
Key parameters which are SUMS-H
monitored or controlled for unman AND camaia PMCES
scrubbers include:
Pressure droo «_ S«UIIM
r I C^JUI C VJI up (tatlTOMD ««A«TE« COllTmLED
~ The pressure drop across
the VentUri throat iS PKWUW «» MBMM mm- Vonwi IHIWAT
monitored and controlled
— For variable throat vSSSU""" "^ *m°* LiauiB FUW **"""•
venturi's the throat
position may be adjusted S«.U«OHI CAUSTIC ,u»,com*
to maintain the desired
pressure drop lma r~"
Static fan pressure
- The static fan pressure aium'""
may be monitored/con-
trolled as an indication
of airflow through the
system
— An ID fan damper may be controlled to maintain static pressure and
control airflow
Scrubber liquid flow rate (or pressure as indirect measurement of
flow)
— A flow valve is controlled to maintain the desired liquid flow
Scrubber pH
— A flow valve is controlled to maintain pH
APCS inlet temperature
— This parameter may be monitored and controlled to protect the
equipment
— Either a dilution air system or water quench system may be
activated to maintain temperature below a setpoint
-- Activation of a bypass stack also may be controlled by the APCS
"inlet temperature
5-10
-------
MONITORED/CONTROLLED PARAMETERS: FABRIC FILTERS
Key parameters which are
monitored or controlled for fabric
filters include:
SLIDE 5-12
HOHITORGl AM CONTROLLED PROCESS PARAMETERS
FOR FABRIC FILTERS
Itanmiia PAMMETE*
FAIAIC FILTER OPERATINC
nmcrins CONTROLLED
is
PIDSWI OHOP
(HIT CAS roirauTun
CYCLE
EMIWUCT IYPASS STACK
EMMEKY OUUCM
Diuirin AIX
also may be controlled by the ARCS
SLIOI 5-13
KMITDRED AM) CfJMTTO.LHI PROCESS PARAMETERS
FOR ESP's
• Pressure drop
— Pressure drop is
monitored and used to
control the cleaning
cycle
• Inlet gas temperature
— Inlet gas temperature
monitored to prevent
damage to the baghouse
— Either a dilution air
system or water quench
system may be activated
to maintain temperature
below a setpoint
— Activation of a bypass stack
inlet temperature
MONITORED/CONTROLLED PARAMETERS: ESP
Key parameters which are
monitored or controlled for
electrostatic precipitators include:
• Gas temperature
— Maintain above dewpoint
• Power input
-- Primary voltage
~ Primary current
— Secondary voltage
— Secondary current
• Particulate resistivity
— Resistance of collected
particulate layer to the
flow of electrical
current
Use voltage and current meters to measure power input.
MONITORING AND CONTROL EQUIPMENT
Next, the types of instrumentation used to monitor or control the
operating parameters.wi11 be briefly described. The objective of describing
the instrumentation is simply to familiarize you with:
— Where the instruments might be found
— The principles of operation of the instruments
— What sorts of problems might be encountered
lONITOREO PARAMETER
ESP OPERATING
FUNCTIONS CONTROLLED
fait* INPUT
— >»INAAT VOLTAGE
— PRIMARY CURRENT
— SECONDARY VOLT««C
— UCOIIOMY CUimtNT
uri
(NUT us ruptiun»f
Ponen
~/R SETTINOS
5»s
RAMM OPERATION
CONDITIONING AGENTS
(RESISTIVITY)
[NCXUSE/OECXEASE
INCINERATO* OX 10ILEH
OUTLET TEMPERATURE
CONDITION CAS
5-11
-------
TEMPERATURE
• Thermocouples are used to
monitor temperatures in the
incinerator's combustion
chambers and inlet gas to
the air pollution control
system.
• Temperature is usually
measured in 'Fahrenheit
• The thermocouple(s) usually
are located near the exit of
each combustion chamber and
upstream of the air
pollution control device.
There may be multiple
thermocouples.
• The temperature readout may
be a strip or circular
recorder, a digital display,
or a temperature gauge. The
chart recorder provides a
permanent record of the
temperatures experienced by
the thermocouples.
TC PLACEMENT
This picture is a schematic of
a thermocouple (TC) assembly in the
refractory. Note how the TC
penetrates through the refractory to
measure the gas temperature.
•L:DE 5-11
TEHPEMTimE
DEGREES P1HKEKHCIT
EXIT OF SECOMOiHT COIUUSTia* CH1NIE*
MIDDLE OF ftmtuni CH*NIE*
APC
SLIDE 5-15
THERMOCOUPLE AND
DRAFT GAUGE CONNECTIONS '
Ref. 5-1
5-12
-------
TC HOUSING
In this photograph the TC Picture
housing is visible in the primary 5-2
chamber.
INCINERATOR DRAFT AND APC PRESSURE DROP
• Pressure drop is measured SUMS-IS
with a differential pressure HCIMEMTIIR BWTAMO ores PRESSURE DROP
gauge.
• The unit of measure is • Diw«t»n«. P«I«UM «««. j>
inches of water column; • imiu & «m» comm. m. ».c.
i.e., it is the force that . „,„„„„ ar Hmu
-------
DRAFT GAUGE
This slide is a schematic of a
draft gauge. Note the low/high
setpoints for automatic draft
control.
Suioe 5-17
METER FOR DIFFERENTIAL
PRESSURE GAUGE'
Ref. 5-1
DRAFT GAUGE
This slide is a picture of an
actual draft gauge on an incinerator
control panel. Note that the actual
draft Indicated 1s not near the
setpoint needle indicated; the
Incinerator was not operating when
this picture was taken.
Picture
5-3
5-14
-------
DRAFT CONTROL DAMPER
5-18
Suck
This slide is a schematic of a
draft control damper for a natural
draft system. On a manual control
system, this damper would be
manually opened or shut. However,
the draft can be automatically „
controlled. The damper auto- ~~'
matically opens and closes (via a
mechanical system) to maintain a
constant pressure differential
between the incinerator chamber and
the atmosphere), as measured by the
draft monitor.
A second type of automatic
damper control for natural draft
systems is a barometric damper. The
set-up looks about the same as in
this slide, except that no
differential gauge/mechanical linkage is used. The damper is counter-weighted
such that the weight works to close the damper; .as the draft increases it
overcomes the counterweight and opens the damper which decreases the draft.
The counterweights are set to maintain the draft at the desired level.
ID FAN DRAFT CONTROL DAMPER
SAHOXITHIC/AUTOIUTIC :
This slide shows a damper
control system for an induced draft
fan. For induced draft systems, the
draft typically is controlled by
opening and closing a damper located
before or after the induced draft
fan. Airflow is decreased as the
damper is closed, as depicted in the
figure. The damper can be adjusted
manually or can be automatically
adjusted by a mechanical system
based upon the output from the draft
monitor.
SUCK
Stack
ID FAN DAMPER CONTROL
5-15
-------
5-20
COMBUSTION AIR CONTROL DAMPER
This schematic shows a
combustion air damper controller.
Note the "position motor" which
receives the signal from the draft
differential gauge and propor-
tionally adjusts the damper via the
mechanical linkage.
COMBUSTION BLOWER
WITH AUTOMATIC CONTROLLER
Ref. 5-1
OXYGEN AND CO CONCENTRATIONS
Some incinerators may be
equipped with continuous emission
monitors (CEMS) for oxygen and
carbon monoxide.
SLIDI 5-21
onsa AM) co MCHITQRS
Continuous mission KO»ITO«I»S SYSTEM*. CEHS
PERCENT O«YG«N. Z 0,
P««TS PE*
c»mo« mncuiDE.
CO
MONITOI LOCATION
— COHIUST10" CH1HICK OUTLET
~ ST»C»
IN IETHCEN
Measure percent oxygen and
ppm CO.
The monitors typically are
located in the duct to the
stack or in a duct at the
exit of the secondary
combustion chamber, in the
stack, or somewhere in
between.
Heat, dirt, and the
possibility of air in-
leakage (which will cause
the measured value to change
due to dilution) are factors
to consider in choosing the
location.
The 02 monitor analyzes the oxygen concentration in the combustion
gases from the secondary combustion chamber so that the operator can
ensure that enough oxygen is available for proper combustion. For
some incinerators with oxygen analyzers, the oxygen levels measured
are used to automatically control the combustion air feed rates to the
incinerator.
5-16
-------
The CO monitors analyze the CO concentration in the combustion gases
from the secondary combustion chamber to ensure that proper combustion
conditions are maintained and CO emissions are minimized. In general,
high CO levels indicate that incomplete combustion is occurring.
Typically, CO monitors are not part of the automatic process control
system.
IN-SITU AND EXTRACTIVE
The two main designs used for
oxygen analyzers are in situ and
extractive analyzers. This slide
depicts the in situ and extractive
designs. In situ oxygen analyzers
provide rapid response to changes in
the oxygen content of the gas
because the sensor is actually
mounted in direct contact with the
gas stream. The extractive
technique involves the continuous
withdrawal of a sample of gas that
is transported via a sample line to
the analyzer which is located some
distance from the sampling point.
SLIDI 5-22
Sucn
sucx
r.
Samoi*
iTfWDOft
Anaiynrl
IN SITU VS EXTRACTIVE GEMS
IN-SITU MONITOR
This slide is a picture of an
in-situ oxygen analyzer.
As with oxygen analyzers, CO
analyzers may be either in situ or
extractive. However, CO analyzers
are usually extractive because water
vapor in the exhaust gas interferes
with the CO analysis and, therefore,
must be removed through gas condi-
tioning steps associated with the
extractive analyzer.
Picture
5-4
Ref. 5-16
5-17
-------
EXTRACTIVE CEMS
This slide is a schematic of an
example extractive analyzer system
showing the gas conditioning and
calibration components of the
system.
Point out the following
components:
• Sample probe
• Gas conditioning system
• Pump
• Analyzer
• Calibration gases
This type system is very complex and
will require specially trained
personnel to operate, calibrate, and
maintain on a regular basis.
CEMS CONTROL PANEL
This photograph shows the
control/monitoring panel and
calibration gases for an extensive
extractive CEMS system at a hospital
incinerator. The system includes
02, CO, C02, and opacity monitors.
SLIDE 5-23
EXTRACTIVE MONITORING SYSTEM
Picture
5-5
5-18
-------
OPACITY
This slide is a schematic of
transmissometer installation.
Opacity monitors (transmissometers)
are used as indicators of proper
operation rather than as part of the
automatic control system. Opacity
monitors are almost always located
in the stack or stack breeching and
measure the amount of light absorbed
by the stack plume from a light
source directed across the stack.
• A transmissometer cannot be
used after a wet scrubber
because the gas stream
contains so much moisture
that a visible plume caused
by the moisture interferes
with the opacity measure-
ment.
This photograph shows a
transmissometer installed at a
hospital waste incinerator; it is
installed in the ductwork between
the boiler and venturi scrubber.
SLJDC 5-21
OPACITY MONITORING SYSTEM -
(Transmissameten
Ref. 5-2
Picture
5-6
5-19
-------
CHARGING RATE
Suit 5-25
Waste charging rate can be
manually or automatically mom'cored.
• LI/LOAO
• Manual monitoring involves . U/H
weighing each load of waste
Ib/load and recording the
weight of the chars* in a
log book.
• Automatic monitoring
involves use of a weigh
scale or weigh hopper that
automatically records the
weight of each charge placed
on the scale or in the
hopper. Automatic systems
can automatically calculate
hourly charge rates, Ib/h.
• Monitoring charge rate may be required by regulation; regardless, it
provides useful information for the operator.
MANUAL WEIGHING
This photograph shows the P1cture
operator manually weighing each 5
charge.
5-20
-------
AUTOMATIC WEIGHING
This photograph shows an" Picture
automatic weigh scale. 5"8
MONITORS FOR APCS
SLID! 5-26
Some of the instrumentation ore
used for monitoring ARC systems is
the same as the equipment just • sauna nomo «.w
discussed, e.g., I " """"• ""
Temperature • * & soum* LIQUID
Differential pressure ~ rt)"t™
Two other parameters which would be ~ n"
monitored for wet scrubbers include • IB*** **».,?
MESSUKE CAUSE
Scrubber liquid flow
— Liquid flow, gal/min. May
be directly measured using
a flow meter such as a
rotameter or magnetic flow
meter located in the flow
line
— May be indirectly monitored by monitoring pump pressure; this gives
some indication of flow but not actual measurement
- Low pressure, pump problem?
- High pressure, pluggage in line or nozzles?
Scrubber liquid pH
The pH of the scrubber liquor is monitored using a pH electrode. The
electrode is placed into a sump or a pipe through which the scrubber liquor
flows. The output from the pH meter can be used to automatically control the
pH of the scrubber liquor by operating a valve which controls the flow of
caustic solution to the scrubber liquor.
5-21
-------
VENTURI AP METER
This slide shows the venturi AP Picture
mater from a. venturi scrubber 5-9
control panel.
VENTURI pH METER
This slide shows the pH Picture
meter for the venturi 5-10
scrubber control system.
Handouts:
Appendix C includes a worksheet
which is to be used by the operators
to summarize information on their
monitoring and control systems. The
objective is for the operators to
determine the types of monitoring
and control systems they have. The
worksheet is for their use and is
not to be turned in to the
instructor. After the students have
completed their worksheets, the
exercise should be discussed to
answer questions they may have about
control systems.
5-22
-------
REFERENCES FOR SESSION 5
1. Cleaver Brooks®. Operation, Maintenance, and Parts Manual for the
Pyrolytic Incinerator. Publication No. CBK6826. September 1988.
2. Jahnke, J. APTI Course SI:476A, Transmissometer Systems Operation and
Maintenance, an Advanced Course. EPA 450/2-84-004. U. S. Environmental
Protection Agency, Research Triangle Park, N.C. September 1984.
3. Code of Federal Regulations, Title 40 Part 60 (40 CFR 60), Appendix B,
Performance Specification 1. Specifications and Test Procedures for
Opacity Continuous Emission Monitoring Systems in Stationary Sources.
4. U. S. EPA. Continuous Air Pollution Source Monitoring Systems Handbook,
EPA 625/6-79-005. June 1979.
5. Simonds Incinerators. Operation and Maintenance Manual for Models 751B,
1121B, and 2151B. January 1985.
6. Ecolaire Combustion Products, Inc. Equipment Operating Manual for Model
No. 480E.
7. John Zink Company. Standard Instruction Manual: John Zink/Comtro A-22G
General Incinerator and One-Half Cubic Yard Loader.
8. Ecolaire Combustion Products, Inc. Equipment Operating Manual for Model
No. 2000TES.
9. Engineering Manual With Operation and Maintenance Instructions.
Anderson 2000, Inc. Peachtree City, Georgia. Undated.
10. Joseph, J. and D. Beachler. APTI Course SI:412C, Wet Scrubber Plan
Review - Self Instructional Guidebook. EPA 450/2-82-020. U. S.
Environmental Protection Agency. March 1984.
11. U. S. Environmental Protection Agency. Wet Scrubber Inspection and
Evaluation Manual. EPA 340/1-83-022. (NTIS PB85-149375).
September 1983.
12. U. S. Environmental Protection Agency. Fabric Filter Inspection and
Evaluation Manual. EPA 340/1-84-002. (NTIS PB86-237716).
February 1984.
13. Beachler, D.S. APTI'Course SI:412, Baghouse Plan Review. U. S.
Environmental Protection Agency. EPA 450/2-82-005. April 1982.
14. U. S. Environmental Protection Agency, Operation and Maintenance Manual
for Fabric Filters. EPA 625/1-86/020. June 1986.
15. Richards Engineering, Air Pollution Source Field Inspection Notebook;
Revision 2. Prepared for the U. S. Environmental Protection Agency, Air
Pollution Training Institute. June 1988.
5-23
-------
16. Lear Siegler, Inc., Measurement Controls Division. Technical Data
Form ES200/PL for the Model ES200 Oxygen Trim Controller- June 1984.
5-24
-------
LESSON PLAN
COURSE: TRAINING COURSE FOR OPERATORS OF HOSPITAL
WASTE INCINERATORS
SESSION TITLE: INCINERATOR OPERATION
SESSION NO: 6
SESSION TIME: 2 HOURS
GOAL
To familiarize students with:
• Proper waste handling procedures
• Proper waste charging procedures
• Key operating parameters for the incinerator for minimizing air
emissions and how they can be monitored and controlled
• Proper ash removal and handling procedures
• Special actions required and possible problems with startup and
shutdown of the incinerator
OBJECTIVES
At the end of this session, each student should be able to:
1. Recognize the do's and don'ts of waste handling and charging;
2. Identify the key operating parameters for multiple-chamber and
controlled-air incinerators;
3. State the operating range that is considered acceptable for each key
operating parameter;
4. Describe how to monitor each key operating parameter;
5. List the special actions required for startup and shutdown of the
incinerator; and
6. Recognize the do's and don'ts of ash removal and handling.
SUPPORT MATERIALS AND EQUIPMENT;
Slide set for Session 6; slide projector
SPECIAL INSTRUCTIONS:
None
6-1
-------
Slide No.
Title
T Title
1 Topics"
2 Waste Handling
Picture-1 Cardboard Boxes
Picture-2 Poor Storage: Waste Bags Piled on Loading Area
Picture-3 Cold Room for Storage
3 • Incinerator Operation
4 Key Operating Parameters: Controlled-Air Incinerators
5 Key Operating Parameters—Waste Charge Rate
6 Key Operating Parameters—Waste Charge Rate
7 Temperature Trend
8 Primary Chamber Temperature
9 Key Operating Parameters - Primary Chamber Temperature
10 Secondary Chamber Temperature'
11 Key Operating Parameter - Secondary Chamber Temperature
12 Primary Chamber Combustion Air Level
13 Key Operating Parameter - Primary Chamber Combustion Air
14 Secondary Chamber and Total Combustion Air Level
15 Key Operating Parameter - Total Combustion Air Level
Picture-4 Combustion Chambers
16 Combustion Chamber Draft
17 Key Operating Parameter - Combustion Chamber Draft
18 Other Parameters to Monitor: Opacity
19 Other Parameters to Monitor: Ash Quality
20 Other Parameters to Monitor: Carbon Monoxide
21 Other Parameters to Monitor: Secondary Burner
22 Control and Monitoring Summary
23 Control and Monitoring Summary (continued)
24 Heat Content of Waste Versus Charging Rate
25 Proper Waste Charging Procedures - Batch
Picture-5 Charging Batch Unit
Picture-6 Stuffing Batch Unit
Picture-7 Smoldering of Waste During Charging of Batch Unit
26 Proper Waste Charging Procedures - Intermittent Duty and
Continuous Duty
27 Pathological Wastes
28 Proper Ash Handling Procedures
Picture-8 Watering of Ash Removed from Unit
Picture-9 Ash Containers for Transport to Landfill
29 Proper Ash Handling Procedures
30 Startup and Shutdown - Batch
31 Startup and Shutdown - Intermittent/Continuous Duty
32 Operator's Log
33 Do
34 Don't
35 Key Operating Parameters: Multiple-Chamber, Excess-Air
Incinerators
6-2
-------
Slide No. Title
36 Key Operating Parameters: Multiple-Chamber, Excess-Air
Incinerators (continued)
37 Key Operating Parameters: Multiple-Chamber, Excess-Air
Incinerators (continued)
38 Summary of Operation
39 Summary of Monitoring and Control
40 Summary of Monitoring and Control (continued)
41 Waste Charging Procedures
42 Preferred Waste Charge Procedure
43 Improper Waste Charge Procedure
44 Proper Recharging
45 Improper Recharging
46 Pathological Wastes
47 Proper Ash Handling Procedures
48 Startup and Shutdown
49 Do's
50 Don'ts
6-3
-------
INTRODUCTION
There are many types of
incinerators used for the incinera-
tion of medical wastes. The
capacity of the incinerators varies
tremendously because each
incinerator model is designed SESSUHS
differently; design criteria, m „„
operating parameters, and operating «««••• o
procedures will vary. The type of
control system used will vary. The
degree of automatic control and
monitoring used with a specific
incinerator will vary.
As a result, this course cannot
instruct you on how to operate your
specific incinerator, and is not
intended to do so. Specific onsite
training from the manufacturer of
your incinerator, or a qualified
consultant, is recommended.
• The objective of this session is to provide you with a basic
understanding of the most important operating parameters and how you
can monitor and control them. With a basic understanding of the key
parameters, you should be able to better understand the operation of
your system.
• The operator is in control of many of the factors that have an impact
on the performance of the incinerator including:
• Startup and shutdown;
• Waste charging procedures;
• Monitoring and adjusting operating parameters; and
• Ash handling.
• The primary concern is to assure that the incinerator is operated in a
manner so that:
• Infectious materials in the waste are rendered harmless; and
• Air pollution emissions are minimized.
6-4
-------
SESSION TOPICS
In this session we will:
• Discuss proper waste
handling procedures;
• Identify key operating
parameters;
• Identify recommended
operating ranges for the key
parameters;
• Discuss operation of
controlled-air incinerators;
and
• Discuss operation of
multiple-chamber
incinerators.
6-1
TOPICS
H«STE HAMDUHG
OPERATIC) Of CdNTdOLLED-Ald INCKE»»TO«S
Oruurioii OF EXCESS-AIR |HCI»B«ATO»S
WASTE HANDLING
Typically, you will be
responsible for handling the waste
prior to charging it to the
incinerator. The primary concern
with infectious waste handling is to
avoid exposure of yourself and
others to pathogens and avoid injury
from sharp objects such as needles
and broken glass.
Proper procedures dictate that:
• Sturdy containers are used;
• Waste handling is minimized;
• Mechanical waste charging
devices are properly
operated and maintained; and
• The waste storage area is
secure and away from public
traffic.
Snot 6-2
HASTE HANDUN6
Srunor co»r»tutus
HlKIKtlt HHKOUNS
P*opcm.r OPERATE/MAINTAIN HASTE OMXGIHG DEVICES
S»M jroiusc—even FOR SHOUT TIMES
6-5
-------
STURDY CONTAINERS
As an operator, you probably do Picture
not have control over the type of 6-1
waste containers that are used.
However, if breakage and spillage is
a problem, you have an obligation to
notify hospital management. Several
things can be done if bag breakage
is a problem. These include:
• Using stronger bags;
• Double bagging;
• Loading less material into
each bag;
• Placing the bags in rigid
containers such as cardboard
boxes or barrels which can
be incinerated.
This picture shows boxes being used to contain red bag wastes.
MINIMIZING WASTE HANDLING
As an operator, you have some control over the handling of the waste.
The less you handle the waste the less chance there is of breaking bags or
injuring yourself. You should think of ways you can minimize handling of the
waste.
One example of how waste handling can be minimized is the use of rolling
carts to transport and store the waste before charging. Once the red bags are
placed in the carts and transported to the incinerator, the bags should not
need to be handled again until the bags are loaded directly from the cart into
the incinerator charging system. It does not make sense to unload the bags
from the cart and pile them on the ground and then, have to pick them up again
to load them into the incinerator.
PROPER OPERATION OF WASTE CHARGING SYSTEM
To minimize breaking and spilling bags, the mechanical charging system
should be properly operated.
Hopper/Ram Systems. Do not overfill the hopper by jamming waste into
it. Do not force the hopper door closed.
Automatic Cart Dump Systems. Do not overfill the carts.
6-6
-------
SECURE STORAGE
The waste should be stored in a picture
safe and secure way—even if stored 6-2
only for a short period of time.
The following are guidelines:
• The waste storage area
should be out of the way of
normal hospital pedestrian
traffic.
• The area should be secure
from public access.
• The storage area or
containers should be secure
from rodents which can
contract and transmit
disease.
• An example of poor waste
storage is throwing the bags
in a pile on the loading
dock adjacent to the
hospital parking lot; this
slide shows poor waste
storage practices.
• An example of better waste storage 1s to leave the bags in transport
carts Inside an area protected by a chainlink fence and with limited
access.
• An example of even better waste storage 1s to leave the bags in
transport carts inside a well ventilated building which houses the
incinerator charging system.
Some State regulations require
that infectious wastes be stored Picture
under refrigeration if they are not 6-3
to be incinerated ;w,1thin a specified
time period (e.g.,.24 hours). This
slide presents a picture of a cold
storage facility located adjacent to
the incinerator charging area.
DO'S AND DON'TS OF WASTE HANDLING
00:
Minimize your handling of
the waste.
Report repeated problems
with bag breakage/spillage
to hospital administrators.
6-7
-------
• Assure that the waste to be charged is safely stored if it will not be
immediately charged.
DON'T;
• Throw bags around and cause the bags to break and spill-
• Misuse mechanical charging systems and cause the bags to break and
spill.
KEY OPERATING PARAMETERS
Next we will identify:
• The key operating parameters
for control!ed-air and
multiple-chamber incin-
erators.
• The operating ranges
consistent with "good suoes-s
operating practice" for the lximAimOPHUTim
key parameters. The
rationales for the operating
ranges also are discussed. • <"oped.niisMii.MTHs
However, incinerator designs . <)„,,.„« ..WB
differ, and operation of a
particular incinerator
outside the recommended * Ca'T"ou-"s °"""'°"
ranges may be appropriate. • *«« '»•«<•« "ocjw.es
• In many cases, specific . *»„««....
operating limits are
..-.,.. ,. • Sr.«TUP/SMUTDO»» Ft
established by regulatory
agencies; these limits may
differ from the recommended
operating ranges presented
here. Obviously, the
incinerator should be
operated within the
regulatory limits.
The objective is to operate the incinerator in such a manner to achieve
complete combustion, sterilize the ash, and minimize air pollutants.
After identifying and discussing key parameters, we will talk about how
the operator can:
• Monitor operation; i.e., what to look for and
• Control operation; i.e., how the automatic control system works and
what manual adjustments might be made
• Finally, the operator is heavily involved in
~ Waste charging
— Ash handling and
— Startup/shutdown of the unit.
6-8
-------
We will discuss each of these activities.
First, the key operating parameters for controlled-air incinerators are
presented and discussed. Then the operating parameters for multiple-chamber
incinerators are presented and discussed.
KEY OPERATING PARAMETERS FOR CONTROLLED-AIR INCINERATORS
This slide summarizes the key
operating parameters for the typical
controlled-air incinerator that we
will discuss.
The key operating parameters
are:
rer gpswiHS PARAMETERS FOR
g INCINERATORS
• Charging rate
• Primary chamber temperature • CH.WUI. ««
• Secondary chamber . ?„„„ „,„,„ r
temperature
_ . , , . , , • SECOKlMr CH«HtCR
• Primary combustion chamber
* ^tuttusTta>l CMAMIEK OR»fT
• Primary chamber combustion • P«I««T CMWIH COMUSTIO* •<» LEVEL
air I eve I . fOML 0^(^1011 »i« LEVEL
• Total excess air level and
oxygen concentration ' Cawuino" "* """" """"""""'
For each of these we will discuss the
Operating range
Factors affecting the parameter
What the operator monitors
How the parameter is controlled
6-9
-------
CHARGING RATE
Operating range: each
incinerator is designed for
a specific heat input
rate. The heat input comes
from the waste, and as SLIOt6-5
necessary, auxiliary fuel **«<*•.
operated within a charge • HUT mm CMSISTENT »i™ OESIG»
ratp that nrnvirlp« fhp " Si«u MTCH OPJMTIOH
rate mat provides tne _ Flu eiMMIII. M ,OT aveMILt
proper heat release rate. • i»T«KimiiT
__ UnHpr idpal rnnriltinns ~ Suu MTCH" " "EOUEMI '««»V»LS
unaer iaea i cona 1 1 ions, _ lo T0 s ,IKMr „,.„ WKirr „ 5 T0 15
an incinerator operates
under "steady state", £iSIS!a:
that is with a constant, • -«TI
. . , . — • OPM«rii<« Nooe OF !HCIHERATO«
steady heat input.
The fundamental control of
the heat release in an
incinerator is obtained by
controlling the quantity and
frequency of waste
charges .
For single batch operation
-- The chamber should be filled, but not overstuffed
For intermittent and continuous duty
— Frequent charges of smaller volume are more desirable than one
large charge
— 10 to 25 percent of rated capacity at 5 to 15 minute intervals is
a good rule of thumb.
Factors affecting the "operating range"
— Waste properties, heat content, percent moisture, percent
volatiles will have an impact on charging frequency/quantity
-- Operating mode of incinerator, i.e.,
- single batch
- intermittent duty— multiple batch
- continuous duty--24 hours /day
6-10
-------
SUDI 6-6
tEY OPERAnHG PAMHETER-MSTE CHARS IMS RATE
OMMTOH
' CMAMI ««rc. LI/H
— Awuiir mo FRCOUIHCT or CHJUGE
• ASH tu
— BUILDUP
• ASH ouurr
— "Gooo" umouT
• TcNPflurUM T«JIOS
— U» TDI«*»TU«— CH««« KMOtD?
— HICN SICO«D«r
COTTIHn. IT!
• SMLLU on u«t« i«rcnts
• LESS on «o« fueouutr CH««SES
MONITORING AND CONTROLLING CHARGE RATE
Monitoring the Charge Rate.
The charge rate can be easily
monitored. It is not necessary to
monitor the rate exactly—unless
required by regulation.
The operator can monitor the
charge rate (Ib/h) in several ways:
• Recording the amount and the
time of each charge;
• Noting the source and type
of waste;
• Observing the depth of the
waste bed in the'primary
chamber;
• Observing ash burnout
quality; and
• Observing trends in the
primary and secondary
temperatures.
1. Using a charging log. Recording the time and amount of each charge
is called keeping a "charging log."
When you keep a charging log, you record the time each charge is made and
the quantity of each charge (1 bag, 5 bags, 1 hopper, etc.). Monitoring
charging in this way should provide sufficient information to determine if
charging procedures are consistent and to provide information for making
adjustments. For example, if overcharging is the suspected cause of black
smoke, it is only necessary to reduce the number of bags charged in each batch
and observe whether the reduced size of each load eliminates the emission
problem.
If you want to know about how much waste you are charging with each load,
you can weigh your loads for a day to. get an average weight. In this case,
you record the time each charge is made and the weight of the charge. This
approach requires a scale. Some mechanical systems will automatically record
the time and weight of a charge. Routinely recording the weight of all
charges should not be necessary, unless regulations require it. However, this
approach is highly recommended if you want to monitor your charging rate.
2. Observing the waste bed. If view ports are available in the primary
chamber, you can observe the waste bed. If the pile of unburned waste (other
than normal ash buildup) inside the chamber is rapidly and steadily increasing
in size, then the amount charged is greater than the amount which can be
consumed in the same period of time. On the other hand, if all the waste is
consumed well in advance of the next charge, it may be desirable to increase
the charge size.
6-11
-------
3. Observing ash quality. If all the combustible waste is not burned,
it may be because the charge rate is too high and not enough time has been
provided for complete combustion. Another reason for poor ash quality is
insufficient underfire air. The term "burnout" is used to describe the amount
of combustible material left in the ash. If all the waste is burned and no
combustible material is left in the ash, the burnout is 100 percent. If only
half the combustible waste is burned and one-half of the remaining ash is
combustible, the burnout is 50 percent; this level of burnout is not good.
4. Observing trends in the primary and secondary combustion chamber
temperatures. You should monitor primary and secondary combustion chamber
temperature trends (that is, whether the temperatures are steady or are rising
or falling). This information helps you evaluate whether the charging rate is
correct.
It is expected that the temperatures will rise and fall in a cycle after
each charge. However, major swings (for example, outside the recommended
operating ranges) may be an indication of a need to adjust charging
procedures.
You should look for:
• Primary chamber temperature drop—if the primary chamber temperature
falls below the desired low temperature setpoint and the auxiliary
fuel burner is activated, the chamber is low on fuel and is overdue
for a charge. (This assumes that the automatic combustion air control
system 1s properly operating and that proper air has been provided to
the primary chamber). Note: When very wet or low Btu waste is added
to the primary chamber, a drop in temperature is expected. Adding
more waste will further decrease the temperature.
• Secondary chamber temperature increase—if the secondary temperature
begins to rise above the desired high temperature setpoint, the
chamber may be receiving more fuel--in the form of combustion gases
from the primary chamber—than the automatic air and burner control
system can handle. Assuming the primary chamber air control system is
properly operating, this situation indicates excess volatile emissions
from a charge; i.e., the previous charge was too large or was too soon
after the last charge.
Control of the Charge Rate.
• The charge rate can be controlled by you. The rate can be controlled
by either:
— Charging less waste with each load or
— By charging less frequently.
• For example: if an incinerator has an automatic hopper/ram charging
system which is automatically controlled to charge one hopper every
10 minutes, the operator can reduce the charging rate simply by not
filling the hopper to the top. The other approach would be to change
the automatic timer to charge less frequently; for example, every
15 minutes instead of every 10 minutes. If the charge rate is to be
increased for a system using a hopper/ram assembly, the frequency of
charges would need to be increased (every 7 minutes, for example)
because you should not overfill a hopper.
6-12
-------
TEMPERATURE TRENDS
This slide depicts a
temperature record for a controlled-
air incinerator charged with a waste
containing a significant volatile
content. The impact of the charge
on the temperatures can be seen.
The temperature peaks just
after each charge can be seen.
There is also a brief temperature
decrease in the secondary chamber as
excess air enters the secondary.
luot 6-7
TEMPERATURE TREND
Especially note what happens
after the last charge is made. The
primary chamber continues to
increase in temperature as the fixed Ref. C-l
carbon is burned out in the ash
bed. The secondary temperature begins to decrease because there is no source
of volatile combustible gases being generated in the primary. This unit is
essentially in the "burndown" phase at this point. Finally, the primary
chamber temperature begins to decrease as the fixed carbon fuel in the ash bed
is depleted.
The major point to make Is that the operators should learn what the
temperature trends for their Incinerators mean and when to modify charging
procedures, if necessary.
PRIMARY COMBUSTION CHAMBER TEMPERATURE
The key parameter most likely
to be monitored by the operator is
the temperature of both chambers.
The temperature ranges for the two
chambers are different because the
functions of the two chambers are
different. Both upper and lower
limits on the temperature range for
each chamber are necessary.
SLIOS 6-8
PH1MRT CHAMBER TEMPERATURE
First, primary combustion
chamber temperature will be
discussed:
• The temperature is
maintained above the lower
limit to assure
sterilization of the ash and
to achieve adequate burnout
lo»n» LIMIT; MiitmiN OMMTtiN rcwnurum
• ACHIIVI »otaurt SUHPWUT
• Srninze »«
lint* LIMIT: taiiMUM or t Mr IK rtureiurune
• LIMIT SUCSIM OF «SH
THESE IMT 8E A REGULATORY REQUIREMENT ON LOHER LIMIT
6-13
-------
• The temperature 1s maintained below the upper limit to prevent damage
to the incinerator refractory and to minimize slagging of the ash
• Slagging is the melting and fusion of glass and metals (such as
aluminum)
PRIMARY TEMPERATURE OPERATING RANGE
The recommended operating
ranges which are considered
to be good operating
practice are as follows:
~ Batch: 1000° to 1800°F
(540° to 980°C)
— Intermittent:
1800°F (540°
-- Continuous:
1800°F (760°
The chamber must be main-
tained at a temperature
sufficient to maintain
combustion, combust the
fixed carbon in the waste,
and sterilize the remaining
ash.
SLIOC 6-9
SET OPERATING PARAMETER-PRIMARY CHAMBER TEMPERATURE
1000° to
to 980°C)
1400° to
to 980°C)
- 1000' r
-------
• For batch units a minimum temperature of 100CTF is recommended. This
temperature should be sufficient to sterilize the waste, and with a
sufficient burndown period ash quality should be acceptable (e.g., no
recognizable" medical wastes). For continuous-duty, controlled-air
incinerators, a minimum temperature of 1400°F is recommended. A
higher temperature may be needed to assure combustion of the fixed
carbon since the retention time of the ash in the incinerator may be
less than for batch incinerators. The temperature necessary to
achieve an acceptable ash burnout quality should be used.
• The chamber must be maintained below a temperature where slagging of
the waste occurs and damage to the refractory may occur. The maximum
upper temperature depends on the refractory properties. However, an
upper temperature—on a continuous basis—of 1800°F is suggested.
NOTE: Many regulatory agencies have established specific lower
temperature limits for each combustion chamber. These limits may differ
from the recommended limits presented in Table 6A-1. Therefore, if your
permit establishes a lower level temperature limit, you must operate
above this limit.
Typical regulatory limits are:
• Primary chamber temperature—must operate at greater than 1400°F-
Monitorinq Temperatures. You use temperature gauges to monitor the
primary chamber temperatures. All incinerators should have a temperature
gauge and preferably a temperature recorder. A recorder will assist you in
seeing temperature trends.
Contro11inq Temperatures. You can control temperature in three ways:
• Adjusting the charging rate;
• Adjusting the combustion air level; and
• Adjusting the auxiliary burner setpoints.
• The importance of charging rate already has been discussed. Adding
additional waste will generally increase the temperature; in a
controlled-air incinerator, the automatic air control system will act
to limit the temperature increase to the desired temperature
setpoint. Note: depending on waste characteristics adding additional
waste may first decrease the primary chamber temperature as heat is
used to raise the temperature of the waste and volatilize water,
before increase is seen. If the fuel has a low heat content, such as
pathological wastes or very wet waste, the temperature can decrease
when a charge is added; an increase will not be seen even after the
moisture volatilizes because the heat content of the waste is too low.
• For a controlled-air unit, controlling the combustion air affects the
temperature. Adjusting the combustion air is the primary control
mechanism used, other than adjusting the charge rate. Increasing the
air in the primary chamber increases the primary chamber temperature;
and increasing the air in the secondary chamber decreases the
secondary chamber temperature. Usually, the automatic control system
on a controlled-air unit will control the air levels. The automatic
control system's operation will be based on:
6-15
-------
— A clock timer sequence which operates in conjunction with each
batch charge, or
— The temperature output from the thermocouples, or
— Some combination of the above two.
Actual adjustments to air damper settings or time/temperature setpoints
normally are not made by you unless problems are persistent. Only properly
trained operators should make damper adjustments on an automatic control
system.
• The final temperature control available to you is use of the auxiliary
burners in the primary and secondary chambers. Again, these burners
normally are automatically controlled; the burner is activated by a
temperature setpoint. Only properly trained operators should adjust
setpoints.
SECONDARY CHAMBER TEMPERATURE
• The temperature of the
secondary chamber must be
maintained at a high enough
level to assure complete
combustion of all organic
compounds. The exact
temperature required for
this is dependent upon many
things, including the type
of organic compounds, the
oxygen level, how well the
gases are mixed with the
oxygen, and how long they
are in the combustion
chamber.
• The temperature of the
secondary chamber must be
maintained below a level
which causes damage to the
refractory.
SLIDE 6-10
SECONDARY CHAMBER TEMPERATURE
lQM» LIHIT: Hi Hi mm opdt»TinE rtnfe««Tu«E
• HlSH CHOUGH TtNMII»TU« TO COKIUJT ILL 0«S*«IC
CWMUHOS
Ufn» LIMIT: N>< [HUH
• PKEVUT OJUUGC ro «EM«CT
-------
SECONDARY TEMPERATURE OPERATING RANGE
Recommended Operating Ranges.
The recommended operating range for
the secondary combustion chamber
is:
1800°
(980°
to 2200°F
to 1200°C)
SUM 6-11
CEY OKMTIN6 PARAMETER— SECONDARY CHAHBER rplPtRATURE
»»»sc:
1800* TO 2200'
HIAOKO
TnrauTum TREHO
Camm. IT:
AUUSTIM S«COIIO
-------
l.iot 6-12
PRIMARY CHAMBER COMBUSTION AIR LEVEL
Controls coJiiujrion HATE >MO rEMPCittTun m
CHMIH
CO»T«OLJ DELCASt RATE OF COMIUSTIILE GASES
SECONDMT CNAHIt*
MAIKTAIHH IELOII STOICHIQNETKIC
Typical regulatory limits are:
Secondary chamber temperature—must operate at greater than 1800°F
PRIMARY CHAMBER COMBUSTION AIR LEVEL
• The combustion chamber air
level is a key parameter
because it controls the
combustion rate and temper-
ature in the primary chamber
• The combustion rate and
temperature in the primary
chamber in turn, controls
the rate of release of
combustible gases to the
secondary chamber (along
with the waste charac-
teri sties). Consequent1y,
the primary chamber air
level can indirectly affect
the secondary chamber
temperature and emission
rates . . . too rapid a
generation of volatiles can
result in overloading the
secondary chamber and,
consequently, emissions.
• The primary chamber is maintained below stoichiometric.
PRIMARY COMBUSTION AIR OPERATING RANGE
Operating Range. The primary
chamber combustion air level is
typically maintained at 30 to
80 percent of stoichiometric.
Monitoring Primary Chamber Air
Levels
• Visual observation within
the combustion chamber
(through sealed glass
observation ports) will
assist the operator in
determining whether air
levels may be incorrect.
You should look for the
following:
Sum 6-13
tEY OPERATING PMAMETEH— ?RIMRT OWIBER OTBUST10H AIR
'UconmiretD qMmrni; nmet:
50 TO 80 'incur OF STOICHIOMTHIC
MIX I T0» !
• VISUAL
— OA«H MO SMKCT COMUSTICW lout
• PlIIIIMY CNAHItX
COHTinH. IT!
6-18
-------
— The primary chamber is supposed to operate with deficient
oxygen. The waste bed should be burning with a dark red color,
and smoke will likely be present. If roaring bright yellow or
orange flames are present, too much air is available. This may be
due to air infiltration from leaks or from improper combustion air
settings.
• Primary chamber temperature
As previously stated, the primary temperature is controlled by the
primary chamber air. Monitoring the temperature is one way of determining if
air levels seem to be correct.
Control of Combustion Air. The combustion air levels are controlled by
adjusting the combustion air dampers or fan speed (for systems using variable
speed fans). Depending upon the control system, you may or may not have
direct control of the air dampers or fan speed. As indicated above, the air
dampers are usually automatically controlled to maintain the desired
combustion chamber temperatures. If you suspect persistent problems with
combustion air levels, the damper settings should be checked and adjusted by a
trained/qualified technician.
SECONDARY CHAHBER AND TOTAL COMBUSTION AIR LEVEL AND OXYGEN CONCENTRATION
• The secondary combustion air
level controls the tempera-
ture of the secondary
chamber; more air decreases
the temperature
• The total combustion air
level is maintained above
stoichiometric (excess) to
assure sufficient oxygen for
complete combustion
• Oxygen is an indicator of
excess air level
SLIDI 6-14
COHTIKJLS rotp(x«Tum at SECO»O»«Y CHUNK*
EXCESS AID ASSURES SUFFICIENT OXYGEN FOR COMPLETE
COmUSTtON
6-19
-------
SLIM 6-!S
-------
Appearance of Gases in Combustion Chamber.
The next slide shows a picture
of the appearance of"the primary
chamber (substoichiometric
conditions and the secondary chamber
[excess air conditions]).
Picture
6-4
Ref. 6-23
COMBUSTION CHAMBER DRAFT
• A negative combustion
chamber pressure typically
is maintained.
• Excess negative pressure is
not desirable because it can
cause fine particulate
matter to be pulled from the
primary chamber through the
secondary chamber and out
the stack.
• Also, excessive negative
pressure can cause excessive
air infiltration through
leaks into the incinerator.
- A positive pressure is
undesirable because it can
cause "puffing" of emissions
from the incinerator.
SLIM 6-16
OMUSTtOH CHAJffiCT DRAFT
EXCESS I Vt PHTlCUUrt (UTTER £NTRMHK(»T
• PREVEUT tin OUT-UEAUSE
6-21
-------
SLIOI 6-17
KEY OPERATING PARAMETER—COMBUSTION CHAMBER DRAFT
fltcmmmpip MUM:
• Niumc 0.05 ro 0.1 IHCHCS »/>rE«
MOIIITOH!
• Ourr tuiti
COHTITOL ir:
• NtruuL oiu'r O»HFEK SETTING
— BMOMTIUC. AUTOMATIC. »»»u»u
• F»» OMPI* SETT us
COMBUSTION CHAMBER DRAFT OPERATING
RANGE
Operating Range. A typical
range for the draft in the primary
chamber is negative 0.05 -to 0.1 inch
of water (in. w.c.) (-0.012 to
-0.025 kilopascals [kPa]).
Monitoring Incinerator Draft.
A draft gauge is required to measure
the pressure in the incinerator
chamber. Your incinerator may or
may not have such a gauge.
Control of Incinerator Draft.
For natural draft systems, the draft
may be controlled by a motorized
barometric damper or stack damper,
or it may be uncontrolled.
Depending upon your system, these
dampers may be manually controlled
or may have an automatic control to
maintain a present draft.
For systems using an induced draft fan, a damper at the fan inlet or
outlet is usually used to control the fan suction. Again, the damper may be
controlled manually or automatically.
OTHER PARAMETERS TO MONITOR
Other parameters you should monitor include:
1. Stack opacity;
2. Ash quality;
3. Stack gas carbon monoxide; and
4. Burner flame pattern.
6-22
-------
SLIOI 6-18
OTHER PAMHETBS TO MONITOR
STUCK c»s QMCITT
• EAST ro DO
• INDICATOR af MUTICULATE onssian/rotm COMIUSTION
• ADJUST SECO«O»«T «m a* ounce MTC
• Cxccx SICO«O««T iumc*
OPACITY
Stack Gas Opacity. You should
make a habit of observing the stack
emissions. It is easy to do.
• Stack gas opacity provides
an indirect measurement of
particulate matter
concentration in the stack
gas. As particulate matter
increases so does opacity.
If high opacity emissions
occur, proper operation of the
equipment should be checked and
operating procedures should be
changed, if necessary. Later we
will further discuss how opacity can
be used to identify combustion
problems and some possible operating
changes to correct the problems.
Operation of the secondary burner should be checked; the secondary air
level may need to be increased to provide more oxygen; or the charge rate may
need to be decreased to reduce the generation of volatiles from the primary
combustion chamber.
If your incinerator is equipped with a transmissometer (continuous
monitor for opacity) you should learn the acceptable opacity range and
frequently check the instrument data to assure that the incinerator is
operating within the acceptable range; pay attention to the "high opacity
alarm" when it goes off.
ASH QUALITY
The operator should routinely
monitor ash quality; it is easy to
do. Changes in ash quality are an
indication that some operating
parameter has changed.
The operator should look for
large pieces of unburned waste; this
situation is undesirable. A fine
grayish ash is an indication of good
burnout as compared to a black ash
which indicates the presence of
carbon.
Some steps that might be
appropriate include:
SLIOI 6-19
POMHETHS TD MONITOR
As* au«LiTT
• EUT TO DO
• PIICU v umumu-iusTi MT GOOD
• GUT COLO* iirru rau imcx
• IKXUU n\uaa
' OtCMMt aunt! MTC
• IKHASI tumnur TIME
6-23
-------
• Increasing primary temperature (but not so high as to cause slagging
problems)
• Decreasing the charge rate to prevent buildup of unburned waste in the
bed or to increase the retention time in the chamber (for continuous
systems)
• Increase the burnout time for batch/intermittent duty systems
COMBUSTION 6AS CARBON MONOXIDE
Carbon monoxide gas (CO) is -
formed during incomplete combus-
tion. Excessive levels indicate
that a poor combustion condition
exists. Levels greater than 100 ppm
are usually considered excessive.
Your State may specifically regulate
the level of CO.
The CO level of the combustion
gas can be monitored by an instru-
ment. If your incinerator
continuously monitors CO, you should
routinely check the levels to assure
they stay within the acceptable
range. If they do not, changes in
your charging procedures or adjust-
ments to combustion air levels are
probably necessary. If no CO
instrument is installed, you cannot
determine CO levels.
SECONDARY BURNER FLAME PATTERN
If sealed observation ports are
available, you should check the
burner flame pattern daily. The
burner flame should:
• Be bright yellow/orange;
• Not smoke;
• Not move back and forth
abruptly; and
• Not impinge on (hit) the
refractory walls.
?Ntf*Wi
ST.« »s c»..o.
-------
SLIDE 6-22
COHTROL AMD MONITOR^ SUMMARY
X«srt COMKSITKM. CHMCC HATE. rcxMiunixcs. tin UVELS
*« »LL
VITHIN LIMITS Or DISIOM— tUTOMTIC CCMTML SYSTEM IOJUSTS
-------
If monitored va'^es such as temperature, ash quality, and stack opacity
indicate operational problems, then adjustments to the automatic control
system snould be considered. These adjustments should only be made by someone
who is properly trained and qualified. Ideally, you will be properly trained
and qualified to make minor adjustments to the control system settings—such
as damper settings and setpoints. The ability to understand and make such
adjustments will allow you to control and operate the system for optimum
performance.
PROPER WASTE CHARGING PROCEDURES
Heat Content of Waste Versus
Charge Rate, Proper waste charging
is probably the most important
procedure for the operator.
Remember that the heat input rate to - :•.'»« e-z«
an incinerator is very important
because the incinerator is sized for
a particular heat release rate: II ~
1
INCINIMTOH CAMCITT vtwus ne*T COKTDIT OF ««STE
• If the heat input rate is
too low, the incinerator
will not operate efficiently
and excessive auxiliary fuel
will be required.
• If the heat input rate is
too high, incomplete
combustion is likely to
occur because more volatile
combustible gases will be
generated in the primary
chamber than can be properly
handled by the secondary
chamber which will result in
pollution.
As an operator, you should be aware that the heat content of wastes may
vary and therefore you may need to vary the charging procedures—that is, you
may need to charge more or less waste.
This slide shows how the heat content of the waste affects the charging
rate. The desired heat release rate is 4,800,000 Btu/h. If the heat content
of the waste is 5,000 Btu/lb the charge rate is 900 Ib/h. If the heat content
is 10,000 Btu/lb the charge rate is only 450 Ib/h. Note that wastes below
5,000 Btu/lb will require auxiliary heat input.
Special care should be taken to avoid overcharging the incinerator
(beyond its intended use) with pathological wastes (animal carcasses and body
parts) because of the high moisture content and low heat value of this type
waste. (Incineration of large quantities of these wastes is discussed later=)
6-26
-------
In Session 3, the operating mode of control ita^ir incinerators was
described as:
• Single batch;
• Intermittent duty; or
• Continuous duty.
The charging procedures used for these three operating modes are slightly
di-fferent and are discussed separately below.
WASTE CHARGING—SINGLE BATCH INCINERATORS
The following general
principles apply for charging single
batch incinerators.
SLIOI 6-25
PROPER **STE OUHSINC P«Oga»S
SIMGU 3JTCH OPERATION
GuiKt
Oa nor 'STUFF' mcttiEiuro*
Cusi »«o SUL ooax sifaKi IGNITION
P»tnur SECONOMT
KFORE ISNITION
Otcxusi size OF LO«O. «s KiCEssiKr. ra ntvur
Mission »r STMTUF
These incinerators are
usually small and,
therefore, are charged
manually.
The incinerator is charged
cold.
The waste is loaded into the
ignition chamber, which is
filled to the capacity
recommended by the
manufacturer.
The incinerator chamber
should not be overstuffed.
Overstuffing can result in
blockage of the air port to
the combustion chamber.
Overstuffing also can result in damage to the primary burner.
After charging is completed, the charge door is closed and sealed.
Once operation is initiated, no further charges are made until the
next operating cycle (i.e., after the incinerator cools and ash is
removed).
Prior to ignition of the waste, the secondary combustion chamber is
preheated. A minimum secondary temperature of 1800°F is recommended
prior to ignition of the waste in the primary chamber.
6-27
-------
Manual Batch Charging. This
slide is a picture of a small single
batch unit which has been manually
charged; it appears full. However,
the next slide shows additional
waste being stuffed (forced) into
the chamber. This procedure is not
recommended.
The usual reason for over-
charging an incinerator in this
manner is that, since the batch
operation typically is a 24-h cycle,
the hospital personnel want (need)
to get all the waste generated each
day into the incinerator . . . when
the amount generated exceeds incin-
erator capacity there is a
problem. This is indicative of the
need for a larger incinerator, or
off-site disposal arrangements.
Smoldering Waste. This slide
shows the waste beginning to smolder
as the incinerator is batch
charged. This indicates that the
refractory was still very hot and
sufficient cool down was not
allowed. The operator is hosing the
waste down to try and prevent
preignition. A better approach
would be to cease charging at this
point and seal the unit; however,
this poses the problem of what to do
with the remaining waste.
If consistent problems with
emissions are noted during startup,
then consideration should be given
to decreasing the size of the load;
secondary burner operation and
combustion air levels should be
checked.
Picture
6-5
Picture
6-6
Picture
6-7
6-28
-------
SLIDI 6-26
PROPER HASTE CHAR61N6 PROCEDURES
IHTEHmTTEHT DUTY MO CONTINUOUS DUTY
• NOKf FKCOUUT SMU.EK CHARGES ARE lETTER THAU ODC LARGE
OUKSE
• ADJUST CHARGE VOUIMI AND FREOUUCY TO ACCOUNT fa* HASTE
VARIATIONS
WASTE CHARGING: INTERMITTENT-DUTY
INCINERATORS
Intermittent-duty, controlled-
air incinerators typically are used
for shift type operation. The
incinerator must be shut down for
ash removal. The charging/operating
system is designed to accommodate
multiple charges safely throughout
the operating cycle rather than
relying on a single-batch charge.
Either manual or automated charging
systems are used.
The following general
principles apply for charging
intermittent-duty incinerators:
• Stable combustion is best
maintained with a constant
heat input to the
incinerator.
• Overcharging (feeding too much waste in a charge) can cause excessive
emissions because of rapid volatilization of organic compounds that
overload the secondary chamber.
• Feeding too little waste results in inadequate heat input and
excessive auxiliary fuel use.
• Differences in charging procedures are appropriate for small manually
fed units and large mechanically fed units. For large systems using
mechanical charging, more frequent charges will not be as disruptive
to incinerator operation because the mechanical system limits entry of
excess air. Frequent, smaller charges are desirable to a point.
For smaller manually fed units, each time the door is opened, excess air
enters and disrupts combustion. Also, opening the door creates a potential
safety hazard. Less frequent charging is desirable. However, the charges
should not be so large as to overload the incinerator.
• A recommended charging frequency is 10 to 25 percent of the rated
capacity (Ib/h) at 5 to 15 minute intervals.
• Charging volume and frequency will vary with waste composition and the
Incinerator design.
• Earlier we looked at a graph that showed how the amount of waste
needed for a given heat input could vary tremendously depending upon
the heat content of the waste. The operator should try to be aware of
major changes in waste heat content and adjust the charge
sizes/frequency.
— E.g., reduce charge size when a large amount of very high Btu
volatile plastics are contained in a batch of waste.
• After the last charge of the day is completed, the incinerator is set
to initiate burndown. The limiting factor on how long the incinerator
6-29
-------
can be operated without shutting down is how quickly ash builds up on
the hearth, i.e., the ash capacity of the primary chamber. Another
limiting factor is the burndown/cooldown period. If it is desired to
operate on a 24-h cycle, where ash is removed each day and charging
done each day, then enough time has to be left each day for burndown
and cooldown. Typically, the operating period during which the
incinerator is charged with waste is limited to 12 to 14 hours.
Continuous-Duty Incinerators. Continuous-duty incinerators typically are
large units equipped with mechanical feed systems.
The mechanical feed system often is automatically operated so that the
charge is fed on a timed sequence. Proper charging involves:
• Frequent charges of 10 to 25 percent of rated capacity (Ib/h) every 5
to 15 minutes.
• Charging frequency may need to be adjusted to accommodate major
changes in waste heat value.
CHARGING PATHOLOGICAL WASTES
If large quantities of
pathological wastes are to be
burned, operation requires special suois-z;
considerations. PMHOLOSICAHIASTES
The amOUnt Of pathological • LIHIT ummt ar MTMOUKICAL »«sTt IF mci»M*TO«
wastes should be limited if „«.,.««.,*,«,..
the incinerator is not * OP°UTE «"«•* »u«««s DURING iMC
designed for pathological . o««« ««« « »u*™ >» SH»U.™
wastes. This is because the
heat content of pathological
waste is low and will
require constant auxiliary
burner operation . . .
unless the waste is a very
small portion of the total
waste volume and sufficient
heat input will be derived
from the other wastes.
Normally, primary burners are operated during the entire incineration
cycle to provide the heat input required.
The waste should be charged in a shallow layer on the hearth so it is
directly exposed to the burner flame. The waste should not be deeply
piled on the hearth, because it will not burn if it is not exposed to
the flame; the top layer that is exposed to the flame will burn and
form an ash layer than insulates the waste underneath; only stoking of
the ash will then be required to expose this unburned waste to the
flames.
6-30
-------
SLIDE 6-23
PROPER ASH HAHDLIH6 PROCEDURES
SlHBLE BATCH/IHTtmiTTtNT 0>t»«TtOH
ALLS* INCIRERATOR TO COOL
Do nor SPRAT KATER INTO comusriox CHAHIER
USE FLAT/tLURT TOOL FOR UK REMVAL
AVOID WHIM ASH iuro UROERFIRE PORTS
PUCE «SH IN Kir XL CONTAINER
DAMPER ASH TO PREVENT FUGITIVE DUST
Pmrvn.i DISPOSE OF «SN
NUI SURE ASH DOOR IS PROPERLY SEALED
IKPECT ASM QUALITY:
*AU CORRECTIONS TO OPERATION. IP NECESSARY
PROPER ASH HANDLING PROCEDURES
Batch-feed and intermittent-
duty incinerators require that the
ash be removed from the incinerator
at the end of each incineration
cycle. (Sometimes, if the incinera-
tion cycle is short, it will not be
necessary to clean out the ash after
each cycle.) The following are
guidelines for good operating
procedures when ash is manually
removed.
1. The incinerator should be
allowed to cool sufficiently so that
it is safe for the operator to
remove the ash. This cooling can
take as long as 8 hours.
2. You should exercise extreme caution since the refractory may still
be hot and the ash may contain local hot spots, as well as sharp objects.
3. The ash and combustion chamber should not be sprayed with water to
cool the chamber because this can damage the refractory.
4. A flat, blunt shovel or raking tool, not sharp objects that can
damage the refractory, should be used for removing the ash.
5. Avoid pushing ash into the underfire air ports.
6. Avoid bumping or knocking burner nozzle assemblies or thermocouple
housings.
7. Place the ash into a noncombustible container such as metal, not
cardboard.
8. After the ash has been removed, dampen the ash with water to further
cool the ash and minimize fugitive (windblown) emissions.
9. Store the removed ash in a safe manner until disposal; cover the ash
container to prevent windblown dust.
10. Discard the ash according to approved procedures (according to your
permit).
11. Assure that the ash door is securely closed; visually inspect the
condition of the sealing material before closing the door. After closing the
door lock make sure nothing (such as a piece of ash) is caught in the door.
6-31
-------
MANUAL ASH REMQVA1
This slide shows th» asn that Picture
has just been removed (manually) 6-8
from a single batch unit. It has
been covered and is being wetted to
prevent windblown dust. After the
ash has further cooled, it will be
placed Into a container suitable for
hauling away for disposal. (Next
slide).
Picture
6-9
6-32
-------
ASH HANDLING— CONTINUOUS DUTY
Continuous-duty incinerators
have automatic ash removal
systems. Generally, your job is to
assure that the system is properly
. . — ,. . .
operating. This includes:
Ca»TiNUom purr
1. Being on the lookout for
jams in conveyor systems.
poopcn ACU UAUOCIHC P
-
2. Assuring that water flow is • AMWI MUM MTM FU» i$
maintained to quench sprays and . Ri^a wu. AS* CO«T»I«« m™ t»m CO»T»I»EI,
pits. Assuring that the water level
in the quench pit needs to be
maintained so that the water seat ' iST.-.^^,..
with the incinerator is not broken.
3. Assuring that full ash
containers are removed and replaced
with empty containers. The ash
should be kept wet or full ash
containers covered to prevent
windblown dust.
4. Inspecting ash quality, noting problems, and determining whether
operating changes are required.
STARTUP AND SHUTDOWN PROCEDURES— SINGLE-BATCH FEED INCINERATORS
Startup and shutdown of an
incinerator typically requires
special steps to be taken. Note:
Specific manufacturer's instructions
should be followed. Some general snote-a
recommended procedures are listed STARTUP am SHUTM*
below.
Smelt 3»rCM UK IT
Startup: *««'
• CHUM IKIIICIUTO* cou>
• The incinerator should be ' P««»T ™« ««««•'»"«« «~«
Remove the ash from the . i«a,u« P*.««Y cwiuino. CH»IM .1* ra
previous cycle; cowan* & mo CAW*
«. . . . . . • ' **w» WIWMT rcnm*Twif oicxusis ro «ts*r LCVIL.
Charge the incinerator; do iw m» acm**, «,«««
nnt nvorrhflrno* ' ^nr COMUSTIM lumus orcuriM ro COOL
not overcnarqe, . R^^, 1J1( .„„ ,«„„„„ COOLJ
Seal the charge door;
Preheat the secondary
combustion chamber to a
predetermined temperature
(1800°F [980°C] is
recommended);
Note: If the incinerator is overloaded and the waste in the primary
chamber enters the air passageway to the secondary chamber, the waste
may self-ignite during the preheat period. This situation should be
avoided; and
6-33
-------
Activate the primary chamber combustion air and burner to ignite the
waste.
Shutdown:
the
• After the waste burns down and all volatiles have been released,
final burndown period is initiated.
— Increase the primary combustion air level to improve combustion of
the fixed carbon.
~ Maintain the temperature in the primary chamber at a minimum
temperature using the auxiliary burner for a predetermined length
of time to assure that the fixed carbon is combusted.
— When the burndown period is complete, as indicated by maintaining
the preset temperature in the primary chamber for a preset period
of time, the cooldown period'is initiated.
— Shut down the primary and secondary burners.
— Keep the combustion blowers operating to assist in cooldown.
STARTUP AND SHUTDOWN: INTERMITTENT-DUTY INCINERATORS
The general procedures for
startup and shutdown of an
intermittent-duty incinerator are as
follows.
SLIM 5-31
an
UTCIMITTIIIT IMP Coir i minus PUTT
P»«HUT stcoiiom
Ounce MSTE
[SUITE MSrC
SmiTDOiiit:
DUTY—«»t «s §«rcx
COHTIMIDUS ounr
— STOP CH1KIIIC STSTEM
— H«inT*i» oPCmmcM ar INCINERATOR mo «SH SYSTEM
UNTIL ILL MITE IS DISCHtKCED F»OK
— SMITMIII mcuEura*
Startup:
• Ignite the primary and
secondary burners and
preheat the combustion
chambers..
• After the secondary
temperature has reached a
minimum predetermined
temperature (1800°F is
recommended), activate the
combustion air blowers.
• Charge the incinerator and
ignite the waste.
Shutdown. After the last charge of the day, the incinerator is set to
initiate a burndown/cooldown procedure. Depending upon the incinerator, this
sequence will be manually or automatically activated and controlled. The
bumdown/cooldown procedure is essentially the same as the procedure discussed
for the batch-type incinerator.
Shutdown of a continuous-duty incinerator involves stopping the charging
process and maintaining temperatures in the combustion chamber until the
remaining waste burns down to ash and is finally discharged from the system in
a normal manner.
6-34
-------
OPERATOR'S LOG
One of the most useful means of
monitoring operation of an
incinerator is to maintain an
operator's log book. This is
particularly useful when different
persons operate an incinerator
because it allows each operator to
read about what problems occurred on
previous shifts, and what
adjustments were made.
A log book has other advantages
including:
• Documenting upsets for the
regulatory agency
• Tracking trends related to
operating parameters (e.g.,
charge rate) and problems.
DO'S AND DON'TS FOR OPERATING A CONTROLLED-AIR INCINERATOR
SLIDE 6-32
*HTTEN uos loos
OPERATOR'S LOG
Ricon SIGNIFICANT EVENTS
— STMTUP/SHUTOOM
— ADJUSTMENTS
— OUNCES IN CH««GE »»TE
• Recom UNUSUAL naiLEHS AMD COMECTIVE tenons
Summarize the operation of a
control!ed-air incinerator by
reviewing the main do's and don'ts
Suoi 6-53
DO:
P»T CMCFUL ATTENTION TO CHtlNIM HATE
— ADJUST CHAHSIBS DATE. IF HECESSARY
fon i ran comusTiON TEMPI
— LEAP* TO DECOGNIZE TIENOS
STACK OPACITY
CHAXIMS THITOUCN
Inner ASH OMUTY
— ADJUST VEJUTION, IF
Pay careful attention to
charging procedures and
charging rates; look out for
and pay attention to extreme
differences in waste
characteristics; adjust
charge rate, if necessary
Monitor combustion chamber
temperatures and learn to
recognize trends that are
good and trends that
Indicate a problem
Routinely monitor stack gas opacity, especially after charging; if
puffing is persistent, modify operation;
Make good use of viewports to visually check the combustion chambers;
learn to recognize problems
Pay attention to the other monitors you may have at your facility,
such as opacity, oxygen, and CO
HMXI MO otsrast or >SN
P*«UT THE SECOUUIIT CHAKIH IEFO«E STMTUP
(CEP
-------
DON'T:
Inspect the ash quality. If visual inspection indicates poor burnout-
-large recognizable pieces of combustible waste such as hospital
gowns, animal carcasses—check your equipment and/or make changes to
operating procedures/conditions
Handle and dispose of the bottom ash properly and carefully
Preheat the secondary chamber before start-up
Ignore problems indicated by
monitors. If it appears
that adjustments to the
control system are required
and you have not been
trained to make these
adjustments—call your
supervisor or maintenance
department.
Overcharge the incinerator;
Charge large amounts of
pathological waste to the
incinerator unless it is
designed for pathological
waste.
Sum 8-34
• lGM*f «fllLEI« KOIOTtl) «r MMITOIK
• OVMOUKt THt l»C!IIEJ«TOIt
KEY OPERATING PARAMETERS FOR
MULTIPLE-CHAMBER INCINERATORS
First we will summarize the key
operating parameters for the typical
multiple-chamber incinerator.
The key operating parameters
are:
• Charging rate
• Primary chamber temperature
• Secondary chamber
temperature
• Total combustion air level
(percent excess air)
• Combustion gas oxygen
concentration
• Combustion chamber draft
Many of these operating
parameters have already been
discussed in detail for controlled-
air incinerators. Therefore, the
discussion of these parameters will
be abbreviated.
Suoi 5-35
fEf OPEMTlKj PMMFTOK
MlTlPU-tHAHBeR. EtCES-Alll
PtKtlUTEH
V«ST( dUKSl MTC
US
RccoivieifocD
10-251 OF «mo CAHCITY
»T ID-IS HIPHJTf [|(T{IIV«LS
Si HSU UUM OH XCAHTH
6-36
-------
Charging Rate.
• The charging rate and procedures used are very important for operation
of a multiple-chamber incinerator.
• Note that charging rates for general refuse/red bag and pathological
wastes are different because of their different waste
characteristics.
• For general refuse/red bag waste, it is important to make frequent,
small charges to avoid large surges of volatile combustible gases that
can exceed the capacity of the combustion air supplied in the primary
and secondary chambers. Ten to twenty-five percent of the
incinerators rated capacity is recommended as a starting point.
• Pathological waste must be exposed to a direct flame to achieve
combustion. A single layer on the hearth is recommended.
Primary and Secondary
Combustion Chamber Temperature. The
key parameter most -likely to be
monitored by the operator of a
multiple-chamber incinerator is the
temperature of each chamber.
SLIDE 5-36
tET
PARAMETERS:
HUlTIPtE-CHAHBER. EXCESS-AIR INCINERATORS
PlUUIT OUMM
—
-------
KEY OPERATING PARAMETERS (continued)
Primary And Secondary Chamber
Combustion Air Levels And Combustion
Gas Oxygen Concentration. The
primary chamber for a multiple-
chamber incinerator is typically
maintained at an excess air level Of rer OPERATING PARAMETERS:
about 200 percent. A multiple-
chamber incinerator is operated at
i -i . i , - , . RECOHMEHDCD
an overall excess air level of about P..»tT» anw,»s ,**<
250 to 300 percent. This results in
, .. 11.1 PtIHMY CH1NIU COKIUSTIOH >I* ;0-150I EICESS tl«
combustion gas oxygen levels in the
15 to 16 percent range. T""L cmiUSTIM "« 12° T0 yal "ct" M"
COMUSTIOII a*s OITSU can. ID- 161
• Multiple-Chamber CWIUSTHW «««« M.FT NESAT.VE 0.05 TO
incinerators burning °-1 '"• ••c-
pathological wastes
typically are operated at
lower excess air levels than
incinerators burning general
refuse. Less excess air is
used because pathological
waste contains less
volatiles and the heat input
comes primarily from
auxiliary burners.
Primary Chamber Draft. A negative pressure must be maintained in the
combustion chambers. Sufficient draft must be maintained to move the
combustion gases through the incinerator.
• Too much draft will cause excessive entrainment of parti cu late matter
from the primary chamber, which will be emitted as an air pollutant.
• The typical range for the primary chamber draft is negative 0.05 to
0.10 in. w.c. (-0.012 to -0.025 kPa).
6-38
-------
SUMMARY OF OPERATION
• Most multiple-chamber
incinerators used for
hospital wastes are designed
for intermittent duty
operation. Typically, the su«6-«
waste is charged by hand to SUHHMTOFOPBIAT.^
the incinerator through the
open charging door or by a • «««« «« i*™ m i»TE«xim«T DUTY
mechanical charging system . *,„„ „.„,„ ls EXCESS 4I, tmm
such a hopper/ram. -»««««.«««««« M COHTMLHO IT ,
• The UnitS Operate With - tSfSmmiu,. -.STE HEAT «LEASE «TE is CO*T«OLLED
excess air in both chambers. 1T"""*"lu""«s
• Remember that the heat input
rate to an incinerator is a
very important parameter
because the incinerator is
designed for a specific heat
input rate.
• The heat input rate is
controlled by the charge
rate and burners.
• The heat input from the waste is determined by the amount of waste and
the heat content of that waste. Therefore, charging rate is very
important. Because the heat content of red bag waste and pathological
waste is so different, operation of an incinerator when burning these
two types of wastes is different; for pathological wastes, the burner
operation controls the heat input.
CONTROLLING AND MONITORING KEY OPERATING PARAMETERS
The specific controls and
monitors for each multiple-chamber
incinerator will be different. Some
incinerators have mostly manual suois-n
controls with few monitors. Some
incinerators have more automated
controls and monitors to assist the
operator.
OUMIM HATE
rOtPUUTUIVES Of IOTH CHANIEMS
We will briefly review some
basic steps you can take for
controlling and monitoring the key
operating parameters. Specific
details of control and how much
control you actually have over the
operation of your incinerator
depends on the specific
incinerator.
fturr
ASM IEO
QUALITY
OMCITT
6-39
-------
CHARGING RATE
The single most important operating parameter that you can easily monitor
and control is charging of the incinerator. The incinerator must be operated
with a charge rate consistent with its design capacity.
Monitoring the Charging Rate. The charge rate can be easily monitored.
It is not necessary to monitor the rate exactly—unless required by
regulation.
The operator can monitor the charging rate in several ways:
• Recording the amount and the time of each charge;
• Noting the type and source of wastes;
Charging Log.
Recording the time and amount of each charge is called keeping a
"charging log."
Record the time when each charge is made and the quantity of each charge
(1 bag, 5 bags, etc.). Monitoring charging in this way should provide
sufficient information to determine if charging procedures are consistent and
to make adjustments. For example, if overcharging is suspected, it is only
necessary to reduce the number of bags charged in each batch. If you want to
know the amount of waste you are charging with each load, you can weigh your
loads for a day to get an average weight. Record the time each charge is made
and its weight. This approach requires a scale. Routinely recording the
weight of all charges should not be necessary, unless regulations require it.
Control of the Charging Rate. The charging rate is probably the easiest
parameter for you to control. The rate can be controlled by changing either
the amount of waste charged with each load or by changing the charging
frequency.
PRIMARY AND SECONDARY CHAMBER TEMPERATURE
Monitoring Temperatures. You use temperature gauges to monitor the
primary and secondary chamber temperatures. All incinerators should have a
temperature gauge and preferably a temperature recorder. A temperature
recorder allows you to monitor trends in temperature.
Control of Temperatures. You can control temperature by controlling
three parameters:
• Charging rate
• Combustion air level
• Auxiliary burner operation
The importance of charging rate has already been discussed. For a
multiple-chamber incinerator, you essentially control temperature by
controlling the charging rate. Increasing the waste feed rate increases
6-40
-------
temperature; decreasing the waste feed rate decreases temperature. You must
balance the charging rate and air supply to sustain the desired temperature
without causing emissions. If sufficient temperature cannot be maintained in
the primary and secondary chambers, either the charging rate is too low,
insufficient heat is being added by the auxiliary burner, or the excess air
levels are too high. Remember, as additional excess air is added, it cools
the combustion gases; this is one of the reasons that incinerator draft should
be closely monitored.
The combustion air levels are adjusted by opening or closing the dampers
controlling the overfire air. Generally, opening the dampers allows more air
to enter the incinerator. Actual control of the air depends on the type of
combustion air system used—natural draft or forced draft.
Damper Settings. Some older multiple-chamber incinerators use natural
draft openings for the combustion air. The'operator can monitor the
combustion air rate by the relative damper setting; a damper that is fully
open allows more combustion air to enter the incinerator than a damper that is
half open. Although a damper setting does not indicate the actual combustion
air rate or the excess air level, it does provide a relative indicator. Other
multiple-chamber incinerators use a forced air blower to supply overfire
combustion air. The damper setting on the blower provides a relative
indicator of the combustion air being supplied; more air will be supplied when
the damper is open relative to when the damper is closed. Note that if the
operator does not have a direct way to measure the combustion air levels, such
as an oxygen monitor, it 1s difficult to determine the most desirable damper
setting. Consequently, if your dampers have been preset by a technician using
monitoring equipment to determine the excess air levels, it may not be
appropriate for you to adjust the damper setting. You should not adjust
damper settings unless you have been properly trained to do so.
The primary auxiliary burner can be used to increase temperatures, if
necessary.
For pathological incinerators, the primary and secondary burners must be
used to control incinerator temperature since little or no heat input is
derived from the waste. The combustion chamber temperatures are increased or
decreased by increasing or decreasing the auxiliary firing rate in the primary
chamber. If excess fuel usage is noted or proper temperatures cannot be
sustained, the combustion air settings should be checked. Too much excess air
will result in greater fuel usage. Since waste properties (heat content and
moisture) will not normally change for pathological wastes, the incinerator
should operate steadily once it is properly adjusted. Once the air settings
are properly adjusted, they should not have to be frequently changed.
INCINERATOR DRAFT
It is important to keep a negative pressure (draft) in the incinerator to
maintain combustion airflow through the incinerator and to prevent fugitive
emissions. However, excessive draft can result in entrainment of particulate
matter which will exit the incinerator combustion stack.
6-41
-------
A draft gauge is required to measure the negative pressure in the
incinerator chamber.
The draft within the chamber is controlled by adjusting control dampers
on the incinerator. For incinerators operating under natural draft
conditions, a damper in the stack gas flue may be used to control draft; or a
mechanized barometric damper often is used to automatically control the
incinerator draft to a preset level. If the incinerator has an induced draft
fan, dampers at the inlet or outlet of the fan typically are used to control
draft. These dampers may be manually controlled, or may be mechanized to
automatically adjust and control incinerator draft to a preset level.
OBSERVING TRENDS IN THE PRIMARY AND SECONDARY COMBUSTION CHAMBER TEMPERATURES
You should monitor primary and secondary combustion chamber temperature
trends (that is, whether the temperatures are steady, rising, or falling).
This information helps you evaluate whether the charging rate is correct. It
is expected that the temperatures will rise and fall in a cycle after each
charge. However, major swings in temperature may be an indication of a need
to change charging procedures.
You should look for:
• Sustained drop in the primary or secondary chamber temperature drop—
if the primary chamber temperature is falling towards the lower
temperature limit, this may indicate that the incinerator is low on
waste and it is time to recharge. However, if low heat content/high
moisture waste is being charged, a drop in temperature may mean too
much waste has been charged. The primary chamber burner should cycle
on when the lower temperature limit is reached.
• Primary or secondary chamber temperature increase—if the primary
chamber temperature is rising towards or exceeds the upper temperature
limit, additional charges should be delayed.
OBSERVING THE WASTE BED
If view ports in the primary chamber are available, you can observe the
waste bed. If the pile of unburned waste (in excess of the ash) inside the
chamber is steadily increasing in size, then the amount charged is greater
than the amount which can be consumed in the same period of time. The charge
rate should be reduced. On the other hand, if all the waste is consumed well
in advance of the next charge, it may be desirable to increase the charge
rate. If view ports are not available, the bed depth can be observed when the
charging door is opened. If most of the previous charge is still unburned, do
not recharge.
OBSERVING ASH QUALITY
If all the combustible waste is not burned and recognizable pieces of
waste are foiind in the ash, it may be because the charge rate is too high and
not enough time has been provided for complete combustion. You can evaluate
ash quality by simply looking at the ash and determining whether complete or
6-42
-------
near complete combustion has occurred. If recognizable pieces of combustible
waste—such as magazines, plastic tubing, pieces of scrub gowns—are seen in
the ash, the ash quality is poor. You should expect to see recognizable
noncombustible objects such as bottles and cans.
Another way to visually evaluate ash quality is by the color of the
ash. If the ash is black, it probably contains a lot of unburned carbon. Ash
that is light gray or white, indicates better burnout.
OBSERVING THE STACK EMISSIONS
When black smoke is emitted from the stack after charging, the amount
charged probably was too much. The incinerator does not have the capacity to
combust all the volatiles released. This situation may be correctable by
increasing the secondary combustion air. If increasing the secondary
combustion air does not alleviate the problem, the size of the charge should
be decreased.
SUKfWRY OF CONTROL AND MONITORING TECHNIQUES FOR MULTIPLE-CHAMBER INCINERATORS
The primary control parameter
for a multiple-chamber incinerator
is the charging rate. Since both
the primary and secondary chambers
operate with excess air, the
combustion rate in the primary
chamber cannot be strictly
Controlled. Consequently, proper agHAur OF MHITOKINS urn CONTROL
charging of the incinerator is
essential. The operator uses qrw«™»<*»™»,*:
combustion chamber temperatures to • GUM. ..a
monitor incinerator operation. The
charging rate (heat input) must be
consistent with incinerator
capacity. The primary chamber
auxiliary burner typically will be
set to cycle on when insufficient
heat input is provided by the
waste. Adjustments to the air
dampers also may be required to
maintain the proper draft and
combustion air levels; damper
control 1s often automatically
controlled by a mechanized system.
For pathological waste incinerators, the primary control variable is the
heat input rate from the primary chamber burner(s). Since the heat content of
the waste is insufficient to sustain combustion, the auxiliary burners operate
continuously, and the combustion air levels required remain essentially
constant.
6-43
-------
SLIDE 6-41
HASTE CHARSIN6 PROCEDURES
• ADJUST CHARGE VOLUHE *NO FIEOUEHCT TO iccounr FOR »»STE
VARIATIONS
• Mo*f FREOUEJIT SMLLEX CHARCES ARE IETTER THAU ONE LARGE
CHARGE
• DO HOT 'STUFF' INCUERATOR
• ASSURE PRIHART IUIMU is OFF mo* ro CHARGIHG
• GUTLT PUSH OLD HASTE TO SACK OF HEARTH: CHARGE DEI
•ASTE >T FROHT OF HEARTH
PROPER WASTE CHARGING PROCEDURES
Most multiple-chamber
incinerators used for hospital
wastes are designed for intermittent
duty operation. Typically, the
waste is charged by hand to the
incinerator through the open
charging door or by a mechanical
charging system such a hopper/ram.
Remember that the heat input
rate to an incinerator is a very
important parameter because the
incinerator is designed for a
specific heat input rate. The heat
input from the waste is determined
by the amount of waste and the heat
content of that waste. Because the
heat content of red bag waste and
pathological waste is so different,
operation of an incinerator when
burning these two types of wastes is
different.
Proper charging procedures for both red bag and pathological wastes charging
procedures are discussed:
Red Bag Waste. The heat content of red bag waste is variable, depending
upon the contents of the bag. Proper operation dictates that:
• Sufficient waste should be charged to the incinerator to sustain the
desired temperature without excessive use of the primary burner; and
• To maintain the incinerator chamber below the upper temperature limit
and to prevent emissions, the charge rate should not exceed the
capacity of the incinerator at any time.
6-44
-------
Therefore, recommended charging
procedures include:
• Use of frequent, small
batches rather than one
large batch. The objective
Is to avoid causing a rapid
release of volatile
compounds that exceeds the
combustion capacity of the
incinerator. The frequency
and size of each charge will
be determined by the
incinerator you have and the
type of waste. A recom-
mended procedure is to
charge about 10 percent of
the rated capacity (Ib/h)
every 15 minutes.
• Keeping a fairly consistent
waste bed in the
incinerator. The
incinerator should not be
jammed full, nor should it
be empty.
Improper Waste Charging
• This slide shows improper
charge procedures. Avoiding
"stuffing and burning" in
the incinerator; that is, do
not fill the incinerator
chamber to full capacity,
floor to celling, ignite the
waste, and allow the
incinerator to operate
unattended.
Sun 6-42
SLIM 6-43
•Stuff and Bum*
6-45
-------
Proper Recharging
• This slide indicates proper
procedures for recharging
the incinerator. When
recharging the incinerator:
— Make sure the primary
burner is turned off.
— The waste bed should be
stoked, if necessary,
and partially burned
waste from the previous
charges should be pushed
towards the back of the
hearth. The new waste
charge should be fed to
the front end of the
hearth (near the charge
door). This procedure
allows good exposure of
the partially combusted
waste to the overfire
air and allows a good
flame from the waste bed
to be maintained.
Improper Waste Charging. If
cold, new waste is thrown on top of
the existing waste bed, it partially
smothers the burning bed which can
result in increased emissions.
Stint 6-«s
Ash Bed Stoked To Rear
Load To Front
P«OP« L04DINC ON HEARTH
SLIM 6-45
Partially Burned
Ash Smotnerea
Inrnrvt UUOIM on HCMTM
6-46
-------
PATHOLOGICAL WASTE
Pathological waste has a low
heat content, high moisture content,
and contains a low percentage of
volatiles. The waste must be
exposed to the auxiliary burners to
be combusted. The following
charging procedures are recommended.
SLID* 6-«6
P«TH0106ICAL HASTES
ClUIKt MSTI TO HE1KTH IK * SHALLOK LITER
—Ofl HOT PILE
—£l«W« TO FtAM£
Turn OFF minion lumm IIFOKI CHARGING
• The waste should be placed
on the hearth in an even
layer that provides maximum
exposure to the burner(s)
flame(s). The waste should
not be deeply piled.
• Recharging the incinerator
should not be done until
considerable reduction in
volume (greater than
75 percent) of the previous
charge has occurred.
• When recharging the incinerator:
— Turn off the primary burner(s)
— Place the fresh charge in a layer on top of the ash bed to provide
maximum exposure to the burner flame(s).
~ Close the charge door before restarting the primary burner(s)
PROPER ASH HANDLING PROCEDURES
Ash is manually removed by the
operator at the end of each incin-
eration cycle. Proper ash handling
procedures for multiple-chamber SUMB-V
incinerators are essentially the
same as for batch and intermittent-
duty, control!ed-air incinerators.
The following are guidelines for
good operating procedures for
manually removing ash from the
incinerator:
PROPER ASH HAMLIM6
1. Allow the incinerator to
cool sufficiently so that it is safe
for the operator to remove the
ash. This cooling can take as long
as 8 hours or more.
2. Do not spray the ash and
combustion chamber with water to
cool the chamber because this can
damage the refractory.
ALUM HKINUUTO* ro COOL
Do MT sn*r HATCH i«ro COHUSTIOR CHANIER
Usi FUT/ILJMT TOOL fan ASH RCMOVAI
fUCl ASM in HITAL CMTAINIR
DMFU ASH TO raivuT FUGITIVE OUST
Pwrravr DISPOSE or ASM
Inner ASM QUALITY: HAM CO««CTIOK m OPCMTIOM. if
•CCIIIAIT
6-47
-------
3. Use a flat blunt shovel or raking tool, not sharp objects that can
damage the refractory, for removing the ash. You should exercise extreme
caution since the refractory may still be hot and the ash may contain local
hot spots, as well as sharp objects.
4. Avoid bumping or knocking of burner nozzle assemblies or thermocouple
housings.
5. Place the ash into a noncombustible container such as a metal
container, not cardboard.
• 6. Dampen the ash with water to cool the ash and minimize fugitive
(windblown) emissions.
7. Store the ash in a safe manner until final disposal. Cover the ash
container to prevent windblown dust.
8. Discard the ash according to approved procedures (according to your
permit).
STARTUP AND SHUTDOWN PROCEDURES
Startup and shutdown of the
incinerator requires some special
steps to be taken to minimize SLIDERS
emissions. Specific manufacturer's
instructions should be consulted.
The following are recommended
procedures for good operating
practice.
STARTUP «m
PREHEAT SECONDARY OUMICR IEFORC IHITIATIHC OURGING
CHARGE »ASTE
IMITE WASTE
- SHUT ootrn IURNERS
• ALLOV mciHCR«TOR TO COOL
• REMOVE «SH
Startup
1. Inspect the ash from the
previous cycle. Is ash quality
acceptable? If not, adjustments to
operating procedures will be
required. Remove the ash from the
previous incineration cycle.
2. Preheat the secondary
combustion chamber to the minimum
recommended temperature (e.g.,
1800°F).
3. Charge the incinerator with the first charge.
4. Close the door.
5. Ignite the waste using the primary burner.
Shutdown
1. After the waste in the last charge has burned down, the primary
chamber temperature will be maintained by the auxiliary burner at the preset
minimum combustion chamber temperature. This is called the burndown period.
2. The burndown period is continued for a predetermined length of time
or until visual inspection indicates that burnout of the waste bed is
sufficient. When the burndown period is completed, the primary and secondary
burners are shut down.
6-48
-------
DO'S AND DON'TS FOR OPERATING A MULTIPLE-CHAMBER INCINERATOR
DO:
DON'T:
SLIDE 6-49
Preheat the secondary
chamber prior to startup
Pay careful attention to
charging procedures and
rates
Shut off the primary burner
when charging
Monitor combustion chamber
temperatures and learn to
recognize trends that
indicate proper operation
and trends that indicate
problems
Monitor combustion chamber
draft and maintain draft
within the proper operating
range
Routinely monitor stack gas
opacity, especially after
charging — should not have
black smoke
Inspect the ash. Does visual inspection indicate poor burnout—are
pieces of uncombusted waste present? If ash quality is poor, make
changes to operating procedures/conditions; properly and carefully
dispose of the ash
For pathological wastes, operate the primary burner at all times
PKCHEAT THI SCCONDART CH/UUJK
PIT CMIFUL ATTCNTION TO CHMCINC MOCEDURtS 1«D MTES
SHUT OM PRIMARY luRNfR KHIH CHMCIHS
HOIITM CONIUSTIOR CH/MIIR TCIIPERATURES
MONITOR COMWSTION CHUMR OR»FT
NtWtrOR STICK GAS OMCITY—CS'CCliLLr 1FTEH CH»«OIMG
IKSPCCT ASM QUALITY
FOR PITMOLOCIDIL MSTtS. OPCRITt PHImKT |u«HM AT ILL
riNis
Overcharge the incinerator
Deeply pile pathological
waste on ttte hearth
SLIOI 5-50
• OvtROURCt THI IKCHKRITOR
• DHPLT PILI MTHOLOSICAL MSTI on m HCIRTH
6-49
-------
HANDOUTS;
Appendix B contains two worksheets to be completed by the students as
review for this session. The worksheets are:
Worksheet No. 3—"Incinerator System Operation—Operating Parameters"
Worksheet No. 4—"Operating Review"
These worksheets are for the student's use and do not need to be turned into
the instructor. They should be used as a basis for stimulating discussion and
questions.
6-50
-------
REFERENCES FOR SESSION 6
1. McRee, R. Operation and Maintenance of Controlled-Air Incinerators.
Ecolaire Environmental Control Products. Undated.
2. Ontario Ministry of the Environment. Incinerator Design and Operating
Criteria, Volume II - Biomedical Waste Incinerators. October 1986.
3. U. S. Environmental Protection Agency Office of Solid Waste. EPA Guide
for Infectious Waste Management, EPA/530-SW-86-014 (NTIS PB 86-199130).
May 1986.
4. Letter from Ken Wright, John Zink Company, to J. Eddinger, U. S. EPA.
January 25, 1989.
5. Personal conversation between R. Neultcht, Midwest Research Institute,
and J. Kidd, Cleaver-Brooks. February 22, 1989.
6. Personal conversation with representatives of the National Solid Waste
Management Association. December 15, 1988.
7. U. S. Environmental Protection Agency. Municipal Waste Combustion
Study: Combustion Control of Organic Emissions, EPA/530-SW-87-021C.
(NTIS PB87-206090). June 1987.
8. Ecolaire Combustion Products, Inc. Technical-Paper: Controlled Air
Incineration. Undated.
9. Siraonds Incinerators. Operation and Maintenance Manual for Models
7518, 1121B, and 2151B. January 1985.
10. Ecolaire Combustion Products, Inc. Equipment Operating Manual for
Model No. 480E.
11. John Zink Company. Standard Instruction Manual: John Zink/Comtro
A-22G General Incinerator and One-Half Cubic Yard Loader.
12. Brunner, C. Incineration Systems Selection and Design. Van Nostrand
Reinhold. 1984.
13. Personal conversation between Roy Neulicht, Midwest Research
Institute and Larry Doucet, Doucet and Mainka Consulting Engineers.
November 29, 1989.
14. Doucet, L. C. Controlled-Air Incineration: Design, Procurement, and
Operational Considerations. American Hospital Association Technical
Series, Document No. 055872. January 1986.
15. Air Pollution Control District of Los Angeles County. Air Pollution
Engineering Manual, AP-40. (NTIS PB 225132). U. S. Environmental
Protection Agency. May 1973.
6-51
-------
16. American Society for Testing and Materials. ASTM Standard
D1709-75. Philadelphia, Pennsylvania. 1975.
17. Consumat Systems, Inc. Technical Data Publication for Waste Handling
System. Undated.
18. Ecolaire Combustion Products, Inc. Equipment Operating Manual for
Model No. 2000TES.
19. Personal conversation between Roy Neulicht, Midwest Research
Institute, and Steve Shuler, Ecolaire Combustion Products.
20. Ashworth, R. Batch Incinerators—Count Them In. Technical paper
prepared for the National Symposium of Infectious Wastes.
Washington, D.C. May 1988.
21. Cleaver Brooks®. Operation and Maintenance Parts Manual Publication;
Publication CBK-6826. September 1988.
22. U. S. Environmental Protection Agency. Workbook for Operators of
Small Boilers and Incinerators. EPA-450/9-76-001. March 1976.
23. Ecalaire Combustion Products. Product Brochure: Incineration
Systems for Institutional, Industrial, and Municipal Installations.
1986.
6-52
-------
LESSON PLAN
COURSE: HOSPITAL INCINERATOR OPERATOR TRAINING
COURSE
SESSION TITLE: AIR POLLUTION CONTROL SYSTEMS OPERATION
SESSION NO: 7
SESSION TIME: 60 MINUTES
GOAL
To familiarize students with:
• The key operating parameters and how to monitor those parameters for
the various types of air pollution control systems (ARCS) on hospital
incinerators.
• Special operating considerations for ARCS startup and shutdown.
OBJECTIVES
At the end of this session, each student should be able to:
1. Identify the key operational parameters for his/her ARCS;
2. Describe the operational ranges considered acceptable for these
parameters;
3. Describe how to monitor the key parameters; and
4. Name the steps to take to ensure proper operation of the ARCS during
startup and shutdown.
SUPPORT MATERIALS AND EQUIPMENT;
Slide set for Session 7; slide projector
SPECIAL INSTRUCTIONS;
None
HANDOUTS
None
7-1
-------
Slide No. Title
T. Title
1 A1r Pollution Control Systems for Hospital Incinerators
2 Recommended Operating Ranges for Key Parameters—Venturi
Scrubbers
3 Venturi Scrubber Parameters Usually Monitored by Operator
4- Venturi Scrubber Operation
5 Venturi Scrubbr Startup Sequence
6 Venturi Scrubber Shutdown Sequence
7 Recommended Operating Ranges for Key Parameters~Packed-Bed
Scrubber
8 Packed-Bed Scrubber Parameters Usually Monitored by Operator
9 Packed-Bed Scrubber Operation
10 Recommended Operating Ranges-for Key Parameters—Spray Towers
11 Recommended Operating Ranges for Key Parameters—Pulse-Jet
Fabric Filter
12 Fabric Filter Parameters Usually Monitored by Operator
13 Fabric Filter Operation
14 Fabric Filter Startup
15 Fabric Filter Shutdown
16 Recommended Operating Ranges for Key Parameters—Dry Injection
17 Recommended Operating Ranges for Key Parameters—Spray Dryers
18 Spray Dryer Operation
19 Spray Dryer Startup/Shutdown
20. Recommend Operating Ranges for Key Parameters—ESP' s
21 ESP Operation
22 ESP Startup/Shutdown
7-2
-------
INTRODUCTION
During this session we will
discuss:
SESSION 7.
• The key operating parameters
• Monitoring these parameters, AIR pouu™ cwraL SYSTDB oreRflTION
and
• Startup and shutdown of ARCS
APCS FOR HOSPITAL INCINERATORS su« ;-i
AIR POU-imoN anna. SYSTEMS FOR HOSPITAL INCINERATORS
The APCS we will discuss
•
_ SM.r
SCB
""""*'
• _ -1,.j_. • YtT SCWIIUS
include:
• Wet scrubbers
— Venturi scrubber • F'""e FILTERS
— Packed-bed scrubber . o»r ^UHm
Cnrav towers ~ °" "(JECTia"
ifjray uuwer s _ SnMT MyERS
• Fabric filters
• Dry scrubbers ' &-£CTmmtc "«
— Dry injection
— Spray dryer
• Electrostatic precipitators
WET SCRUBBERS - GENERAL
SCRUBBER OPERATION
Many of the key operating parameters, monitoring methods, and operation
techniques are the same for both venturi and packed-bed scrubbers. Because of
their greater complexity, venturi scrubbers will be addressed first in the
following discussion. The discussion of packed-bed scrubbers will focus only
on those items that differ from venturi scrubbers. Spray towers are
relatively simple to operate, requiring only that a proper liquid flow rate be
maintained. Spray towers will not be discussed separately.
7-3
-------
YENTURI SCRUBBERS
RECOWENDED OPERATING RANGES FOR KEY PARAMETERS
The key operating parameters
that are necessary for effective
operation of a venturi scrubber are
1-1
REOWENDED UPSWING RAHGES FOR KEY PARMIETCRS
VENTURI SCRUBBER
• PRESSURC UUCP
• LIQUID surpt.r
20-50 m. '.c.
7-10 GAL/L.000 'CF
5.5-7.0
0-3 FtUCWT
• Energy as measured by
pressure drop (&P)
• Liquid supply; and
• Suspended solids in the
scrubbing water.
• Proper operation of a
venturi scrubber requires
that scrubber AP, water
supply, and solids content
be maintained within
acceptable ranges as
specified by the
manufacturer or by the air
agency permit specifica-
tions.
• Recommended ranges of the parameters are:
— Pressure drop range is 20 to 30 in. w.c. (5.0 to 7.5 kPa)
The pressure drop you maintain will be based upon the performance
desired. Typically, once performance is established at a particular AP,
(e.g., 25 in.), the permitting agency will require that this minimum AP always
be maintained. A higher AP is acceptable because a higher AP generally
improves efficiency.
— Liquid supply is 7 to 10 gallons per thousand actual cubic feet
(gal/1,000 acf) (0.9 to 1.3 liters per actual cubic meter [1/m )]
This will be based upon manufacturer's recommendation
— Solids content is 0 to 3 percent
As solids build-up in the water, then any droplets that get past the mist
eliminator will contain these solids and will result in increased particulate
emissions. Therefore, it is necessary to keep solids content low.
7-4
-------
MONITORING OF KEY PARAMETERS
To ensure proper operation of a
venturi scrubber, the operator must
monitor the key operating
parameters.
7-3
vanmi SCRUBBER PARAMETERS USUALLY
MONITORED BY OPERATOR
• PWSSUM onor
LIQUID FLOW »»TE
ft*
— Snnc PMSSUM
•— RPM
— AMMIMCE
• Scrubber parameters which
can be monitored by the
operator include:
— Venturi pressure drop
— Liquid flow rate
— Fan static pressure,
rpm, or amperage
• Pressure drop can usually be
monitored directly from
installed gauges or
manometers.
• The liquid supply also is usually indicated by installed gauges. The
gas flow rate can be estimated from fan specifications, which relate
gas flow rate to either fan static pressure, rpm, or amperage. At
least one of these fan parameters is usually readily available from
manufacturer installed gauges and should be monitored.
• Suspended solids content is not easily measured on a routine basis
(e.g., dally). Acceptable levels are usually obtained by maintaining
adequate scrubbing liquid makeup water and blowdown rates. "Adequate
rates" can be determined by measuring the suspended solids during an
initial performance test. One method of estimating suspended solids
is by monitoring the conductance of the scrubber water. As salts
begin to concentrate in the water, the conductance increases.
Conductance can be measured using a conductance meter.
VENTURI SCRUBBER OPERATION
Proper operation of the
scrubber also requires that the
operator be able to correct problems
when the key operating parameters
fall outside acceptable ranges.
SUD»
SCRUBBER OPERATION
Pressure drop across the
venturi throat can be
increased or decreased by
adjusting the throat
constriction on a variable-
throat venturi scrubber or
by adjusting the fan damper
(fan speed if variable rpm
fan) to charge the airflow
rate through the system.
Ill P»»IUI€Tt»
PftfSSQM MOP
LIMIO SUPPLY
SuSPUOU SOLIDS
pH
V«»t»ILI THROAT
F«» DMPH
Fim SPUD
LIQUID FLO* MTC
N»«ur »«TC«
BlOVOOVN
N»IUP CAUSTIC
7-5
-------
• Liquid flowrate is increased or decreased by adjusting a flow control
valve for the liquid supply.
• If suspended"solids cause solids buildup problems, the makeup water
and blowdown rates should be increased.
VEMTURI SCRUBBER STARTUP
Manufacturer's specifications
should be followed for startup of
the APC equipment. The following
are some general guidelines for the
procedures typically followed.
Startup of a venturi scrubber
requires adherence to the following
in-sequence steps:
June 7-5
VEMTURI SCRUBBED STARTUP SEQUENCE
1. Tan a* uouio SUPPLT mo RECIRCUUTIO"
2. StT LIQUID FLO« TO »«NUP»CTU«tR SPECIFICATIONS
3. CLOSI FIN OJMPER
_1. Sr«r F4«
5. GMmuLLr OPEN DUMPER
6. ADJUST LIQUID FLU* ro oir*m DESIRED LIQUID SUPPU
7. ADJUST vtHTuti ™«»
Preheat the incinerator
venting the combustion gas
through the stack bypass
system. Prior to charging
waste;
Turn on the liquid
recirculation system and
liquid flow to the venturi
throat and the mist
eliminator;
Adjust the liquid flow rates to those specified by the manufacturer;
If the fan is equipped with a damper, close the damper;
Start the fan;
Gradually open the damper until the proper gas flow rate is
established;
Recheck the liquid flow rate, compare with the gas flow rate, and
adjust as necessary to obtain the proper liquid supply;
Check the scrubber pressure drop and adjust the fan energy or fan
damper as necessary to obtain the desired pressure drop; and
Initiate the liquid blowdown to treatment or disposal, as specified by
the manufacturer.
7-6
-------
Suoi 7-6
VENTURI SCRUBBER SHUTDOWN
To shut a venturi scrubber
system down, the following
procedures should be adhered to in
sequence after shutdown of the
incinerator:
• Shut off the scrubber fan;
• Wait until the fan impeller
has stopped turning and shut
off the scrubber water
recirculation pump; and
• Shut off the makeup water
supply system.
PACKED-BED SCRUBBER
RECDMODED OPERATING RANGES FOR KEY PARAMETERS
The key operating parameters
for a packed-bed scrubber
are liquid supply, pH,
suspended solids content,
and inlet gas temperature.
Packed-bed units do not have
high pressure drop
requirements to enhance
scrubbing; instead, they
rely on high liquid supply
rates and increased surface
area for absorption.
The recommended range for
liquid supply is 10 to
15 gal /I, 000 acf (1.3 to
2.0 i/m ). The actual flow
rate is based upon manufac-
turer's recommendation for
the particular installation.
VCTTURI SCRUBBER SHlfTDCTH SEQUENCE
1. SMUT OFF SCXUIIM FAN
2. SHUT OFF ncctftcuunox
3. SHUT OFF M««EUP HITCH
SLIOI 7-7
PuiKlUTEH
LIQUID SUPPLY
SUSMNOCO SOLIDS
INLIT s«s
OPERATING RANGES FOR (Ft PAMHETBS
PACKED-BED SCRUBBER
15-25
5.5-7.0
0-J P6RCEKT
SPECIFIED sv X>MJF»CTU«ER
1-5 m. ».c.
Since packed beds are primarily used for acid gas removal, it is
assumed that a significant amount of acid gases will be absorbed in
the scrubber water which will, if not adjusted, increase the scrubber
water pH; therefore, pH maintenance is important. The recommended pH
range is 5.5 to 7.0.
High suspended solids levels can cause pluggage problems. The
recommended range for suspended solids is 0 to 3 percent.
High inlet gas temperature can damage plastic packing media.
Acceptable inlet gas temperatures are dependent on the packing media
and should be specified by the manufacturer.
7-7
-------
MONITORING OF KEY PARAMETERS
Monitoring of liquid supply,
suspended solids, and gas flowrate
for packed-bed scrubbers are the
same as previously discussed for
venturi scrubbers.
• Liquid feed pH usually can
be monitored directly from a
manufacturer-installed pH
meter located in the supply
line or the scrubber liquid
sump tank.
• A thermocouple usually is
provided to monitor the gas
inlet temperature.
:..OE 7-8
SCRUBBER PARAMETERS USUALLY
MONITORED BY OPERATOR
• LIQUID FLO* RATE
• PRESSURE DROP
• INLET GAS TEMPERATURE
• PH
• FAN
— STATIC PRESSURE
— RP*
— UNPERAtE
PACKED-BED SCRUBBER OPERATION
Operation of packed-bed
scrubbers with respect to liquid
supply and suspended solids is the
same as that for venturi scrubbers.
SLIDE 7-9
PAdED-flED SCRUBBER OPERATION
KEY PARAMETER
LIQUID SUPPLY
PH
SUSPENDED SOLIDS
INLET US TEMPERATURE
The liquid feed pH can be
increased or decreased by
adjusting the alkaline
sorbent material feed rate
to the scrubber water.
Automatic systems often are
used for this purpose.
Gas inlet temperatures can
be controlled by:
— Controlling the flue gas
exhaust temperatures
from the incinerator/
boiler
— Use of a prequench (water sprays) to cool the gases,
or
— By adjusting an ambient air damper upstream of the
scrubber to allow dilution air into the system to
cool the gases.
ADJUSTMENT
LIQUID PLOV RATE
CAUSTIC PEED RATE
MAKEUP WTER
8i.oiioom
INCINERATOR EXHAUST TEMPERATURE
PREOUCNCH
7-8
-------
PACKED-BED SCRUBBER STARTUP AND SHUTDOWN
Startup and shutdown procedures for packed-bed scrubbers
are the same as those indicated above for venturi scrubbers.
SPRAY TOWERS
RECOMMENDED OPERATING RANGES
The two key parameters of
interest for spray towers are:
• Liquid/gas ratio—5 to 20
gal/I,000 acf
• Pressure drop—1-3 in. w.c.
If scrubber water is
recirculated the pH also will need
to be monitored and controlled.
SLIDI 7-10
HEQMODB) OPERATING RANEES FOR KEY PARAMETERS
SPRAT TOKER
• LIQUID supptr 5 TO 20 UL/1.000 «CF
• PKESSUM DROP 1 ro 5 m. «.c.
FABRIC FILTERS
RECOMMENDED OPERATING RANGES FOR KEY
PARAMETERS
• The key operating parameters
for pulse-jet fabric filters
are:
— The maximum and minimum
flue gas temperatures
~ The pressure drop
through the unit, and,
— The cleaning air
pressure.
• Proper operation of a pulse-
jet fabric filter requires
that flue gas temperatures
do not get high enough to
damage the bags or low
enough to allow condensation
of moisture or add gases to
blind or corrode the bags.
SUM 7-11
RCCBBUBED OPERHTIM6 RAMSES FOR
-------
• The maximum flue gas temperature is dependent on the bag material and
should be specified by the manufacturer.
• The minimum gas temperature is dependent on the moisture content and
acid gas content of the gas stream and should be maintained above the
dewpoints of both. In practice, the fabric filter vendor or hospital
engineer should specify a minimum flue gas temperature.
• The bags should be cleaned on a frequency that will prevent excessive
pressure drops that could result in ruptured bags and excessive fan
energy costs. Too low a pressure drop can be an indication of leaking
bags. The recommended pressure drop range for a pulse-jet fabric
filter is 5 to 9 in. w.c. (1.2 to 2.2 kPa).
• The cleaning air pressure should be high enough to ensure a shock wave
in the bag sufficient to dislodge -the filter cake. The recommended
range for the cleaning air pressure is 60 to 100 psig (410 to
690 kPa).
MONITORING OF KEY PARAMETERS
To ensure proper operation of a \iU7.i2
fabric filter, the operator should
anfii«.a *U=+ , 11 K-,,.,. ,«.- ,'_4._.J. FAMIC FILTER PARAHETBg USUALLY
ensure that all bags are intact, —WTOEDBYo
without holes or tears, and that the
bags are cleaned on an appropriate . o«m
frequency with adequate cleaning air . f9tauntmr
pressure. The integrity of the bags
should be checked by a visual ' '"UT "s r
inspection when the system is off- • °«"-«=«
line for routine maintenance.
• Parameters that can be
monitored to maintain
optimum fabric filter
performance are:
— Opacity
— Pressure drop
— Inlet gas temperature
• Opacity readings are taken at the stack by a trained observer or from
an opacity monitor. Visible emissions of greater than 5 percent
opacity may indicate holes in the bags or too frequent cleaning. If
high opacities are observed, the bags should be inspected visually by
maintenance personnel.
• A manometer or pressure gauge is usually provided by the manufacturer
for measuring pressure drop. Excessively high pressure drop can
indicate
— Inadequate cleaning
— Bag blinding
— Excessive gas volume
• Fabric filters on hospital incinerators should be equipped with
continuous stripchart temperature recorders and high temperature
alarms. The stripchart recorder will indicate .whether potential bag
damage may have occurred due to high temperature. The aVarm should be
set lower than the critical bag damage temperature to allow for
7-10
-------
preventive actions. The alarm temperature setting depends on the type
of bag fabric used. These same devices can be used to monitor against
excessively low temperature which will result in condensation problems
causing bag blinding or acid gas damage.
FABRIC FILTER OPERATION
Under normal conditions, the
operator only has to monitor the key
parameters and ensure that the
airflow rate through the fabric SUM 7-13
filter is sufficient to maintain
negative draft in the combustion.
chamber of the incinerator. tlT ,.,„„., AojuST,E[.r
• If the flue gas temperature *" "s rE""""u":
approaches the damage point, UW.HHIT 3»«ss»MicMUTER
, J T , , U»C* IHCINERiroit (BOILER)
emergency procedures snould -XH.UST-O.««TU«
be taken to reduce the ;"r"OOUCE ccm- '""ENT ""
temperature byi LW«» U«IT ;ncRe«st »uxiu«» «JEL
~ Bypassing the fabric run**** BM own* maura
filter
~ Dropping the incinerator fr«««•«»•« c^«SH...,,„«,
temperature by
increasing combustion
gas air flow in the
secondary chamber or
reducing auxiliary fuel
rates
— Introducing cooling ambient air
— Or increase prequench water flow or increase spray dryer slurry
flowrate or water content of spray dryer slurry
• If the dewpoint temperature is approached, the incinerator secondary
chamber burner firing rates should be increased to raise the inlet
temperature
• If the pressure drop is too high, the bag cleaning frequency should be
increased
• If the cleaning air pressure is too low, adjust the pressure gauge on
the compressed air system
7-11
-------
FABRIC FILTER STARTUP
Follow specific manufacturer's
recommendations, the following
provides some general guidelines.
• Precautions should be taken
during initial startup of a
new fabric filter or after
bag replacement to prevent
abrasion damage to the new fa*K F"J"
bags before a protective
coating of dust has '
formed* ' U*i «IIH.I««T FUEL-MHIM ro sums STSTEN TO OPCMTING
• New bag abrasion can be .TOP*.™,
prevented bye * 5**°i"iu-T IUH.DW OUST C»E
— Precoating the bags
— Operation of the
incinerator at reduced
throughput of waste
charge material to allow
the gradual buildup of
the dust cake
• Condensation of moisture and acid gases should be prevented at all
startups to prevent acid attack and bag "blinding."
• Condensation of acid gases and moisture in a cold fabric filter can be
prevented by operating the incinerator on auxiliary fuel prior to
charging with waste until the fabric filter is heated up.
FABRIC FILTER SHUTDOWN
The top priority during
shutdown of a fabric filter is to
avoid dewpoint conditions which will
result in condensation.
• The incinerator secondary su»«7-is
chamber burner should be FABm. F|tTg
left on for a few minutes
after waste combustion is . SW.«T. c««,«8
completed to remove moisture
from the fabric filter. ' """"*' «""»» •»•"««"«»«
After the secondary chamber
burner is shuts down,
ambient air should be drawn ' *"" "•""'"" »"•«"«"
through the system to purge • CLU. •»«
remaining combustion
products.
7-12
-------
• After combustion products are purged, the fabric filter should be
allowed to go through 5 to 20 minutes of bag cleaning to remove the
filter cake that could cause blinding if condensation occurs later in
the unit after shutdown.
DRY SCRUBBERS - GENERAL
DRY SCRUBBER OPERATION
The basic operating principle for both spray dryers and dry injection is
to mix an adequate supply of alkaline sorbent with the flue gas and allow
sufficient contact time for the reaction to occur.
DRY INJECTION
RECOMMENDED OPERATING RANGES FOR KEY PARAMETERS
- The key operating parameters
for a dry injection system
are the sorbent injection
rate and the particle size
of the sorbent. SL1.iWS
• The particle size and
injection rate Of the "OTHBBED drawn*; WHBB RE KEY PAMMETERS
sorbent should be specified
by the manufacturer.
• The sorbent injection rate EiB2EH
should provide adequate • SOH«»T micnm «•« S«CIFUD IT «.N
sorbent for neutral izat ion . So.im fmtCLf SIZE 90 raem ,y <€IGHT
of the acid gases and is ns MSH sc««
dependent on the acid gas
content of the flue gas.
• As particle size decreases,
the surface area to volume
ratio increases which
improves the efficiency of
add gas collection.
• Generally the sorbent feed will have a particle size where 90 percent
by weight will pass through a 325 mesh screen. This dust is
approximately the consistency of talcum powder.
MONITORING OF KEY PARAMETERS
The primary monitored parameter is the sorbent feed rate.
• The sorbent feed rate can be determined directly from manufacturer
installed gauges.
• Pro'per particle sizes for the sorbent are specified at purchase and
are maintained by transporting and fluidizing the sorbent through a
positive pressure pneumatic conveyor. The air flow rate in the
pneumatic line is set at a constant level and is not varied with the
load.
7-13
-------
• Add gas outlet concentration may also be monitored; however,
currently, HC1 monitoring systems are first becoming commercially
available arid there has not been alot of operating experiences with
these.
DRY INJECTION OPERATION
Operation of a dry injection system is relatively simple.
• Maintain the pneumatic transfer line at a constant airf.low rate.
DRY INJECTION STARTUP
There are no special startup considerations for dry injection. At
startup of the incinerator, the dry sorbent can be injected without any
special preparations.
DRY INJECTION SHUTDOWN
The only special concern for shutdown of a dry injection system relates
to the particulate control device used in conjunction with the dry injection
system, e.g., the fabric filter or ESP- If a fabric filter is used, the same
precautions previously discussed apply.
SPRAY DRYERS
RECOhfODED OPERATING RANGES FOR KEY PARAMETERS
• The key operating parameters
that are necessary for
effective operation of a SLIM 7-17
Spray dryer are. Mommai ofEmnm MHSB FOR KEY
— Sorbent feed rate
— The slurry sorbent
content, and ?••*&**
— The outlet gas wet and . SU««T so.™* «•««•
dry bulb temperatures.
___ .•• ,~ - • K«r lULi/oirr iuu rEXPM.rgiie 90* TO 180'F
• Effective operation of a ,,r,f,lKl
spray dryer requires
adequate sorbent for
reacting with the acid gases
and prevention of solids
buildup. Solids buildup can
occur if slurry moisture is
not evaporated within the
design time period.
• The liquid slurry feed rate and sorbent content should be balanced
with the hot flue gas volume and acid gas content to ensure the
desired removal of acid gases and evaporation of all moisture.
— The recommended range of slurry sorbent content is 5 to 20 percent
solids by weight.
• The wet bulb/dry bulb temperature readings give an indication of the
saturation of the gas stream and the potential for evaporation of
moisture.
7-14
-------
• A wet bulb/dry bulb outlet gas temperature difference of 90° to 180°F
(30° to 80°C) will ensure evaporation of all moisture. As the gas
stream approaches saturation, the wet bulb temperature approaches the
dry bulb temperature.
• The gas temperature leaving the spray dryer must be consistent with
the inlet gas operating range for the particulate control device which
follows the spray dryer. The gas temperature must be within the
operating range for a fabric filter.
MONITORING OF KEY PARAMETERS AND SPRAY DRYER OPERATION
• The sorbent content of the
slurry does not require
continuous monitoring. The
sorbent content is set at
the slurry. mix tank. The
outlet wet bulb and dry bulb
temperatures are indicated *.<«Ma
by manufacturer installed SPMT DRYER OPERATION
gauges.
• The feed rate of dry sorbent t
-------
SPRAY DRYER STARTUP/SHUTDOWN
Manufacturer's recommendations
should be followed. Some general
considerations are:
jwiOt 7-19
• Startup of a spray dryer SPMLBRTER
should follow procedures
that prevent condensation in *"""^"""":
the System and enSUre '• "" *ux"-"ulr FUEL-FIRI»« ro IRIW SYSTEM UP ro OPERATING
. . f , , , TEHPERATURE IEFORE INJECTIKS SLURRY
evaporation of all slurry
moictlirp in thp srrtlhhpr 2l GIUWMUY INCREASE SLURRY FEED AS EXHAUST TEMPERATURE
moisture in tne scruuoer ,«a.usu TO MAI«TAU «• TO IM-F «T .UU/ORY iuu
reaCtOr VeSSel. DIFFERENCE
~ One method of ensuring
evaporation is to use saisas*
auxiliary fUel firing tO I. ust AUXILIARY FUIL-*IRI»S TO MAUTAII TEMPERATURE »BOVE
bring the eXhaUSt gaS SATM.TIM U«TIL ALL .ASTE is COI.IUSTED
temperature up to the :. SHUT OFF SP«Y ORYER
normal operating range
before injecting the
slurry.
• Another method would be to gradually increase slurry feed at startup
to maintain a 90° to 180°F (30° to 80°C) wet bulb/dry bulb temperature
differential.
Proper shutdown should ensure that no liquid moisture remains or
condenses in the spray dryer or fabric filter after shutdown.
• Auxiliary fuel firing should be used to maintain temperatures above
saturation until all sorbent is purged from the system.
• To prevent bag blinding and reaction product salt corrosion, the
fabric filter should go through a complete cleaning cycle before
shutdown.
7-16
-------
ELECTROSTATIC PRECIPITATORS
RECOMMENDED OPERATING RANGES FOR KEY PARAMETERS
Proper operation of an ESP
requires that the gas temperature,
particulate resistivity, and power
input be maintained within
acceptable ranges as specified by
the manufacturer or by the air
agency permit specifications.
Recommended ranges for these
parameters are:
- ,0,7-20
»*** ™ tpr
I»UT
- xor siot ESP
— COLO SIDE £SP
P..T.WUT, «s,Smm
(>m<" ••"•
• Gas temperature range:
~ 572° tO 800°F (hOt-Side
ESP)
-- less than 400°F (cold-
side ESP)
• Particulate7resist]vity
range is 10 to 10 ohm-cm
• Power ratio of secondary
power, to the primary power
input should range from 0.5
to 0.9
— secondary power = secondary voltage x secondary amperage
— primary power = primary voltage x primary amperage
MONITORING OF KEY PARAMETERS AND ESP OPERATION
To ensure proper operation of
an ESP, the operator must monitor
the key parameters and make
adjustments as necessary to maintain
. . . , . . .
the parameters in the appropriate
s«sa
570- TO 800'F
<«00"F
10 TO 10 OHN-O.
3.5 TO 0.9
...
KIT MMKtTH
P»i««» vm.T«et/cu»imir
s«««w«/«n«r
ESP OPERATION
JOJUSTHEKT
G.a«/»ojujT ELtcrnooes
GM rowciuTun
COUITIOHIW «wr
C»,I«TIO«/C..«».
&»
I«CI«.W/IQII« OP«.T,O.
ESP parameters that can be
monitored by the operator
. 1 . J r
inC lUOe.
— gas inlet temperature
-- particulate resistivity
— primary voltage
— primary current
— secondary voltage
— secondary current
The gas inlet temperature can be measured using a thermocouple mounted
at the inlet to the ESP. A temperature readout such as a stripchart
recorder or LED display should be available. Temperatures should be
maintained above the dewpoints of both hydrochloric acid and
moisture. Temperatures that are too low allow moisture and acid to
condense causing sticky particulate that is difficult to collect and
7-17
-------
causing corrosion. Temperatures that are too high may cause damage to
the ESP and in hot-side ESP's may cause the gas density to be so low
that effective collection is difficult.
• Particulate resistivity is a measure of the resistance of the
collected dust layer to the flow of electrical current. A high
resistivity indicates that little electricity will flow. The
condition of high resistivity is indicated by increased sparkover or
by excessive current at greatly lowered voltages. Low resistivity
(i.e., high electricity flow) means that particles lose their charge
too quickly. Particles take longer to move to the collection plate,
the particles are not held strongly to the collection plate, and
particle reentrainment is a problem. Resistivity is measured using
high voltage conductivity cells - the accepted method is the point-
plane method.
• The transformer-rectifier (TR) powe'r equipment of most modern ESP's
are equipped with primary voltage and current meters on the low-
voltage (ac) side of the transformer and secondary voltage and current
meters on the high-voltage rectified (dc) side of the transformer.
Therefore, the input side is the primary side of the transformer. The
primary meters measure voltage and current in volts and amps,
respectively. The secondary meters measure voltage in kilovolts
(volts multiplied by 1,000) and current in milliamps (amps divided by
1,000). To get the power ratio: (1) multiply the primary voltage
reading by the primary current reading to get primary power,
(2) multiply the secondary voltage reading by the secondary current
reading to get the secondary power, and (3) divide the secondary power
by the primary power level to get the power ratio.
Under normal conditions, the operator need only monitor the key operating
parameters and ensure that the airflow rate through the ESP is sufficient to
maintain negative draft in the combustion chamber of the incinerator.
• If the dewpoint temperature is approached, the incinerator secondary
chamber burner firing rates should be increased to raise the inlet
temperature.
• If the flue gas temperature is too high, the temperature should be
reduced by:
— dropping the incinerator temperature
— introducing cooling ambient air.
• If the resistivity is too high (i.e., increased sparking and/or
excessive currents at greatly lowered voltages), it can be reduced by:
— introducing cooling ambient air to reduce the gas temperature
— adding moisture to the gas stream to both cool the gas and to
enhance the conductivity of the particulate in the gas stream.
• If the resistivity is too low (i.e., increased particle reentrai nment,
poor collection efficiency), it can be increased by:
— increasing the temperature of the gas by increasing the
incinerator secondary chamber burner firing rates
— checking operation of rappers
— investigating incinerator feed characteristics for high-sulfur
content or for excessive conditioning agents such as alkalis
7-18
-------
~ Improving incinerator combustion efficiency to reduce amount of
carbon in collected dust.
• If the primary voltage is too low, it can be corrected by:
~ removing excessive ash from electrodes
— checking power supply
— checking for improper rectifier and control operation
— checking for misaligned electrodes
-- checking for high resistivity.
ESP STARTUP/SHUTDOWN
Startup of an ESP is generally
a routine operation involving
heating a number of components such
as support insulators and hoppers
prior to incinerator operation. The
following steps should be taken to
startup the incinerator.
Prior to operation of the
incinerator:
Sum 7-22
S runup
ESP
MO?ft«/«SH HMOUM
"»EHUT HOFPUS
SET »»»»!» CYCLE
CHICK mrK* oM»Ano»
CHECK r/R SETTIHO
Scoiuruur CNEMIZE r/R ir BIELO
SHU remii
SHuraoim
OcniiKizi r/R ir mm
A»TI» < Houa ofEmmizc HUTEIK
*m» a HOUB SHuroon turnn
• Check hoppers
— level-indicating system
should be operational
— ash-handling system
operating and sequence
check - leave in
operational mode
— hopper heaters should be on
• Check rappers
— energize control, run rapid sequence, ensure that all rappers are
operational
— set cycle time and intensity adjustments, using installed
instrumentation - leave rappers operating
• Check TR sets
— test-energize all TR sets and check local control alarm functions
— set power levels and deenergize all TR controls
— lamp and function-test all local and remote alarms
After the incinerator has gone through its preheat mode:
• Energize TR sets, starting with inlet field, setting Powertrac voltage
to a point just below sparking.
• Successively energize successive field as load picks up to maintain
opacity, keeping voltage below normal sparking (less than
10 flashes/min on spark indicator).
• Within 2 hours, check proper operation of collected dust removal
system.
• After flue gas at 200°F has entered ESP for 2 hours, perform the
following steps:
— check all alarm functions in local and remote
7-19
-------
~ deenergize bushing heaters after 2 hours.
• Set normal rapping.
When charging has stopped and the incinerator goes into burndown mode,
shut the ESP down by doing the following:
• Deenergize ESP by field, starting with inlet field to maintain opacity
limit
• Deenergize outlet field when all fuel flow ceases and combustion
airflow falls below 30 percent of rated flow.
• Leave rappers, ash removal system, seal-air system, and hopper heaters
operational.
• Four hours after incinerator shutdown, deenergize seal-air system and
hopper heaters. Secure ash removal system.
• Eight hours after incinerator shutdown, deenergize rappers.
Note: Normal shutdown is a convenient time to check operation of
alarms.
7-20
-------
REFERENCES FOR SESSION 7
1. Engineering Manual With Operation and Maintenance Instructions.
Anderson 2000, Inc. Peachtree City, Georgia. Undated.
2. Joseph, J. and D. Beachler. APTI Course SI:412C, Wet Scrubber Plan
Review, Self-Instructional Guidebook. EPA 450/2-82-020. U. S.
Environmental Protection Agency. March 1984.
3. U. S. Environmental Protection Agency. Wet Scrubber Inspection and
Evaluation Manual. EPA 340/1-83-022. (NTIS PB85-149375).
September 1983.
4. U. S. Environmental Protection Agency. Fabric Filter Inspection and
Evaluation Manual. EPA 340/1-84-002. (NTIS PB86-237716). February 1984.
5. Beachler, D.S. APTI Course SI:412, Baghouse Plan Review. U. S.
Environmental Protection Agency, EPA-450/2-82-005. April 1982.
6. U. S. Environmental Protection Agency, Operation and Maintenance Manual
for Fabric Filters, EPA 625/1-86/020. June 1986.
7. Richards Engineering, Air Pollution Source Field Inspection Notebook;
Revision 2. Prepared for the U. S. Environmental Protection Agency, Air
Pollution Training Institute. June 1988.
8. U. S. Environmental Protection Agency: APTI Course SI:412B, Electrostatic
Precipitator Plan Review, Self-Instructional Guidebook.
EPA 450/2-82-019. July 1983.
9. U. S. Environmental Protection Agency. Operation and Maintenance Manual
for Electrostatic Precipitators. EPA 625/1-85-017. September 1985.
7-21
-------
LESSON PLAN
COURSE: HOSPITAL INCINERATOR OPERATOR TRAINING
COURSE
SESSION TITLE: MAINTENANCE INSPECTION—A NECESSARY PART OF
YOUR JOB
SESSION NO: 8
SESSION TIME: 45 MINUTES
GOAL
To familiarize students with:
• The hourly, daily, and weekly maintenance inspections that they should
make on their hospital waste incinerators and air pollution control
devices;
• Maintenance problems that should be reported to the maintenance
department; and
• Recordkeeping systems.
OBJECTIVES
At the end of this session, each student should be able to:
1. List the maintenance inspections that should be made on an hourly
basis;
2. List the maintenance inspections that should be made on a daily
basis;
3. List the maintenance inspections that should be made on a weekly
basis;
4. Identify and alert maintenance personnel of potential problems; and
5. Implement a recordkeeping system.
SUPPORT MATERIALS AND EQUIPMENT;
Slide set for Session 8; slide projector
SPECIAL INSTRUCTIONS;
None
HANDOUTS;
None
8-1
-------
Slide No. Title
T Title
1 Preventive Maintenance
2 Typical Maintenance Inspection Schedule
Picture 8-1 Damaged Thermocouples
3 Typical Maintenance Inspection Schedule for a Wet Scrubber
4 • Typical Maintenance Inspection Schedule for a Fabric Filter
System
5 Recordkeeping
6 Dally Maintenance Inspection Log
8-2
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INTRODUCTION
Present to students the major
goals of the session: To
familiarize them with:
• Hourly, daily, weekly
maintenance inspections for
incinerators and air
pollution control systems
• Problems that should be
reported to the maintenance
department
• Recordkeeping
SESSIONS.
NAINTENWCE INSPECTION-* NECESSARY PART OF YOUR JOB
PREVENTIVE MAINTENANCE
Preventive maintenance work is
usually done by the maintenance
department and includes such
activities as lubrication of moving
parts, replacing parts, and
repairing equipment.
Suo« 8-1
PKEVEMTIVE HAIHTEMAHCE
PWCIM TO CONDUCT KMNTEMNCE ON REGULAR SCHEDULED IHSIS
OF MINTEN/WCE
You CM HILP
— INSPECT UNIT
— IDENTIFY NINO* PKOBLEMS
— »tPOItr TO MIINTEIUNCE OEP/WTMENT
The operator's
responsibility concerning
maintenance is to
— Inspect the different
parts of the incinerator
and air. pollution
control device on a
regular basis.
— Detect minor problems
early.
— Report problems to the
maintenance department
before they develop into
large, expensive repairs
and result in improper
operation and increased
air emissions.
Similar in concept to maintenance for an automobile
— Check oil regularly
— Check tire pressure
— Change oil
— "Pay now or pay later"
8-3
-------
INCINERATOR MAINTENANCE INSPECTIONS
We will discuss the regular
inspections that should be performed
on an incinerator and the
recommended frequency. However,
these are general recommendations.
Each incinerator manufacturer
provides a maintenance schedule that
should be closely followed for
specific incinerators.
HOURLY INSPECTIONS
The hourly incinerator
inspections apply only to large
incinerators with automatic ash
removal conveyors. On these
systems, the following inspections
should be made every hour:
SLIOI 8-2
ACTIVITY
FREQUENCY
HOUULT
DAILY
tfCULT
MONTHLY
90 DAY
TYPICAL miNTEHAHg 1HSPECTIOH SCHEDULE
|MC1NE«ATON COMPONENT
ASH KEMOVAL CONVEYO*
•ATE* QUENCH PIT
RAM COOLius SYSTEM
STACK
THERMOCOUPLES
LIMIT SNITCHES
UNDUFIHI
-------
• On control!ed-air Incinerators, inspect and clean underfire air ports-
-on batch units, cleaning is best accomplished by rodding the air
ports after the previous shift's ash has been removed—large,
continuous feed units usually have cleaning mechanisms that may be
used to rod out the air ports while the unit is in operation. (Note
that multiple-chamber incinerators (i.e. excess-air units) are
supplied with air through overfire air ports that are unlikely to
become plugged.]
WEEKLY/BIWEEKLY/MONTHLY INSPECTIONS
Weekly
• All blower Intakes and induced-draft (ID) fans used for heat recovery
should be inspected for dirt accumulation and cleaned as required.
• ID fans used for heat recovery should be inspected for corrosion
• V-belt drives and chains should be checked to make sure they are not
frayed or loose.
• Any corrosion or wear and any loose or frayed V-belts or chains should
be reported to the maintenance department.
• Dampers should be checked to be sure they are not binding and in need
of lubrication.
Biweekly
• The incinerator's control panel should be inspected for dirt
accumulation and cleaned as required.
• The control panel door should be kept closed to prevent dirt
accumulation and electrical malfunction.
Monthly
• Inspect the outer surface of the incinerator.
• Any discoloration or white "hot" spots on the outer surface may
indicate a loss of refractory inside the unit and should be reported
to the maintenance department. These white spots are usually the
first indication of internal refractory damage.
• Inspect the refractory lining inside the incinerator. When the
refractory lining is cold, random cracks may be seen that vary in
width from 1/32 to 3/16 inch. These cracks are normal and close up
when the refractory expands at operating temperatures. The purpose of
Inspecting the cold refractory each month is to observe any changes in
existing cracks and to discover any holes larger than the cracks.
These inspections are very important because replacing badly damaged
refractory is very expensive. However, minor damage caught early
enough may be repaired by the maintenance department using plastic
refractory material.
8-5
-------
DAMAGED THERMOCOUPLES
This photograph shows two
thermocouples which have burned
out. A preventive maintenance
program which has regularly
scheduled thermocouple replacement
(based on experience of how long a
thermocouple usually lasts In your
system) can save you unnecessary
down time.
Picture
8-1
WET SCRUBBER MAINTENANCE INSPECTIONS
As with incinerators,
maintenance inspections for wet
scrubbers should be performed
according to the manufacturer's
recommended schedule. We will
discuss common inspection activities
and frequencies for wet scrubbers.
DAILY INSPECTIONS
The following inspections
should be made on a daily basis:
• Inspect the following
equipment for leakage by
looking for scrubber liquid
escaping from the components
and for any liquid on
surfaces directly under the
equipment. All leaking
components should be
reported to the maintenance
department for repair.
SLIM 8-J
TtTICM. HAHfTBttNCE INSPECTION SCHEDULE FOR
A ffT SCRUBBER
Inner i ON
CUar
COTHMEIIT
ScroiiE* LIQUID FUHP
VHIAILI rmratr «criv«ro«
Scmiuin LIQUID LIKES
RUSIKT FEED SrSTDI
Fi»
•H BETED
if «€!!«
DUCT iran
8-6
-------
~ Scrubber liquid pump
-- Variable throat activator
— Scrubber liquid lines
— Mist eliminator pressure lines
— Reagent feed system
Inspect the scrubber liquid pump for proper operation by noting the
flowmeter reading—lower flow rates than normal may indicate pump
problems.
On variable throat venturi scrubbers, inspect the variable throat
activator for proper operation by moving the activator and checking
the resulting pressure drop—the activator should move freely and the
pressure drop should increase as the activator is moved upwards to
constrict the venturi throat.
Inspect the scrubber fan, belt, for any abnormal vibration or noise—
any abnormal vibration or noise indicates that the fan should be
serviced by the maintenance department.
OTHER INSPECTIONS
Every month, the off-gas ductwork should be checked for leakage, i.e.
look for holes (positive side) and listen for air being sucked in
(negative side). Any problems should be reported to the maintenance
department for repair.
All other maintenance activities will likely be performed by the
maintenance department during regular shutdowns. Such activities
include:
— Inspecting the internal scrubber components for corrosion,
abrasion, and material buildup (monthly)
— Lubricating scrubber components including fan and pump (weekly)
— Inspecting fan, pump, motor, and drag chain bearings, and damper
seals, bearings, blades and blowers for wear and loose fittings
(semiannually); and
— Checking the accuracy of flowrates (semiannually).
8-7
-------
FABRIC FILTER MAINTENANCE INSPECTIONS
DAILY INSPECTIONS
The following inspections
should be made on a daily basis:
Suoc 8-4
• Inspect the exhaust Stack TYPICAL MIHTBWICE iHsrecnoH SCHEDULE FOR
for visible emissions—a * *****
sudden change in opacity may
indicate the failure of one
or more system components
. , , . , . ., . . D«ILY
including broken/leaking
bags or a malfunctioning
cleaning system — the KOTOS/OUST «iwv»i. SYSTW
appearance of puffing smoke F*"
indicates pinhole leaks in a
filter bag(s);
• Check and record fabric
pressure loss and fan static
pressure — sudden changes in
the pressure drop may
indicate problems; i.e. high
pressure drop may indicate
mudded bags or cleaning system failure (listen to the system-does it
sound different?) while low pressure drop may indicate fabric failure
(holes).
• Check the compressed air system for air leakage by observing the
system's pressure gauge—air leakage may be indicated by a lower
pressure than normal ;
• Check all indicators on the fabric filter control panel and listen to
the system in operation— you should become familiar with the sounds
that your system makes when operating normally ; and
• Inspect the dust removal system to see that dust is being removed from
the system by checking the conveyor for jamming, p luggage, wear,
broken parts, etc. — problems with the conveyor system are indicated
when the conveyor appears to be moving but no dust is dropping into
the dust storage container, when the
conveyor does not move, or when the conveyor makes unusual sounds.
• Check the fan for excessive vibration.
• Lubricate pumps and bearings
If you encounter any of the indicators of deteriorating performance listed
above, you should report the problem(s) to the maintenance department for
repair.
8-8
-------
RECORDKEEPING
• The objectives of
recordkeeping are:
-- To prevent premature
failure of equipment
— To increase equipment
life, and
— To minimize air
pollution.
• These objectives can be
achieved by observing trends
in the frequency and types
of maintenance required and
by detecting problems early
through regular maintenance
inspections.
• Keeping records provides
valuable information to aid
in evaluating the
effectiveness of the
preventive maintenance
program.
• Accurate records are
necessary to keep the spare
parts inventory up-to-date
and make inventory
decisions.
MAINTENANCE INSPECTION LOGS
• Daily, weekly, and monthly
maintenance inspection logs
are useful in keeping
records. You could set a
log up for the incinerator
and another for the air
pollution control device.
SLIDE 8-5
8ECORD*EEPIN6
• RECORDS «LLO« THEMIS TO IE THUCKED
• ASSISTS KITH EV*LU»TING PN M06XM
• ASSISTS INVENTORY DECISIONS
SLIDE 8-6
f«ciiitr "—
OMntor'i *
Out!
DAILY MAINTENANCE INSPECTION LOG
TIM
Ear
•otn
40 »lt>« MUM
SUct
... Haul* Hi
nn iitoiM
•HIM r«M
8-9
-------
REFERENCES FOR SESSION 8
1. Personal Conversation between Mark Turner, MRI, and William Tice, Rex
Hospital, Raleigh, North Carolina. August 16, 1988.
2. Murphy, P., and Turner, M. Report of Site Visit to Ecolaire Combustion
Products, Charlotte, North Carolina. July 20, 1988.
3. Allen Consulting and Engineering, Municipal Waste Combustion Systems
Operation and Maintenance Study. EPA-340/1-87-002. June 1987.
4. Ecolaire Combustion Products, Inc. Equipment Operating Manual for Model
No. 2000TES; Equipment operating manual for Model No. 480E.
5. U. S. Environmental Protection Agency. 'Wet Scrubber Inspection and
Evaluation Manual, EPA 340/1-83-022. (NTIS PB 85-149375).
September 1983.
6. Joseph, J. and Beachler, D., APTI Course SI:412C, Wet Scrubber Plan
Review, Self-Instructional Guidebook. U. S. Environmental Protection
Agency. EPA 450/2-82-020. March 1984.
7. Engineering Manual with Operation and Maintenance Instructions.
Anderson 2000, Inc. Peachtree City, Georgia. Undated.
8. U. S. Environmental Protection Agency. Operation and Maintenance Manual
for Fabric Filters. EPA 625/1-86/020. June 1986.
8-10
-------
GOAL
LESSON PLAN
COURSE: HOSPITAL INCINERATOR OPERATOR TRAINING
COURSE
SESSION TITLE: TYPICAL PROBLEMS
SESSION NO: 9
SESSION TIME: 60 MINUTES
• To familiarize students with the most frequent operational problems
and how to prevent or correct them.
• To stimulate discussion about the types of problems students have had
and things they have tried to solve them.
OBJECTIVES
At the end of this session, each student should be able to:
1. Identify the most frequent operational problems with incinerators and
air pollution control systems;
2. Recognize the causes of operational problems; and
3. Describe the actions to take to correct and prevent operational
problems.
SUPPORT MATERIALS AND EQUIPMENT:
Slide set for Session 9; slide projector
SPECIAL INSTRUCTIONS:
None
HANDOUTS
Appendix C: Worksheet No. 5—"Operating Problems Review"
9-1
-------
Slide No. Title
T Title
1. Problems
2 Incinerator Problems
3 Black Smoke from Incinerator Stack
4 White/Blue-White Smoke from Incinerator Stack
5 White Smoke/Haze a Short Distance from Incinerator Stack
6 . Smoke Leaving Primary Chamber of Incinerator
7 Too Much Auxiliary Fuel Usage
8 Incomplete Burnout/Poor Ash Quality
9 Proper Burner Flame Pattern
10 Improper Burner Air
11 Flame Impingement
12 Prevent Incinerator Problems
13 Wet Scrubber Problems
14 Prevent Scrubber Problems
15 High Opacity from Fabric Filter
16 High Pressure Drop in Fabric Filter
17 Prevent Fabric Filter Problems
18 Other Problems
19 What Problems Do You Have?
9-2
-------
INTRODUCTION
As an incinerator operator, you
will experience problems period-
ically with the incinerator and air SESSION a
pollution control system. HPICAL
• In this session, the most
frequent operational
problems are identified.
The possible causes for each
problem are discussed along
with actions you can take to
correct the problem.
• It will be helpful to
everyone if you share with
the class some of the
problems you have had and
how you have gone about
solving them.
PREVENT PROBLEMS
Many times, problems can be SUM 9-1
prevented if you are aware of how to
keep them from happening. It is
better to prevent problems rather IT-* mm. ™
. . . \_ r. ., ™MI TO comer
than have to correct them.
An effective preventive
maintenance program can reduce the
number of problems by correcting
malfunctions, making changes to
prolong equipment life, and
correcting minor problems before
they require costly, time-consuming
repairs.
Sometimes, though, there are
problems that you could not have
prevented, and you need to know how
to correct them as quickly as
possible. Knowing how to prevent
and correct operational problems
will help you to do your job better
and will also help to reduce air
pollution from the incinerator.
9-3
-------
SLIOI 9-2
INCINERATOR WBIB6
BLACK SMIC
UMITC/ILUI-KHITE snocc
VMITC BWU/MZC
PUFPIUS SMU "0" CMMIE*
Excnsivc AiniLiAxr FUEL USAGE
Pom »sx WACKY
PIOILOB
INCINERATOR PROBLEMS
The most frequent problems we
will discuss are:
PROBLEM
NO. PROBLEM DESCRIPTION'
1 Black smoke leaving stack
2 White smoke leaving stack
3 White smoke or haze
appearing a short distance
above the stack
4 Smoke leaking from primary
chamber
5 Excessive auxiliary fuel
usage
6 Incomplete burnout/poor ash
quality
7 Burner problems
For each of the problems presented below the instructor should:
1. First try to identify the causes of the problem so that the student
clearly understands the basic factors that can be causing the
problem . . . only after the student understands the cause of the problem can
they begin to identify possible solutions.
2. Identify possible solutions to the problem.
3. Identify possible preventive steps to follow to prevent the problem
in the first place or from happening again. Note that each incinerator is
different and the corrective action necessary to address specific problems may
be different for each type of incinerator. Manufacturer's instructions should
be consulted or manufacturer's assistance requested as necessary. This
session is not intended to provide step-by-step procedures for corrective
action.
PROBLEM NO. 1: BLACK SMOKE LEAVING STACK. An example of black smoke is the
diesel exhaust one often sees from buses or trucks climbing a hill.
CAUSE:
Incomplete burning of waste-
resulting in soot formation
• Not enough air for complete
combustion
• Overcharging or charging
highly volatile material
• Poor mixing in secondary
chamber
• Burner failure
SLIOI 9-3
BLACK SMOKE WOMWCWEHATOfl STACK
9-4
-------
• Operating at too high a primary chamber temperature. Too high a
temperature can cause rapid increases in combustion gases due to
volatilization of wastes (such as plastics). The rapid increase in
combustion gas volume and volatile content can cause the secondary
chamber capacity to be exceeded.
SQLUTION/PREVENTIQN:
Do the following, in order, to correct the problem:
• Check/increase secondary chamber combustion air
• Check/decrease primary chamber combustion air (underfire air or
overfire air)
• Check secondary chamber temperature/assure above minimum level
• Check secondary chamber burner operation—if no flame or a poor flame
1s visible through the flame viewport, call maintenance to repair
• Decrease charge size or charge rate-
PROBLEM NO. 2: STEADY STREAM OF WHITE SMOKE LEAVING STACK
PROBABLE CAUSE: :LI" 9'"
Small aerosols in stack gas-
incomplete combustion of
hydrocarbons
• Too much air entering
incinerator
• Secondary chamber
temperature too low
• Note that white smoke should
not be confused with a
condensing water plume or
"steam plume" which is a
very dense billowing
white. This type "Steam WHITE/BLUE-WHITE SMOKE FROM INCINERATOR STACK
plume" would be expected
after a wet scrubber.
• An example of a "white/blue hazy plume is an automobile that is
smoking because it Is burning oil"—albeit not very efficiently.
Think about how this smoke from the "oil burner" looks and smells
differently than the wispy white exhaust that you often see on a cold
morning when the car first starts—this very white exhaust that
quickly dissipates and goes away is simply water or a "steam plume".
SOLUTION/PREVENTION:
Do the following, in order, to correct the problem:
• Be sure secondary burner is operating properly
• Be sure temperature of secondary chamber is above 1200°F
• Check/decrease underfire air
• Check/decrease secondary chamber air
9-5
-------
• If the above steps fail to eliminate white smoke, the feed material
may contain pigments, metallic oxides, or minerals (often found in
paper sacks).
PROBLEM NO. 3: WHITE SMOKE/HAZE APPEARING A SHORT DISTANCE ABOVE STACK
PROBABLE CAUSE:
Hydrochloric acid gas
condensing; do not confuse this with
a condensing water or "steam plume"
SOLUTION/PREVENTION:
Not much you can do unless you
SLIDE 9-5
can:
Reduce amount of chlorinated
waste incinerated in each
load, or
Eliminate chlorinated
plastics from use in
hospital, or
Install acid gas scrubbing
system
PROBLEM NO. 4: SMOKE LEAKING FROM PRIMARY CHAMBER
CAUSE:
\J
WHITE SMOKBHAZE A SHORT DISTANCE FROM INCIN6HATOS STACK
Positive pressure in primary
chamber
• Too much highly volatile
material charged
— If primary chamber
smokes just after charging,
it is probably because too
much volatile matter was
charged
• Problem with draft damper or
Induced draft fan (poor
draft)
• Too much underfire air
• Primary chamber temperature
too high
SLIDE 9-6
SMOKE LEAVING PRIMARY CHAMBER OF INCINERATOR
9-6
-------
SOLUTION/PREVENTION:
Do the following, in order, to correct the problem:
• Decrease feed rate, if smoking occurs immediately after charging
• Check stack damper or fan operation
• Check/decrease underfire air
• Check charging door seals for leakage
PROBLEM NO. 5: TOO MUCH AUXILIARY FUEL USAGE
CAUSE:
Not enough heat input from
waste to keep temperature high
enough
Inconsistent charging of
i nci nerator
Insufficient underfire air
(starved-air units)
Too much secondary
combustion air
Too much air infiltration
Fuel leakage
Wet waste
Excessive draft
Burner setting too high, too
high temperature
SLIOI 9-7
TOO MUCH AUXJLARY RJH. USAGE
9-7
-------
SOLUTION/PREVENTION:
Do the following to correct the problem:
• Charge waste at regularly timed intervals at a rate near 100 percent
of incinerator capacity
(Example: For 500 Ib/h (230 kg/h) unit, charge 50 Ib (23 kg) every
6 minutes)
• Spread wet waste with other waste through several charges—do not
charge all of the wet waste at one time
• Check/increase underfire air (controlled-air unit); check air ports
and distribution
Check/reduce secondary combustion air
Check/reduce draft
Check charging door seals and other seals "for air in-leakage
Check/decrease burner setting
Check fuel trains and burners for fuel leakage
PROBLEM NO. 6: INCOMPLETE BURNOUT/POOR ASH QUALITY
Suot 9-8
INCOMPLETE 8URNOUT/POOB ASH OUAUTV
Three possible causes of this
problem are detailed below.
CAUSE NO. 1:
Not enough underfire air or
poor underfire air distribution
• Improper underfire air
setting
• Clinker buildup around
underfire air ports
• Air ports clogged with ash
from previous charges
SOLUTION/PREVENTION:
Do the following to correct the
problem:
• Check underfire air setting and adjust if needed
• Check around underfire air ports for clinker buildup and clean as
needed
• Rod underfire air ports daily to remove clinker buildup and ash
CAUSE NO. 2:
Improper waste charging
• Overstuffing incinerator
• Too much wet waste
9-8
-------
SOLUTION/PREVENTION:
Do the following to correct the problem:
• Charge waste at regularly timed intervals at a rate near 100 percent
of incineration capacity (Example: For 500 Ib/h (230 kg/h) unit,
charge 50 Ib (23 kg) every 6 minutes). Do not overstuff
• Spread wet waste through several charges—do not charge all of the wet
waste at one time
CAUSE NO. 3:
Insufficient burndown time
SOLUTION/PREVENTION:
Do the following to correct the problem:
• Allow longer burndown period
• Check underfire air setting for burndown period; more air needed?
• Use primary burner to maintain temperature during burndown period
PROBLEM NO. 7: SECONDARY BURNER MALFUNCTIONS
This sl.ide shows what the flame
pattern should look like when
properly operating, as well as some
typical problems which may be
encountered. Someone qualified to
make burner adjustments should be
contacted if you suspect burner
problems.
Proper burner flame pattern.
This figure shows a proper flame
pattern. It is even and steady and
originates near the burner; it
should be bright yellow or orange in
color (oil) or blue (gas).
Prooer Flame
Pattsm
BURNER FLAME PATTERNS'
Ref. 9-1
9-9
-------
Improper burner air.
• If the burner air is set too
high, the flame will be
"blown away" or detached
from the burner.
• The flame should not
smoke. A smoking flame
means there is not enough
combustion air.
SLIDE i-10
Detaened Rarne: Too
Mucn Burner Air
Smoking Rama:
Not Snougn Air
BURNER FLAME PATTERNS
Ref. 9-1
Impingement
• The flame should not hit or
"impinge" on the
refractory. The burner
needs adjustment if it is
hitting the refractory.
3uoi 9-U
Flams imorngsmant
On Refractory
BURNER FLAME PATTERNS'
Ref. 9-1
9-10
-------
PREVENTING PROBLEMS
SLIOI 9-12
Reminder: It is better to
prevent a problem than to have to
correct a problem after it has
occurred. A couple of things you
can do on a regular basis to prevent
problems with your incinerator are
noted below.
1. Properly charge the
incinerator.
— prevent black smoke
— prevent sudden
increases or decreases
in temperature
— prevent poor ash
burnout.
2. Identify small maintenance
problems and fix them—if you're
qualified and have the tools or have
them fixed before they become big
problems;
— For example, sticking or squeaking dampers
before they jam or fail altogether
WET SCRUBBER PROBLEMS
Wet scrubber problems are
usually the result of corrosion,
erosion, scaling, or plugging.
PREVENT IHCINERATOR PROBLEMS
CHMGt
Halt UULL aPWKTINS AND »« KUNAHCt "OILENS
tU SET FIXED IEFORC THEY lECOIte SIS PK01LEMS
should be lubricated
SLIDE 9-13
Typically, these problems will
be invisible to the operator because
they occur inside the scrubber.
• Most operational problems
encountered by wet
scrubbers can be prevented
with a good preventive
maintenance program.
Steps that you can take to
help prevent or detect some
of these problems are
outlined below.
• Call maintenance once the
problem occurs—you
probably cannot do much to
fix it.
HET SCRUBBER PROBLEMS
• CaxmsiON
• PLUGGED snur NOZZLES
• FAD vii«»Tto»
9-11
-------
PROBLEM NO. 8: CORROSION OF SCRUBBER PARTS
(Scrubbers, absorbers, fans, dampers, ductwork, exhaust stack, pumps,
valves, pipes, tanks, feed preparation equipment)
CAUSE:
Corrosion is a process where the scrubber internal components are worn
away by the chemical action of the acid exhaust gas from a medical waste
incinerator or by the alkaline scrubber liquor. Acid buildup in scrubbing
liquid from absorption of sulfur dioxide, sulfur trioxide, and hydrogen
chloride
SOLUTION/PREVENTION:
Maintain the pH of the scrubbing liquid by doing the following:
Check alkaline addition system for leaks daily and have the
maintenance department repair if needed
Check pH monitor that controls alkaline additions daily
Have the maintenance department perform regular preventive
maintenance on pumps, pipes, valves, tanks and feed preparation
equipment in slurry service
PROBLEM NO. 9: SPRAY NOZZLE PLUGGING
CAUSE:
Plugging occurs mainly in scrubber spray nozzles when scrubber water
containing captured particulate is recycled and scaling occurs in and around
the nozzle tip. Plugging spray nozzles will reduce the water flow, change the
spray pattern, and result in poor performance, i.e., increased emissions.
SOLUTION/PREVENTION:
Periodic cleaning of equipment
• Maintaining proper level of dissolved solids
• Maintaining proper pH
PROBLEM NO. 10: FAN VIBRATION, DAMPERS STUCK
CAUSE:
Scaling which occurs when the particles in the incinerator exhaust gas
begin to build up on the scrubber internal components such as fan blades which
can result 1-n fan vibration
SOLUTION/PREVENTION:
Preventive maintenance; periodic cleaning of equipment
9-12
-------
PROBLEM NO. 11: EROSION IN DRY SERVICE COMPONENTS
(Fans, dampers, ductwork)
CAUSE:
Erosion is a process where the scrubber internal components are worn away
by the abrasive action of the airborne particles in the incinerator exhaust
gas.
SOLUTION/PREVENTION:
Preventive maintenance
Repair/replacement of equipment
PROBLEM NO. 12: EROSION IN WET SERVICE COMPONENTS
Components affected include scrubber and scrubber spray nozzles. If
recirculation is not practiced, then erosion in wet service will not be a
problem.
CAUSE:
Suspended solids in scrubbing liquid
High recirculation flow rate compared to makeup and purge flow rates
Infrequent purging of system
SOLUTION/PREVENTION:
Preventive maintenance
• Purge system frequently to prevent solids buildup
• Adjust recirculation rate as needed
9-13
-------
Sum 9-14
PREVENTING PROBLEMS
It 1s better to prevent a
problem than to have to correct a
problem after it has occurred. A
few actions you can take to prevent
problems with a wet scrubber are
noted below.
1. Maintain proper pH for
scrubber liquid.
2. If recirculation is used,
maintain low level of solids in
scrubbing liquid.
3. Establish preventive
maintenance program to inspect and
clean scrubber parts, including
nozzles, fan, and dampers. (The
Maintenance Department would be
responsible for this action.)
FABRIC FILTER PROBLEMS
Problems with fabric filters are usually indicated by either:
High opacity
PREVENT SCRUBBER PROBLH6
COMECT m FOK SCRUBIE* LIQUID
1«I»T»K LOV LEVEL OF SOLIDS III RECHCUUTEO
scmiuiw LIQUID
USE raEVE»TivE lumTENANCE naaiiut FO»
[HSPECTIUS/CLEAN ING NOZZLES. F»«S. OAHFERS
SLIDE 9-15
High opacity indicates
increased emissions and is very
undesirable. It is usually due to
holes in the filter bags (caused by
abrasion or acid gas condensation)
or improper bag installation (fallen
bags, improperly sealed or tensioned
bags).
HIGH OPACITY FROM FABRIC FILTER
9-14
-------
Pressure drop
High pressure drop indicates a
higher resistance to"airflow meaning
that the filter bags are not being
cleaned properly or that they are
mudded or blinded because of
condensation of moisture.
SLIOC 9-16
HIGH PRESSURE DROP IN FABRIC FILTER
PREVENT FABRIC FILTER PKOBLSS
• NMITMII nmnx Totnmmint ««»« KITHIM UGNOUSE
• Nature* if
• ««I»T»IN mart* CLEANING CTCLE
• Noil i Ton OMCirr
PREVENTING PROBLEMS
It is better to prevent a
problem than to have to correct a
problem after it has occurred. A SUM9-1;
couple of actions you can take to
prevent problems with a fabric
filter are noted below.
1. Maintain proper operating
temperature. Acid gas and water
condensation can be prevented by
maintaining the temperature of both,
the inlet gas to the fabric filter
and the fabric filter itself above
the dewpoints of water and the acid
gas. Additionally, the inlet gas
temperature must not be excessive
such that damage to the filter bags
or fire occurs. Some fabric filters
are equipped with alarms and a
bypass stack that diverts the gas if
the temperature exceeds or falls
below a certain limit.
2. Observe pressure drop readings. Any low or high readings indicates a
problem and should be reported to the maintenance department.
3. Maintain the proper cleaning cycle so that AP remains within the
acceptable range.
4. Observe opacity. High opacity indicates fabric failure and should be
reported to the maintenance department.
9-15
-------
Other problems
Other problems you might
encounter include: ' OTHER
• Sticking limit switches. • K«TM coou«s sm«s »* «•«
These switches should be :2I«III! «'£/£.
checked routinely by
checking movement of the
switch. If the switch is
sticking it should be
lubricated.
• Clinker formation. Clinker
formation is caused by
melting and fusing of metal
(aluminum) and glass in the
ash bed.
Possible solutions include
reducing the ash bed temperature and
reducing the amount of glass and
aluminum in your waste.
WHAT PROBLEMS DO YOU HAVE?
The instructor should try to
initiate a discussion among the SLIM 9-19
operators regarding
• How they identify problems
• What kind of problems do
they have?
• How have they attempted to
fix their problems.
• Have they been successful?
HANDOUTS
Worksheet No. 5, Appendix C,
provides a worksheet for each
operator to use to summarize their
three most frequent major problems.
9-16
-------
REFERENCES FOR SESSION 9
1. U. S. Environmental Protection Agency. Workbook for Operators of Small
Boilers and Incinerators. EPA 450/9-76-001. March 1976.
2. Letter from K. Wright, John Zink Company to J. Eddinger, U. S. EPA.
January 25, 1989.
3. Personal conversation between R. Neulicht, MRI, and G. Swan, Ecolaire
Combustion Products and J. Kidd, Cleaver Brooks. February 22, 1989.
4. Joseph, J., and D. Beachler. APTI Course SI:412C, Wet Scrubber Plan
Review—Self Instructional Guidebook. EPA 450/2-82-020.
U. S. Environmental Protection Agency. March 1984.
5. U. S. Environmental Protection Agency. 'Wet Scrubber Inspection and
Evaluation Manual. EPA 340/1-83-022. (NTIS PB85-149375).
September 1983.
6. U. S. Environmental Protection Agency. Operation and Maintenance Manual
for Fabric Filters, EPA 625/1-86/020. June 1986.
7. McRee, R. Operation and Maintenance of Controlled-Air Incinerators.
Ecolaire Environmental Control Products. Undated.
9-17
-------
LESSON PLAN
COURSE: HOSPITAL INCINERATOR OPERATOR TRAINING
COURSE
SESSION TITLE: STATE REGULATIONS
SESSION NO: 10
SESSION TIME: 30 MINUTES
GOAL
To familiarize students with major aspects of air pollution regulations
that apply to their incinerators.
OBJECTIVES
At the end of this session, each student should be able to:
1. List the air pollutants from hospital waste incinerators that are
likely to be regulated by his/her State;
2. Recognize the types of requirements that may be included in
regulations; and
3. Describe how regulatory agencies determine whether a facility is
complying with applicable regulations.
SUPPORT MATERIALS AND EQUIPMENT;
Slide set for Session 10; slide projector
Summary table for State regulations
SPECIAL INSTRUCTIONS:
None
HANDOUTS;
Appendix C, Worksheet No. 6 "Regulatory Limits"
10-1
-------
Slide No. Title
T Title
1 Types of Requirements in State Regulations
2 Concentration Standards (Weight/Volume)
3 Concentration Standards (Volume/Volume)
4 Correction for Dilution
5 Opacity
Example slides for State regulations:
6 Maryland Regulations
7 Maryland Visible Emission Limits
8 Maryland Particulate Matter Emission Limit
10-2
-------
INTRODUCTION
Present the-major goal of the
session to the students:
• To familiarize them with the
major aspects of air
pollution control
regulations for hospital
waste incinerators.
SESSION 10.
STATE REGULATIONS
Since regulatory requirements
vary from State-to-State, typical
regulations will be described as
well as those specific to your
State.
Suoi 10-1
FTPS OF RHMIREHEHTS IN STATE REGULATIONS
EMISSION LIHCTS
M»CTICK/Ll*[TS
• ConTimjouj EHISSIOK no* iron m«
• Recommits IMG »*o DEPORT me
• OMMTOI nomine
In most States, some or all
of the requirements may be
specified according to the
size of the incinerator.
Large incinerators may be
required to meet stricter
requirements for more
pollutants than small
incinerators, and very small
Incinerators may have few
restrictions.
State regulations typically
Include the following types
of requirements which are
discussed in this session:
— Emission limits for air pollutants that leave the incinerator
stack
- particulate matter
- HC1
- CO
- opacity
— Operating practices/limits
- temperature limits
- waste storage
- charge rate
- type of waste charged
10-3
-------
~ Continuous monitoring of emissions or other indicators of
performance
- CO
- opacity
— Recordkeeping and reporting
- charge rate
- temperatures
- air pollution control device liquid flow rate/pressure drop
— Operator training
The requirements for your particular State will be summarized later.
• Your facility will also have received a "permit" from the State and/or
local Agency which may include specific requirements for your
incinerator and air pollution control system that may be more strict
than the general State regulations.
THE AIR POLLUTANTS
• Listed below are the air pollutants from hospital waste incinerators
that may be covered by emission limits in State regulations:
— Particulate matter
— Carbon monoxide
— Hydrochloric acid gas
— Toxic metals (arsenic, beryllium, cadmium, chromium, nickel, lead,
mercury)
— Organlcs (dioxins/furans, benzene)
— Sulfur dioxide
— Nitrogen oxides
10-4
-------
REGULATORY REQUIREMENTS
EMISSION LIMITS
Emission limits may be expressed in several different ways depending on
the type of pollutant.
Concentration Standard
• The most common type of emission limit is the concentration standard,
which limits either the mass (weight) or volume of the pollutant in
the gas exiting the stack. This type of emission limit is expressed
as follows.
MASS BASIS:
1 grain per dry
standard cubic foot
(1 gr/dscf at 7 per-
cent oxygen)
Type of pollutant - Explanation
Particulate matter
For metric units:
Milligram per dry
standard meter, mg/dscm
1 gr/dscf =
2,300 mg/dscm
No more than 1 grain (there
are 7,000 grains in 1 pound)
of particulate matter may be
contained in each cubic foot
of gas leaving the stack
corrected to 7 percent oxygen
and standard conditions (20°C,
and 1 atra). (Oxygen
correction and standard
conditions are explained
below)
SLID* 10-2
1 Grain
1 Foot
f
\ Foot
-1 Foot-
-*^
1 Grain Per Dry Standard
Cubic Foot
7000 Grains-1 pound
10-5
-------
VOLUME BASIS:
100 parts per
million (100 ppm)
Type of pollutant Explanation
Carbon monoxide
Hydrochloric acid
Sulfur dioxide
Nitrogen oxides
No more than 100 cubic feet
(meters) of pollutant may be
contained in 1 million cubic
feet (meters) of gas leaving
the stack.
Sum 10-3
100 Cubic
Meters
Contains 1 Million
Cubic Meters
100 Parts Per million
10-6
-------
Percent Reduction Standard
Sometimes the emission limit is expressed as a percent reduction of
the pollutant. In. other words, the pollution control device must operate
at a minimum efficiency level (such as 90 percent) to reduce the pollutant
emissions. This type standard frequently is used for acid gases such as
HC1. For example, if the emission standard requires 90 percent reduction
of- HC1, and the HC1 in the combustion gas entering the scrubber inlet is
20 Ib/h (9.1 kg/h) then the allowed emission rate is 2 Ib/h (0.9 kg/h)
(20-[0.90x201).
Correction for Dilution
• A concentration standard SLIDI l(M
limits the amount of
pollutant in a certain
amount of stack gas. Adding
air to the stack gas would
dilute the concentration of
the pollutant and increase
the oxygen concentration
because the air contains
21 percent oxygen.
• Thus, a facility adding air
might be able to achieve the
concentration standard while cc^c™*™™
another facility with the
same total amount of
pollutant, but not adding
air, would not be able to
achieve the standard.
• To keep this from happening, regulations usually either forbid the
addition of dilution air or require that the concentration be
"corrected" to a standard level of oxygen, usually 7 percent, or
standard level of carbon dioxide, usually 12 percent.
• When a stack test is performed to check the level of emissions from an
incinerator, both temperature and pressure are measured during the
test in addition to the pollutant of interest.
• The test results are then converted to standard conditions (grain/dry
standard cubic foot) using the temperature and pressure measured.
• Standard temperature 1s 20°C (68°F) and standard pressure 1s
760 millimeters of mercury (29.92 Inches).
• A cubic foot measured at this temperature and pressure is known as a
standard cubic foot.
• Using standard conditions, all test results of all sources including
incinerators can be compared on the same basis, i.e., all results are
reduced to standard conditions.
Ambient concentration standard
•Another type of standard (shown below) sometimes found in State
regulations is called an ambient concentration standard. It limits
the amount of pollutant that collects at ground level in areas
surrounding the emission source.
10-7
-------
Usually, the regulation requires that the pollutant be measured as it
leaves the stack. This measurement information is then used by a
computer to calculate the amount of the pollutant at various locations
near the source.
Example
1 mlcrogram per cubic
meter (lyg/m )
Opacity standard
Type of pollutant Explanation
Toxic metals
Organics
Hydrogen chloride
No more than 1 microgram of
pollutant may be contained in
each cubic meter of air.
(There are 1 million
mlcrograms in 1 gram).
SLIOI 10-5
ftftf
OPACITY AND THE RINGLEMANN CHART
A third type of standard
that is almost always
included in regulations is
an opacity standard. It is
expressed as a limit on the
degree to which the stack
emissions are visible and
block the visibility of
objects in the background.
Stack emissions of
100 percent opacity would
totally block the view of
background objects and
indicate high pollutant
levels. Zero percent
opacity would provide a
clear view of the background
and indicate no detectable
particulate matter
emissions.
Opacity may be measured by one or/more of the following ways:
— Taking "readings" every 15 seconds and averaging the readings over
a specified time period. The "reader" must be certified. The
U. S. EPA has an official method for reading opacity, EPA
Reference Method 9 "Visual Determination of the Opacity of
Emissions."
— Comparing the opacity of the smoke to the six sections of a
Rlngelmann Smoke Chart. The six sections are numbered from 0 to 5
, with No. 0 being completely white and No. 5 completely black.
Sections 1 through 4 correspond to opacities of 20 percent
(No. 1), 40 percent (No. 2), 60 percent (No. 3), and 80 percent
(No. 4). Opacity is estimated by choosing the section which most
closely resembles the opacity of the exhaust gas.
— Using an instrument called a transmissometer that is installed in
the stack.
The following further illustrates an opacity standard.
10-8
-------
Example
10 percent opacity
(6-minute average)
Type of pollutant Explanation
Particulate matter
The opacity of the emissions
cannot average more than
10 percent for any 6-minute
period.
• Opacity is always a good indicator of performance for dry control
devices, such as baghouses. However, for wet control devices,
such as wet scrubbers, opacity may be difficult to measure because
of the presence of a steam plume.
MONITORING AND RECQRDKEEPING
• Certain types of records are commonly required by State
regulations or operating permits. Most of them are listed below
and involve recording the levels indicated on automatic monitoring
devices periodically or require recording the parameters
continuously.
-- Temperature of incinerator chamber(s)
— Oxygen concentration of exhaust gas
— Temperature at inlet and/or outlet of control device
— Continuous emission monitoring records (carbon monoxide or
opacity)
~ Weight of waste charged to incinerator
~ A1r pollution control device operating parameters:
a. Scrubber
• Pressure drop
• Liquid flow rate
b. Fabric filter
• Pressure drop
• Keeping good records of instrument readings and operating
practices is Important because it:
— Helps you to know if a problem develops that would cause air
pollution standards to be violated so that you can take
corrective action
— Provides proof that you are properly operating and maintaining
equipment
~ Allows you to prepare accurate annual (or more frequent)
reports that may be required by State regulations
ENFORCEMENT OF STATE REGULATIONS
• State enforcement officials may inspect your incinerator if
complaints are received from neighbors. Frequent complaints may
cause officials to make random inspections.
• A State enforcement official may take the following steps to
determine if you are complying with regulations:
— Examine your daily, weekly, and monthly records
— Inspect equipment and monitoring devices
— Observe your work procedures
10-9
-------
~ "Read" the opacity of stack emissions
— Measure stack emissions ("stack test")
OPERATOR TRAINING
• Some State regulations now require that infectious waste incinerator
operators be proper trained.
• The training requirements vary from State to State, but usually
include some classroom and hands-on instruction.
YOUR STATE REGULATION
Specific State Regulations
• Note: A section on specific State requirements for course
participants should be presented at this point. It is suggested that
slides be prepared listing the specific emission limits (according to
incinerator size, if applicable) and other requirements of which the
operators should be aware. Use actual operating permits as much as
possible to fully inform participants of requirements for their
incinerators. Slides 10-6 through 10-8 are provided as examples of
the type of information that should be presented. Table 10-1 lists
the most common requirements for State regulations for hospital waste
Incinerators. This table can be used by the instructor when preparing
the specific applicable requirements for the State(s) where the course
is presented.
IXAHM.E 10-6
HAIfftAHO REGULATIONS
• REGULATED POLLUTAHTS
-- PIRTICULATE HATTER CONCENTRATION.
SR/DSCF AT 12 PERCENT CO,
— PERCENT OPACITY
• Mission LEVELS V«RY IT:
-- 1REA LOCATION
— INSTALLATION DATE
— SIZI
EIAKPLE 10-7
PARTICULATE HATTER aissim LIHIT
U1ISSION LIMIT
GR/OSCF «T
12 PERCENT CO.
10-3
MRYIAND VISIBLE EMISSION LIMITS
1. 2. 5. 5
• AFTER JANUARY 1972
• PRIOR TO JANUARY 1972
- «200 Li/N
- iZOO UJ/H
AREAS S. t
• <1 T/H AND <8 T/DAY
• >l T/H AND >8 T/0
O.I
0.5
0.2
0.1
Q. 05
NORMAL OPERATION
STARTUP. CHAKCIM.
APC EQUinENT CLEANIMS
*S NINUTE tVCRACE ONCE
PER HOUR
1. 2. 5. 5
^20 PERCENT
i"0 PERCENT*
3. 4
3 PERCENT
<»0 PERCENT*
Worksheet
Worksheet No. 6, Appendix C provides a format for summarizing
applicable regulations. There is space in the table for students to
list the specific requirements of their State's regulation and how
they apply to their incinerator. This worksheet should be completed
and discussed as a part of this session. Explain that the specific
limitations in their operating permits are the requirements they must
follow.
10-10
-------
TABLE 10-1. SUMMARY OF REGULATIONS FOR THE STATE OF
Your Incinerator
Regu1ated
Type of requirement State regulation (Yes/No) Level
Applicability
Type of waste charged
Size of incinerator
Age of incinerator
Emission limits
Particulate matter
Opacity
Carbon monoxide
Sulfur dioxide
Hydrogen chloride
Nitrogen oxides
Toxic metals
Organics
Other
Operating practices
Limits on characteristics of
waste charged (moisture,
volatility, etc.)
Waste packaging
Waste charging practices
Primary chamber temperature
Secondary chamber temperature
Residence time
Feed rate
Ash burnout levels
Ash handling and disposal
practices
Shutdown requirements
Control device temperature
Other
(continued)
10-11
-------
TABLE 10-1. (continued)
Your incinerator
Regulated
Type of requirement State regulation (Yes/No) Level
Equipment requirements
Incinerator design
Interlock systems
Automatic charging
Automatic ash removal
Other
Recordkeepinq
Incinerator temperature
Primary chamber
Secondary chamber
Control device
Temperature
Pressure drop
Liquid flow rate
Continuous monitoring records
Weight of waste charged
Other
Continuous emission monitoring
Opacity
Sulfur dioxide
Nitrogen oxides
Hydrogen chloride
Carbon monoxide
Other
Operator training
10-12
-------
LESSON PLAN
COURSE: HOSPITAL INCINERATOR OPERATOR TRAINING
COURSE
SESSION TITLE: SAFETY: AN IMPORTANT PART OF YOUR JOB
SESSION NO: 11
SESSION TIME: 30 MINUTES
GOAL
• To familiarize students with steps they can take to prevent
job-related injury and disease.
OBJECTIVES
At the end of this session, each student should be able to:
1. Name the activities in his/her job that could result in possible
injury or disease if proper precautions are not taken;
2. Name the types of containers used for infectious waste;
3. Describe proper waste-handling procedures;
4. List the protective clothing and safety equipment that should be
worn on the job;
5. Recognize the types of waste that must be discarded in red bags;
6. Name types of materials that shou-ld never be fed into an
incinerator;
7. Describe the safety precautions to take when charging the
incinerator;
8. Describe the safety precautions to take when removing the ash
from the incinerator ash compartment;
9. Describe the safety precautions to take when working around the
chamber of a mechanical ram feeder, ash conveyor, or incinerator;
10. Recognize the parts of the incinerator around which special
precautions are necessary;
11. Name the hazards associated with wet scrubber and fabric filter
operation and how to avoid them.
SUPPORT MATERIALS AND EQUIPMENT;
Slide set for Session 11; slide projector
SPECIAL INSTRUCTIONS;
None
HANDOUTS;
Appendix C: Worksheet No. 7—"Safety Review"
11-1
-------
Slide No. Title
1 Torn Waste Bag
2. Waste Handling Safety
3 Proper Safety Gear
4 Incinerator Operation—Injuries and Safety Hazards
5 Burner Flame Safeguard Systems
6 Incinerator Operation Safety Precautions: Do's
7 . Incinerator Operation Safety Precautions: Dont's
8 Incinerator Operation Safety Precautions: Charging
9 Ash Removal s~0o's
10 Ash removal s—Oont's
11 Wet Scrubbers—Hazards
12 Wet Scrubbers: Safety Precautions—Do's
13 Wet Scrubbers: Safety Precautions—Dont's
14 Fabric Filters: Hazards
15 Fabric Filters: Safety Precautions—Do's
16 Fabric Filters: Safety Precautions—Dont's
17 Emergency Procedures
11-2
-------
INTRODUCTION
Present the major goals of
the session to the
students: to familiarize
them with steps they can
take to prevent job—related
injury and disease.
SESSION 11.
SAFETY: AN IMPORTANT PART OF YOUR JOB
WASTE HANDLING
"RED BAG' WASTE
SLIOI 11-i
Hospital infectious wastes
usually are discarded in red
plastic bags or containers
marked with the universal
biological hazard symbol.
The following types of
infectious waste that are
considered infectious:
— Sharps (needles,
laboratory glass wastes,
etc.);
— Pathological wastes;
— Blood, blood products,
and body fluids;
— Human and animal tissue,
body parts, and bedding;
— Waste that has been in
contact with isolation
patients with communic-
able diseases; and TORN-RED-BAG
— Microbiological laboratory wastes, including cultures and stocks
of infectious agents.
11-3
-------
POSSIBLE HEALTH AND SAFETY PROBLEMS WITH RED BAG WASTE
There's a risk of injury and/or
disease from the red-bag waste, as
follows:
• Sharp objects (e.g.,
needles) might pierce through a bag
and puncture your skin.
• Infectious waste from an
open or torn bag might spill onto
your skin or clothing or be
swallowed accidentally.
• Airborne microorganisms
might be inhaled or
swallowed.
:.iat 11-2
HASTE HANDLING SAFETY
• SHARP flUKTS IN WASTE BAGS
• INFECTIOUS HASTE SPILUGE
• MICRO-ORGAN I SMS IN 1IR
PRECAUTIONS
• NlNINIZI IAG IUNOLINE
• 00 HOT OPEN OK CRUSH IKS
• NEAR PROTECTIVE CLOTHING INO SAFETY GEAR
• DO NOT EAT 0« DRINK IN THE
-------
PROTECTIVE CLOTHING
Suot 11-5
• Do wear proper
protective clothing and
safety equipment
— Thick rubber gloves
— Hard-soled rubber shoes
— Safety glasses
— Dust mask
~ Disposable coveralls or
hospital scrubs
• Do change clothing and
launder daily
• Do wash hands with soap
after handling waste and
before eating or drinking.
• DO NOT open bags or
crush/compact bags
• DO NOT eat or drink around
incinerator
INCINERATOR OPERATION
There are a number of potential hazards you may face in operating a
hospital incinerator, and they can be avoided if you take the proper
precautions.
POSSIBLE INJURIES AND SAFETY HAZARDS
PROPER SAFETY GEAR
Burns caused by:
— Contact with hot
surfaces of incinerator
or other equipment
— Careless charging
procedures
— Careless ash removal
procedures
— Opening inspection ports
when incinerator is
operating
Injury caused by:
— Getting too close to
moving belts or
hydraulic cylinders
— Lack of caution on
elevated walkways
Exposure to air contaminants
or lack of oxygen caused by:
Sum 11-4
INCINERATOR OPERATION—
INJURIES AHD SAFETY HAZARDS
Sums
— HOT SURFACES
— CAIILIIS CJUftfilM
— UMLUS *SN HUKHH.
— OMIIM imricnon WWTS
IftJIMY
— KOVIM HUTS 1*0 HTOMULIC CTUNOtM
Exnmni TO »i« cwrMiHUTs/uci or DITCH
— LIU II IQUtmUT M OUCTVOM
— no* VOTIUTIIM of »«u
11-5
-------
-- Leak in equipment or ductwork-positive side of fan
-- Poor ventilation of area-sufficient air needed
BURNER SAFETY
All burners have a burner safe
guard system. This system is
designed to stop fuel (gas or oil)
from going into the chamber if the
burner flame is out. If the chamber
were to fill with gas, and then
ignite, an explosion would occur.
The operator should be
encouraged to learn how the
safeguard system works and
should know NOT to try and
override the system.
BUHHER FLAKE SAFEGUARD SYSTEM
• CONTROLS sumu» IGNITION
• PUWEI STITCH
• PILOT iwinod
— OBTECTOH
-- IS SECONDS
— FUEL MUT
• HMN lUHNfK ISNITfCN
• SMUTDOVN
— FLAM OUT
— »m surfer FMLUIU
GENERAL SAFETY PRECAUTIONS
There are several do's and don'ts based on simple common sense concerning
activities involved with operating the incinerator. They are as follows:
00
Sum U-S
INCINERATOR OPtMTIOH SAFETY PRECAUTIONS
VIM nOTCCTIVI CLOTMIM mo SAFETY SEJU
8f OUtim. mown MIVIM IELTS. MTDIUULIC CYLINDERS.
Wear proper protective
clothing with no loose
flaps, belts, etc., that
might get caught on moving
mechanical parts
— Thick rubber gloves
— Hard-soled rubber shoes
— Safety glasses
— Oust mask
— Disposable coveralls
Be careful around all moving
belts, hydraulic cylinders,
and doors
Avoid contact with hot
surfaces of:
— Incinerator chamber
— Heat recovery equipment
(boiler)
— Ductwork
— Stack
Be on the lookout for fuel (gas/oil) leaks
Use caution on elevated walkways and keep your hands on the
siderails. Be alert to gaps in the walkway or obstacles you could
trip over.
AVOID comer HITN HOT SUKFICJS
HATCH FOX FUIL LUU
3l CMEFUL CM ELfVtTEO MLKIUTS
VfNTiurt mxM IF mute is utcx or OXYCE* on UNUSIML aoons
Lf*vi *«u IF rau otvtLor
— HUMOII. ommiusi. SMMTNCSS o* IHMTH. uusu
11-6
-------
If you notice unusual odors around an indoor incinerator, open doors
or windows to ventilate the room
If you develop any of the following symptoms that may indicate
contaminated" air or lack of oxygen, leave the area immediately:
— Headache — Nausea
— Drowsiness ~ Loss of coordination
— Shortness of breath — Eye irritation
DO NOT
Sum n-7
IHCHtMTOR OPGUT10H SAFETY PRECAUTIONS
DOJI'TS
• Do nor OPCN imf€CTio» rmn out me OPERATION
• Do HOT PUCI HANDS o* FEET INTO FEED »«» >SSEMILT an ASM
ctravti SYSTEM
• OO HOT LEAH ON CUAHOHAlCS OF "n
• Da nor LOOK mra an» CHAMI oaon
• DO HOT CHAKC IOTTLES OF FLAMHAILE LIOUIOS
11-7
-------
ASH REMOVAL SAFETY PRECAUTIONS
DO
Use either
— The mechanical ash ram
, or conveyor (if
available), or
— Rakes or flat shovels
with handles long enough
to reach the back of the
compartment.
Be careful of "hot spots"
and sharp objects in the ash
Place ash into a
noncombustible heat-
resistant container (metal)
and dampen with water to
cool it and to reduce
fugitive emissions (dust)
Sum 11-9
IHCIHEMTTJR OPERATION SAFETY PREOUITIOHS: ASH REKOVAL
Use rmn* laummr TO KCHOVE ASH
MITCH our ran HOT SPOTS ADO SHAH? OIJCCTS
Pur ASH i«ro MmcOMtusniLi CCNTAINM
SMUT MTM OK ASH III CO«TAIIU» TO COOL
00 NOT
SLIM 11-10
IMC1NEMTDR OPSMTini SAfETT BffCAUTIfJE; ASH HGCVAL
OOH'Tt
DO MT arm I»CI»C«ATO« CMUlf*
DO «OT OAHASl mciXUUTO* tC«ACTO»T
1) MT Sn*r MTCK IMTO CMMIf*
DO DOT MMOLI ASH OKtCTLT
• Damage the incinerator
refractory with the shovel
or rake
• Spray water into chamber
• Handle ash with bare hands;
if you must pick something
up by hand, wear protective
gloves
• Enter the incinerator
chamber
-- If, for some reason, you
must enter the chamber,
take proper
precautions. Be sure
the chamber has cooled
sufficiently to be safe
and purge it with air
before entering.
AIR POLLUTION CONTROL DEVICE OPERATION
The two types of air pollution control devices that you are most likely
to find at a hospital incinerator are wet scrubbers and fabric filters. This
section contains information about hazards associated with control devices and
safety precautions that you should be aware of.
11-8
-------
WET SCRUBBERS—POSSIBLE INJURIES AND HAZARDS
• Chemical burns can be caused
by the scrubber liquor if it
gets on your skin or in your
eyes.
• Falls could occur on wet
areas around the scrubber
caused by leaks in the
scrubber vessel, ductwork,
or piping.
• Injury could result from
getting too close to a fan
or fan belt drive assembly,
in which clothing could get
caught. A vibrating fan
could cause- the fan assembly
to disintegrate, causing
serious injury.
• Hearing loss could be caused
by the noise of operation of
the scrubber. Figure 10-4
shows the noise levels for
different activities and the
level at which hearing
protection is needed.
WET SCRUBBERS—SAFETY PRECAUTIONS
SLIOI 11-11
VET SCRUBBERS! HAZARDS
CHUMCAL IUIHI
FULLS
F»I1/MI| HLTS
HtAIIIM LOSS
00
Avoid contact with scrubber
liquor. If it does get on
your skin or in your eyes,
flush with water for at
least 15 minutes and seek
medical attention for eye
injuries.
Know the location of the
nearest eyewash and how to
use it
Be alert for scrubber leaks
and potential slippery
walkways. Ask maintenance
to repair major leaks.
Stay clear of rotating fan
drive shafts where clothing
could get caught.
SLIOI 11-12
UET SQaiMBB! SAFETY
• (UP sc»uui« LIQUOI arr s«i» ««o tvcs
• Lum LOCATION or urn MM ro usi jrt»«sH
• Srr icwuix LIAKS MPIIIHO
• SFAT A«r mm FANS, omvt SHAFTS. A»O n» ULT
WOOL I IS
• tfui wmuw M utmirn MOUM MIST
11-9
-------
DO NOT
Stay clear of fan belt drive
assembly where clothing
could get caught or belts
could break
Protect your hearing by
wearing earplugs or ear-muffs
Place hand in fan
belt/pulley assembly
Continue to operate scrubber
if fan is severely
vibrating; shut down
incinerator and call
maintenance
Suoc 11-13
; SAFETY PRECAUTION
DOH'TS
00 DOT PLACI HMD III ft* IILT/fULLtT ISSINILT
Do HOT coNTimic TO OPtMTi tr fu> is VIM* nice
SLIOI 11-il
FABRIC FILTERS: HAZARDS
FABRIC FILTERS—POSSIBLE HAZARDS
• Exposure to toxic chemicals
could occur when handling
dust collected from the
fabric filter
• Exposure to excessive heat
will occur if you get too
close to or touch the
surfaces of the fabric
filter. Fabric filters
generally operate at about
350°F.
• Injury could result from
getting too close to a fan
or fan belt drive assembly
in which clothing could get
caught. A vibrating fan
could cause the fan assembly
to disintegrate, causing
serious injury.
• Hearing loss could be caused by the noise of the fabric filter fan.
• Special hazards are inside the fabric filter, where you may be
required to go. However, you should enter a fabric filter ONLY IF YOU
HAVE BEEN SPECIFICALLY TRAINED AND EQUIPPED to survive the potential
hazards inside. These hazards include the following:
TOXIC CUtXIClLS III ftHE OUSTS
EXCESSIVE HUT
F»«/M» IU.TS
Hunt IK LOSS
(MIDI MM ic
— roue uiu ««o DUST
— HOT. Hll FUKIW SOLIDS
— oma
— (OTITIM
— MVIM KIOUHICJU. MKTS
11-10
-------
-- Moving mechanical parts (e.g., hopper air lock valves)
— Toxic gases and dust
-- Hot, free flowing solids
— Oxygen deficiency
— Rotating equipment (e.g., screw hoppers)
FABRIC FILTERS—SAFETY PRECAUTIONS
00
Wear safety shoes and other
protective clothing
Protect your hearing by
wearing earplugs or earmuffs
Stay clear of rotating fan
drive shafts where clothing
could get caught
Stay clear of fan belt drive
assembly where clothing
could get caught or belts
could break
If you must enter the fabric
filter:
— Thoroughly clean bags
SUM 11-15
FUHC. FILTERS! SAFETY PRECAUTIONS
Pitcvur INHALATION at OUST ir HEARING OUST »AS«
HUD URMJJSS OR EARMim AROUND noisr EQUIPMENT
STAT ANAT FKOM PAHS. DRIVE SHIFTS. AND FAN BELT ASSEMBLIES
3IFOM ENTERING A FAIRIC FILTER
— CLIAN OUST FRO» BASS AND HOPPER
— PURSI WITH Al*
— II Suit FAN IS "LOCKED OUT*
— HA»t A sican TRAINED PERSON STANOINC IT
-- HJU TO STAT INSIDE AS SHOUT A HUE AS POSSIILI
and hopper with
mechanical vibration
before entering
Purge the incinerator and fabric filter with air to drive out
exhaust gases before entering
Be sure fan is "locked out"
Be sure a second person is watching you in case you need help.
This person should be trained to go for help if needed and should
never enter the fabric filter, too.
Stay in the fabric filter for as short a time as possible to avoid
excessive exposure to heat
Wear a respirator to protect against dust
11-11
-------
DO NOT
Place hand in fan
belt/pulley assembly
Continue to operate fabric
filter if fan is severely
vibrating; shut down
incinerator and call
Maintenance Department
NEVER ENTER FABRIC FILTER
UNLESS YOU HAVE BEEN
PROPERLY TRAINED AND
EQUIPPED
•;iat 11-16
FAHHC FILTHS: SAFETY PRECAUTIONS
OON'TS
• 00 HOT PUCE H«NO IN H* iELT/PULLET «SSEJI«Lr
• Do HOT CONTINUE TO OPERUTE IF FAN is VIIMTIM SEVERELY
• NEVER ENTER FABRIC FILTER WITHOUT PROPER TRAINING AND
EQUIPMENT
EMERGENCY PROCEDURES
Post in convenient location
the phone number to call in
the event of an emergency
In the event of a spill,
follow proper cleanup and
decontamination procedures
Post procedures that are to
be followed if a puncture
occurs from a sharp
SLIDE 11-17
EHERSBIOr PROCEDURES
• POST TELEPHONE MJIIIERS FOR UUGMCY SERVICES
• SfOniTT SHOULD INCLUDE I»CI«»»TO» ON ROUNDS
• POST SPILL CDNriKlL/OtCONTiNINiTtaN PROCEDURES
• POST PROCEDURES FOR 1DDRESSINC =U»CTU«E KOUNOS
11-12
-------
REFERENCES FOR SESSION 11
1. U. S. Environmental Protection Agency. EPA Guide for Infectious Waste
. Management. EPA/530-SW-86-014. (NTIS PB 86-199130). U. S. EPA Office of
Solid Waste. May 1986.
2. U. S. Environmental Protection Agency. Operation and Maintenance Manual
for Fabric Filters. EPA 625/1-86/020. June 1986.
3. U. S. Environmental Protection Agency. Wet Scrubber Inspection and
Evaluation Manual. EPA 340/1-83-022. (NTIS PB 85-149375).
September 1983.
4. Richards Engineering. Air Pollution Source Field Inspection Notebook;
Revision 2. Prepared for the U. S. Environmental Protection Agency, Air
Pollution Training Institute. June 1988.
5. U. S. Environmental Protection Agency. Air Pollution Source Inspection
Safety Procedures: Student Manual. EPA-340/l-85-002a. September 1985.
6. Doucet, L. Waste Handling Systems and Equipment. Fire Protection
Handbook. 16th Edition. National Fire Protection Association.
11-13
-------
LESSON PLAN
COURSE: HOSPITAL INCINERATOR OPERATOR TRAINING
COURSE
SESSION TITLE: HANDS-ON DEMONSTRATION
SESSION NO: 12
SESSION TIME: 2-3 HOURS
GOAL
• To provide an opportunity conducive for the students to ask questions
about what they have learned
• To provide an opportunity for the students to see an Incinerator in
operation
OBJECTIVES
At the end of this session, each student should be able to locate the
major components of the incinerator system.
• Should understand the basic principles of this incinerator's control
system
• Should be able to point out any problems or safety hazards
SUPPORT MATERIALS AND EQUIPMENT:
1. Incineration facility
2. Applicable safety gear
— Hearing protection
— Safety glasses
— Hard solid shoes
— Other, as specified by facility
SPECIAL INSTRUCTIONS:
1. The course instructor should make prior arrangements in conjunction
with the course sponsor to have a facility available for a hands-on
demonstration. The instructor should make arrangements to visit the facility
and meet with the operator well in advance of the course, and should become
familiar with the Incinerator operation.
2. If possible, arrangements should be made to have someone who is
intimately familiar with the units design/operating features (e.g.,
representative from the incinerator manufacturer) available during the hands-
on demonstration.
3. When the hands-on demonstration is scheduled is crucial. If the
facility is intermittently operated and is located indoors, it may actually be
better to have the hands-on demonstration when the unit 1s shutdown. This
approach has two advantages:
12-1
-------
a. It may be Impossible to talk above the noise of an operating unit;
b. It is safer when the unit is not operated.
The ideal situation is to conduct the hands-on when the unit is down and then
foTIowup with brief observations as the unit comes on-line or is operating.
4. The purpose of the brief hands-on demonstration is not to provide
specific training for operators on the unit, but to provide a conducive
atmosphere for questions and for further exploring the concepts and issues
raised during the classroom portion of the course.
5. An outline for the hands-on demonstration is provided.
12-2
-------
HANDS-ON OUTLINE
I. System Walkthrough
A. Identify system type
B. Identify key components
•Combustion chambers
•Burners
•Combustion air fans/dampers
•View ports
•Charge System
•Ash System
•Control Panel
C. Identify location of monitors
•Temperature
•Pressure
•Opacity
•CO
•Oxygen
II. Control System/Key Parameters
A. Operating Mode
B. Type of Control System
C. Identify Control!ers/Setpoints/Functions Adjusted
•Primary Temp.
•Secondary Temp.
•Draft
•Charge rate
•Other
III. Observe Operation
A. Waste Handling
B. Charging
•Procedure
•Rate
C. Incinerator Operation
•Appearance of burner flame
•Appearance of waste bed
•Adjustment by automatic controllers
•Stack opacity
•Temperature trends
D. Ash Handling
•Procedures
•Ash quality
IV. Safety
•Any special precautions noted?
•Any apparent hazards?
12-3
-------
APPENDIX A.
COURSE REGISTRATION FORM
-------
REGISTRATION FORM
TRAINING COURSE FOR OPERATORS OF
HOSPITAL WASTE INCINERATORS
1. Name: Date:
Last First MI
2. Employer name:
Address:
3. Major job responsibility (check those that apply):
Supervisory
Operating incinerator/making adjustments
Loading waste
Ash handling
Minor upkeep of equipment (lubrication, etc.)
Maintenance, repair
Other. Describe:
4. Department you work in:
Housekeeping
Engineering
Maintenance
Other. Describe:
5. Experience - indicate number of years experience in each category below:
Supervisory
Operating incinerator/making adjustments
Loading waste
Ash handling
Minor upkeep of equipment (lubrication, etc.)
____ Maintenance, repair
Other. Describe:
6. Training:
Type of training
Approximate date(s)
Conducted by (other operator, supervisor, incinerator manufacturer,
consultant, etc.)
A-l
-------
APPENDIX B.
PRETEST AND POSTEST
-------
TRAINING COURSE FOR OPERATORS OF
HOSPITAL WASTE INCINERATORS
pretest
Note: The entire test is closed book. Enter all
answers on the ANSWER SHEET provided.
Part I: True-False
Note: For each of the following statements, circle on the answer sheet
letter T if the statement is True or the letter F if the statement is False.
1. T F The state or local air pollution control agency can include
special'rules and limitations in your permit to operate that are
more strict than typical State regulations.
2. T F No special training is required before entering a "fabric filter
baghouse.
3. T F It is always better to charge the incinerator with very large
charges and as few times as possible in a day.
4. T F When burning pathological waste, preheat of the secondary
combustion chamber is not needed.
5. T F Waste ash that does not meet landfill requirements can be refused
by the landfill, and monetary fines may be imposed for improper
ash disposal.
B-l
-------
Part II: Multiple Choice
Note: Circle the proper letter(s) on the answer sheet. All questions
have at least one answer and some questions require multiple answers.
1. The reason you need to be especially careful when handling "red bag" waste
1s because it might contain one or more of the following things that could
be harmful to you.
a. Human blood and blood products
b. Pathological wastes
c. Contaminated needles
d. Eploslve chemicals
e. Dloxins and furans
f. Carbon monoxide
2. Continuous-duty incinerators must include which of the following important
features not normally included in intermittent-duty incinerators?
a. Automatic waste feed
b. -Continuous ash removal
c. Temperature monitors
3. Excessively high pressure drop in a fabric filter may indicate what?
a. Inadequate cleaning
b. Bag blinding
c. Excessive gas volume
4. The unique feature of the controlled-air incineration principle is:
a. Large incinerators can be built
b. Combustion is controlled by limiting the air in the primary chamber to
below stoichiometric
c. The combustion chambers are shaped like cylinders
5. Corrosion of parts of a wet scrubber is caused by:
a. Too much iron in the water
b. Acid buildup in the scrubbing liquid
6. Which of the following problems is probably caused by too much air
entering the incinerator and Insufficient temperature?
a. Black smoke leaving stack
b. White smoke leaving stack
c. Poor ash quality
d. Incomplete burnout
B-2
-------
Part III: Fill in the Blanks
Choose from the list of terms at the bottom of this page and fill in the
blanks with the correct answers on the answer sheet.
1. List the three factors required for combustion.
•
I and
2. List the major objectives of hospital waste incineration.
•
; and
3. are used to monitor temperatures in the incinerator's
combustion cnambers and the inlet gas to the air pollution control system.
4. The oxygen concentration of the incinerator exhaust is measured with
an analyzer.
5. An monitor is used to monitor particulate matter
emissions from the incinerator.
Choose from the following terms to fill in the blanks in Part III.
preheat
aesthetic reasons-destroy wastes public finds objectionable
thermocouples
oxygen
incomplete combustion
waste sterilization
organic material
waste feed composition
opacity
heat
low emissions
ash handling
waste volume reduction
B-3
-------
Part IV; The schematic on the next page represents your incinerator. To the
best of your knowledge, answer the following questions on that sheet.
1.- What type of waste charging is used:
a. Single batch per run
b. Intermittent batch
c. Continuous
2. What type of primary chamber is used:
a. Fixed hearth—excess air
b. Fixed hearth—controlled air
c. Rotary kiln
3. Does the system have a primary air blower? (Circle the right answer)
4. Does the system have a secondary air blower? (Circle the right answer)
5. What type of auxiliary fuel -is used?
a. None
b. Natural gas
c. Fuel oil
d. Other
6. List the components of the air pollution control system.
7. Does your system have an induced draft fan?
8. The legends shown list parameters which might be monitored for a system.
Identify on the diagram with those symbols which parameters are monitored
at which locations.
B-4
-------
8.
CO
01
Auxiliary Fuel
5.
4. Yes/No
Air Blower
3. Yes/No
- Temperature
- Pressure (or Pressure Difference)
- Liquid Flow Rate
- Solids Rate
- Gas or Air Flow Rates
- Oxygen
- Carbon Monoxide
Secondary
Combustion
Chamber
Waste
Charging
Primary
Combustion
Chamber
1.
2.
-o
pi
rt-
XD
n>
(/>
rt
_j.
o
3
00
to
o
Air Pollution
Control
System
6.
I.D. Fan
7. Yes/No
-------
TRAINING COURSE FOR OPERATORS OF HOSPITAL WASTE INCINERATORS
Answer Sheet for Pretest
Date: Name:
Part
l'.
-2.
3.
4.
5.
I True-False
T F
T F
T F
T F
T F
Part III Fill In the Blanks
1. ;
; and
; and
Part II Multiple Choice 3.
4.
1. a b c d e f 5.
2. a b c
3. a b c
4. a b c
5. a b
6. abed
B-6
-------
TRAINING COURSE FOR OPERATORS OF
HOSPITAL WASTE INCINERATORS
POSTTEST
Note: The entire"test is closed book. Enter all
answers on the ANSWER SHEET provided.
Part I: True-False
Note: For each of the following statements, circle on the answer sheet
the letter T if the statement is True or the letter F if the statement is
False.
I.I. T F The greater the opacity of stack emissions, the better. That
is, 30 percent opacity is better than 10 percent opacity.
2. T F The most important parameters that the incinerator operator
should rely upon to monitor operation are the primary and
secondary chamber temperatures.
3. T F On batch units, the ash pit should be cleaned out every 2 days.
4. T F The only materials in red bag waste that present environmental
and safety concerns are pathogens in pathological wastes.
5. T F Your local air pollution control agency can only set limits
that are more lenient than those required by State
regulations.
B-7
-------
Part II: Multiple Choice
Note: More than one answer may be used. Circle the proper letter(s) on
the answer sheet.
A. Which of the following symptoms may indicate exposure to air
contaminants or lack of oxygen?
1. Headache
2. Drowsiness
3. Shortness of breath
4. Nausea
5. Loss of coordination
6. Eye irritation
B. You should avoid contact with scrubber liquor because it:
1. Can cause chemical burns to your skin or eyes
2. Will make you pass out if you smell it
3. Will give you a fatal skin disease
d. Can cause respiratory problems if you inhale fumes.
3. The unique feature of the controlled-air incineration principle is:
a. Large incinerators can be built
b. Combustion is controlled by limiting the air in the primary
chamber to below stoichiometric
c. The combustion chambers are shaped like cylinders
4. Overcharging can cause
a. Increased CO emissions
b. Incomplete combustion
c. High temperatures
d. Excessive auxiliary fuel usage
5. Key parameters monitored on a wet scrubber are:
a. Liquid flow rate or pressure
b. Opacity
c. pH
d. Pressure drop
e. Water temperature
6. Key parameters monitored on a fabric filter are:
a. Pressure drop
b. Inlet temperature
c. pH
d. Airflow rate
e. Opacity
B-8
-------
Part III; Fill in the Blanks
Choose from the list of terms on the following page and fill in the
b-lanks with the correct answers on the answer sheet.
II. 1. Name the proper clothing and equipment you should wear when
handling hospital waste or operating the incinerator or air
pollution control system.
.»
; and
III. 2. Name at least two types of records that you may be required to keep
by State regulations.
3. List two combustion conditions that can cause high stack gas CO
concentrations.
4. Describe the combustion conditions that result in high opacity of
emissions from the incinerator stack.
5. The operator should routinely look at the stack to monitor the
stack gas .
6. List the main air pollutants of concern from hospital waste
incinerators.
.»
; and
7. White spots or discoloration of the outer surface of the
incinerator found during inspection may indicate a loss
of inside the unit and should be reported to the
maintenance department.
B-9
-------
8. The types of monitors used to measure these parameters are:
a.
b.
c.
Temperature
Pressure _
Opacity
or
Choose from the following terms to fill in the blanks in Part III.
refractory
opacity
poor mixing or low excess air which
causes soot formation
particulate matter
thick rubber gloves
poor mixing
magnahelic
chlorine
hydrochloric acid gas
low temperature
hard-soled rubber shoes
temperature of incinerator chamber(s)
pathogens
low excess air
disposable coveralls/long-sleeved shirt
control device temperature
earplugs or earmuffs
toxic metals
thermocouple
toxic organics
safety glasses
weight of waste charged
dust mask
scrubber pressure drop or liquid
flow rate
carbon monoxide
transmissometer
U-tube manometer
Thermometer
Venturi-meter
B-10
-------
Part IV. Matching
The numbered, list on the left identifies common operating problems. The
list on the right identifies possible causes of-the problem. All problems are
associated with one or more causes and causes can be used more than once.
Write all appropriate letters in the numbered blanks on the answer sheet.
1.- High fabric filter pressure
drop
2. Wet scrubber corrosion
3. High opacity—black smoke
4. Poor ash quality
a. Excess airflow
b. Too little underfire air
c. Acid buildup in liquid
d. Positive pressure in primary
chamber
e. Bag blinding
f. Too little water flow
g. Too much air in secondary chamber
h. Too much waste charged
i. Tears in bag
j. Primary temperature too low
k. Too little air in secondary chamber
B-ll
-------
Part V: The schematic on the next page represents your incinerator. To the
best of your knowledge, answer the following questions on that sheet.
1. What type of waste charging is used:
a. Single batch per run
b. Intermittent batch
c. Continuous
2. What type of primary chamber is used:
a. Fixed hearth—excess air
b. Fixed hearth—controlled air
c. Rotary kiln
3. Does the system have a primary air blower? (Circle the right answer)
4. Does the system have a secondary air blower? (Circle the right
answer)
5. What type of auxiliary fuel is used?
a. None
b. Natural gas
c. Fuel oil
d. Other
6. List the components of the air pollution control system.
7. Does your system have an induced draft fan?
8. The legends shown list parameters which might be monitored for a
system. Identify on the diagram with those symbols which parameters
are monitored at which locations.
B-12
-------
CD
h-»
CO
8.
- Temperature
- Pressure (or Pressure Diflerence)
- Liquid Flow Rate
- Solids Rate
- Gas or Air Flow Rates
- Oxygen
- Carbon Monoxide
Auxiliary Fuel
5.
4. Yes/No
Secondary
Combustion
Chamber
Air Blower
3. Yes/No
Waste
Charging
Primary
Combustion
Chamber
1.
2.
fu
n>
to
rt
00
10
0
:T
Air Pollution
Control
System
6.
I.D. Fan
7. Yes/No
-------
TRAINING COURSE FOR OPERATORS OF HOSPITAL WASTE INCINERATORS
Answer Sheet for Pretest
Date: Name: Answer key
Part I True-False Part III Fill in the Blanks
1. (?) F 1. Oxygen
Organic material ; and
2. T © Heat
3. T (F)
2. Aesthetic reasons :
4. T (£) Wa-ste sterilization ; and
Waste volume reduction
5. © F
3. Thermocouples
Part II Multiple Choice 4. Oxygen
5. Opacity
B-14
-------
TRAINING COURSE FOR OPERATORS OF HOSPITAL WASTE INCINERATORS
Answer Sheet for Posttest
Date: Name: Answer key
Part I True-False Part III Fill in the Blanks
1. T (F) 1. Thick rubber gloves
Hard-soled rubber shoes
2. (T) F Disposable coveralls/long-sleeved shirt;
Earplugs and eannuffs ;
3. T (F) Safety glasses ; and
Dust mask .
4. T ©
2. Temperature of incinerator chamber(s) ;
5. T (?) ' Weight of waste charged
3. Poor mixing
Low excess air
Part II Multiple Choice 4. Poor mixing or low excess air which
causes soot formation
5. Opacity
6. Hydrochloric acid gas
Toxic metals
Toxic organics
Carbon monoxide
Particulate matter
7. Refractory
.Thermocouple
b.Magnahelic
or U-tube manometer
c.Opacity monitor/transmissometer
Part IV Matching
1. e
2. c
3. b. h. k
4. b, h
B-15
-------
rt-
8.
—Mj - Temperature
—("p) - Pressure (or Pressure Difference)
- Liquid Flow Rate
- Solids Rate
CD
I—'
o>
c.
n>
in
o
3
00
TJ
O)
— iv«
-------
APPENDIX C.
REVIEW EXERCISES
-------
WORKSHEET NO. 1
INCINERATOR SYSTEM INFORMATION
Can you describe the type incinerator you operate? Fill out this
table. Circle the answer that best fits your system.
Operator's name
Incinerator manufacturer
A. Incinerator type (Circle)
1. Controlled ("starved") air
2. Multiple chamber "excess" air
• In-line
• Retort
3. Rotary kiln
4. Other
5. Don't know
B. My incinerator is designed especially for pathological waste:
Yes No Don't know
C. Operating mode
1. Single batch
2. Intermittent duty
3. Continuous duty
4. Don't know
D. Waste feed charge system
1. Manual - I do all the work
2. Mechanical hopper/ram
a. Manually operated
b. Automatic timer sequence
3. Mechanical hopper/ram with cart dumper
4. Other
5. Don't know
E. Ash removal system
1. Manual - rake and hoe
2. Continuous mechanical
3. Don't know
C-l
-------
INCINERATOR SYSTEM INFORMATION (CONTINUED)
F. Combustion Gas Flow
1. Natural draft
2. Induced draft
3. Balanced draft
• Forced combustion air/natural draft stack
• Forced combustion air/induced draft fan
G. Waste heat boiler
1. Yes
2. No
C-2
-------
WORKSHEET NO. 2
INCINERATOR SYSTEM INFORMATION
Monitoring and Control Systems
Operator's name
Incinerator manufacturer
A. How would you describe the operating made of your incinerator?.
1. Single batch
2. Intermittent duty
3. Continuous duty
B. How would you describe the control system used on your incinerator?
1. Manual
2. Automatic timer sequence
3. Automatic modulated control
C. What operating parameters are monitored or used as control parameters
on your incinerator?
Function
Monitored Controlled Controlled
1. Primary Chamber
Temperature
2. Secondary Chamber
Temperature
3. Draft
4. Charge rate
5. Oxygen
6. Carbon Monoxide
7. Opacity
8. Other:
C-3
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INCINERATOR SYSTEM INFORMATION
WORKSHEET NO. 3
Operating Parameters
Operator's name
Incinerator manufacturer
What are the
key operating parameters for your incinerator. What are the setpoints or
operating ranges used?
Key Parameter Setpoints/Operating Range No setpoint
1. Primary chamber
temperature
2. Secondary chamber
temperature
3. Draft
4. Charge rate
5. Oxygen concentration
6. Carbon monoxide
concentration
lower
C-4
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WORKSHEET NO. 4
OPERATING REVIEW
A. List the things to do when operating your incinerator that you
think are the most important:
1.
2.
3.
4.
5.
B. Name the things to watch (monitor) when operating your
incinerator that you think are the most important.
1.
2.
3.
4.
5.
C. Name the things not to do when operating your incinerator that
your think are the most important:
1.
2.
3.
4.
5.
C-5
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WORKSHEET NO. 5
OPERATING PROBLEMS REVIEW
What are the most frequent problems you usually have?
A. Problem;
Possible causes:
Possible solutions:
B. Problem;
Possible causes:
Possible solutions:
C. Problem:
Possible causes:
Possible solutions:
C-6
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WORKSHEET NO. 6
INCINERATOR SYSTEM INFORMATION
Regulatory Limits
Operator's name
Incinerator manufacturer
What regulatory limits are you required to meet during operation of
your incinerator?
Limit
A. Emission Limits:
1. Opacity.
2. Particulate
3. Other
B. Operating Limits
1. Charge rate
2. Primary chamber temp
3. Secondary chamber temp
4. Oxygen concentration
5. Ash quality
6. Other
C. Record Keeping
1. Charge rate
2. Primary chamber temp
3. Secondary chamber temp
4. Other
C-7
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WORKSHEET NO. 7
SAFETY REVIEW
A. What personal safety gear do you use?
1. Coveralls
2. Hard soled shoes
3. Eye protection
4. Gloves
5. Oust mask
6. Ear protection
B. List the most serious safety hazards to which you are exposed.
How do you minimize your chances of injury??
1.
2.
3.
4.
5.
C-8
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TECHNICAL REPORT DATA
'Please reaa instructions on me reverse oerore comotennei
REPORT NO.
EPA 450/3-89-010
12.
|3. RECIPIENT'S ACCESSION NO.
i
I
. TITLE AND SUBTITLE
Hos'pital Incinerator Operator Training Course:
Volume III Instructor Handbook
|5. REPORT DATE
! Marrh 1Q8Q
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
8. PERFORMING ORGANIZATION REPORT NO. I
Neulicht, R. M.; Chaput, L. S.; Wallace, D. D.;
Turner, M. B.; Smith, S. G.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Midwest Research Institute
401 Harrison Oaks Boulevard, Suite 350
Gary, North Carolina 27513
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-02-4395
68-08-0011
12. SPONSORING AGENCY NAME AND ADDRESS
U. S. Environmental Protection Agency
Control Technology Center
Research Triangle Park, N. C. 27711
13. TYPE OF REPORT AND PERIOD COVERED I
Final _J
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
James Eddinger, Office of Air Quality Planning and Standards
Justice Manning, Center for Environmental Research
16. ABSTRACT
This document is Volume III of a three-volume training course for operators of
hospital waste incinerators. Volume I is the Student Handbook (EPA 450/3-89-003).
and Volume II is the Presentation Slides (EPA 450/3-89-004). This training course
was originally prepared by the Control Technology Center for the State of Maryland.
The purpose of this course is to provide hospital waste incinerator operators with a
basic understanding of the principles of incineration and air pollution control and
to identify, generally, good operation and maintenance (O&M) practices. Proper O&M,
in addition to reducing air emissions, improves equipment reliability and perfor-
mance, prolongs equipment life, and helps to ensure proper ash burnout. The course
is not intended to replace site-specific, hands-on training of operators with the
specific equipment to be operated.
Volume III provides the basic materials for use by the course instructor. It
presents the course description and agenda, course goals, lesson plans, and pretest
and posttest materials. Each lesson plan specifies the goals and objectives for the
session and presents an outline and discussion keyed to thepresentation slides and
the student handbook. The lesson topics include basic combustion principles and
incinerator design; air pollution control equipment design, function, operation, and
monitoring; incinerator operation; maintenance inspections; typical problems; and
State regulations.
7.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lOENTIFIERS/OPEN ENDED TERMS
COSATI Held/Group
Medical Waste Incineration
Hospital Waste Incineration
Air Pollution Control Technology
Incinerator Operator Training
Incineration
Medical Waste
Hospital Waste
Air Pollution Control
Training
pa. DISTRIBUTION STATEMENT
! Release unlimited
19. SECURITY CLASS (This Reporti
\O. OF PAG53
20. SECURITY CLASS iThayagei
i2. PRICE
SPA Form 2270-1
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