On-Site Incineration at the
Petro Processors Superfund Site
Baton Rouge, Louisiana
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Incineration at the Petro Processors Superfund Site
Baton Rouge, Louisiana
Site Name:
Petro Processors Superfund
Site
Contaminants:
Chlorinated Hydrocarbons,
Polynuclear Aromatic
Hydrocarbons (PAHs), Heavy
Metals, and Oils
• Hexachlorobutadiene and
hexachlorobenzene
Period of Operation:
November 1994 to Present
Location:
Baton Rouge, Louisiana
Cleanup Type:
Remedial action
Site General Contractor:
NPC Services, Inc.
500 Brooklawn Drive
Baton Rouge, Louisiana 70816
(504) 778-6200
Technology:
On-Site Incineration
• Combustion of fumes and
liquids from groundwater
treatment system
• Incineration system consisting
of a horizontal, direct-fired
kiln
• Air fan delivers fumes and
centrifugal pump delivers
liquids to the unit
• Kiln temperature of 2,000°F
to 2,400°F
• Blowdown from the system is
pH adjusted with lime and
discharged
Cleanup Authority:
CERCLA and State: Louisiana
• ROD Date: No ROD,
Consent Decree took the
place of the ROD
• RP-lead
SIC Code:
4953 (Refuse Systems)
Point of Contact:
Cynthia Kaleri
Remedial Project Manager
U.S. EPA Region 6
1445 Ross Avenue
Dallas, Texas 75202-2733
(214) 665-6772
Waste Source:
Disposal of petrochemical
wastes in on-site lagoons
Type/Quantity of Media Treated:
Liquids and Fumes
• 213,376 gallons of DNAPLsto date
Purpose/Significance of
Application:
Incinerator treats liquid
organics and air stripper fumes
from a groundwater treatment
system
Regulatory Requirements/Cleanup Goals:
• Destruction and Removal Efficiency (DRE) of 99.99% for organic constituents of concern as
required by Resource Conservation and Recovery Act (RCRA) incinerator regulations in 40 CFR
part 264, subpart O
Results:
• Emissions and trial burn data indicate that all DRE and emission standards have been met to date
Cost Factors:
• Total cost of the incinerator is approximately $32,827,799 to date
• Approximate Total Capital Costs: $18,159,087 (including equipment, site preparation,
construction/engineering, startup); Projected Future Capital Costs: $500,000
• Approximate Total Operating Costs: $14,668,912 (including maintenance, project management,
sampling and analysis, supplies): Projected Future Monthly Operating Costs: $300,000 per month
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Incineration at the Petro Processors Superfund Site
Baton Rouge, Louisiana
(Continued)
Description:
Between 1961 and 1980, the Petro Processors Superfund Site operated as a petrochemical waste
disposal area. A remedial investigation determined that soil and groundwater at the site were
contaminated. A Consent Decree entered into Federal Court on February 16, 1984 specified that a
plan of action be developed for the site. The plan included a groundwater treatment system which
utilized an incinerator to treat liquid organics and air stripper fumes. Site cleanup goals and DRE
standards were specified for the organic constituents of concern.
The treatment system began operation in November 1994 and is ongoing at the time of this report.
The incineration system consists of a horizontal, direct-fired incinerator. A centrifugal pump and an
combustion air fan deliver the liquid and fume waste, respectively, to the incinerator. The incinerator
is equipped with an air pollution control system consisting of a quench tank; an HCI absorber/caustic
scrubber tower; a particulate scrubber; and a entrainment separator.
The total cost of the remedial action is approximately $32,827,799 to date. Capital costs accounted
for approximately $18,159,087 with a projected future cost of $500,000. Operation and maintenance
costs accounted for approximately $14,668,912 with a projected future monthly cost of $300,000.
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Petro Processors Superfund Site
Executive Summary
This report presents cost and performance data
for the application of on-site incineration at the
Petro Processors (Petro) Superfund site in
Baton Rouge, Louisiana. Since November
1994, an incinerator designed to dispose of
fumes and liquids from the groundwater
treatment system has been operating as part of
a remedial action. Contaminants of concern at
the site include chlorinated hydrocarbons,
polynuclear aromatic hydrocarbons (PAHs),
heavy metals, and oils.
The Petro site operated as a petrochemical
waste disposal site from 1961 to 1980. During
this period, various chemical wastes were
disposed of in lagoons. It was estimated based
on the results of an investigation conducted at
the site that 330,000 m3 of soil was
contaminated. Groundwater and soil at Petro is
contaminated with hexachlorobutadiene and
hexachlorobenzene.
In 1984, a Consent Decree was signed by
Federal and State government agencies and the
Responsible Parties (RPs) for the Petro site. A
Destruction and Removal Efficiency (DRE) of at
least 99.99% for organic constituents of concern
was called for by the approved operating
specifications.
Remedial activities at the site include the
design, construction and operation of a
groundwater treatment system which uses the
incinerator for the destruction of the residuals
generated. This report focuses on the cost and
performance of the incinerator and does not
present any detailed information on the
groundwater treatment system.
Groundwater is currently being extracted with a
system of 165 recovery wells. Recovered
groundwater is treated by phase separators to
remove non-aqueous phase liquids (NAPLs)
from the water; the separated water is treated
with air strippers to remove additional
contaminants.
The NAPLs removed by the groundwater
treatment system are stored in a waste feed
tank prior to being fed to the incinerator
through a liquid waste feed nozzle. The
vent gas from the air strippers also is fed to
the incinerator as part of the combustion air.
The incineration system consists of a vent
gas feed system; a liquid waste feed
system; a horizontal, direct-fired incinerator;
a quench tank; a HCI absorber/caustic
scrubber; a particulate scrubber; and an
entrainment separator.
The incinerator volatilizes and destroys
organic compounds from the liquid and
fumes. Treated gas is then drawn into the
quench tower for cooling. The HCI
absorber/caustic scrubber then removes
HCI, Cl2, S02, and some particulate matter.
The particulate scrubber and entrainment
separator remove additional particulate
matter before off-gas is released through
the stack.
During the 30 months of operation, the
incinerator has processed approximately
213,376 gallons of dense non-aqueous
phase liquids (DNAPLs). Treatment
performance and emissions data collected
during this application indicate that all
performance standards and monitoring
requirements are being achieved.
The cost for treatment of the residuals using
the incineration system is approximately
$32,827,799 to date. This amount consists
of $18,159,087 in capital costs and
$14,668,900 in operating costs.
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Solid Waste and Emergency Response
Technology Innovation Office
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Petro Processors Superfund Site
Site Information
Treatment Application
Type of action: Remedial (groundwater
treatment with on-site incineration of
residuals)
Period of operation: 1994 - present
Identifying Information
Petro Processors Superfund Site
Baton Rouge, Louisiana
CERCLIS #: LAD057482713
ROD Date: Not Applicable. A Consent Decree
was issued in lieu of a ROD.
Background
Historical Activity that Generated
Contamination at the Site: Waste collection
and disposal
Corresponding SIC Code: 4953 (Refuse
Systems)
Waste Management Practice That Contributed
to Contamination: Disposal of waste in on-site
lagoons.
Site History:
The Petro site operated from 1961 until its
closure in 1980. The site is comprised of
two former petrochemical waste disposal
areas, the Scenic Highway and Brooklawn
areas, which are located approximately 1.5
miles apart.
The Scenic Highway area operated from
1961 until 1974 and covers approximately
17 acres. The area was filled and closed in
1974, but there was still concern over the
potential for leachate migration and erosion.
The Brooklawn site operated from 1969 until
1980 and covers approximately 60 acres.
No known actions were taken to mitigate
potential risks to human health and the
environment at the time operations ceased.
During the site's period of operation, various
petrochemical wastes were disposed of in
unlined lagoons. It was estimated based on
investigation at the site that 330,000 m3 of
soil was contaminated.
Soil and groundwater at Petro were
contaminated with chlorinated
Quantity of material treated during
application: 213,376 gallons of LNAPLs to
date
hydrocarbons, PAHs, heavy metals, and
oils.
A spill from the waste lagoons in 1969
contaminated a local ranch, killing 30
cattle. Additionally, on several
occasions, waste in the lagoons
spontaneously ignited.
The Petro site is located over a drinking
water aquifer for the area referred to as
the 400-foot sands.
In July 1980, the U.S. Department of
Justice, the State of Louisiana, the City
of Baton Rouge, and the Parish of East
Baton Rouge filed suit against the site
owner and several waste generators
who had transported material to the site
for disposal [1],
A Consent Decree was entered into the
Federal Court's record on February 16,
1984. Under the terms of the decree
the site was closed and the RPs were
required to investigate and develop a
detailed plan of action for the Petro Site
[1]-
The proposed remedy included the
excavation and incineration of visibly
contaminated soil; the solidification,
incineration, or off-site disposal of all
non-aqueous phase wastes in the
lagoons; and the installation of recovery
wells to recover NAPLs [1],
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Solid Waste and Emergency Response
Technology Innovation Office
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Petro Processors Superfund Site
Site Information (Cont.)
Background (Cont.l
In 1987, during the early phases of the
excavation at Brooklawn, on-site air
monitoring equipment detected volatile
organic compounds. Operations at the site
ceased in order to protect the safety of on-
site workers and the safety of workers at
industrial plants adjacent to the site.
In December 1988, the RPs reported in a
Supplemental Remedial Action Plan
(SRAP) that the remediation could not
continue under the proposed plan without
future unacceptable releases of volatile
organic compounds. As required by the
Consent Decree, the RPs also proposed
methods for remediation in the SRAP. EPA
Region VI, however, found the RPs' findings
insufficient and began an internal 18-month
review of potential remedial solutions.
In 1989, the SRAP was approved amending
the Consent Decree and the remedy
changed to capping the lagoons and
hydraulic containment of the groundwater
plume. Based on the findings of the
amended Consent Decree, the RPs began
design and construction activities.
The majority of the Brooklawn area was
covered by a soil cap, seeded, and
contoured to control erosion. This action
was completed July 1990, at which time the
RPs also submitted a workplan for the
earthwork which was needed at the Scenic
Highway site. One lagoon in the area was
and currently is left open in order to deposit
drill cuttings from the wells installed on site.
A groundwater treatment system was
installed in 1994, which currently includes
98 sumps and 190 operating recovery wells
of a planned number of 213.
As in the Brooklawn area, the Scenic
Highway area was covered with a soil cap,
seeded, and contoured to control erosion.
This action was completed September
1992. In October 1996, eleven
recovery wells were installed to recover
NAPLs from the area and thirty-four
monitoring wells were installed to gauge
the natural attenuation of the plume.
The contingent remedy had not been
implemented at the time this report was
prepared.
The treatment system that was
constructed at the Brooklawn area
included an incinerator which was
capable of disposing of both organic
liquids and fumes. A trial burn was
conducted the week of November 7,
1994, after which the incinerator began
operating under interim conditions. The
final operating specifications were
approved by EPA on December 28,
1995.
Bayou Baton Rouge was re-routed
during remedial activities so that it did
no flow through the site. Portions of the
site are located within the Bayou Baton
Rouge flood plain.
A section of the Brooklawn area is in the
Mississippi River flood plain.
Additionally, the Mississippi flood plain
located to the south of the Brooklawn
area, known as Devil's Swamp, is
classified as a wetland. A state health
advisory currently covers parts of
Devil's Swamp.
Regulatory Context:
In 1984, the Petro Site was placed on
the National Priorities List (NPL).
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Solid Waste and Emergency Response
Technology Innovation Office
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Petro Processors Superfund Site
Site Information (Cont.)
Background (Cont.l
In 1984, a Consent Decree was filed into
Federal Court, which required remedial
activities at the site in Baton Rouge,
Louisiana.
Treated groundwater is discharged under a
National Pollutant Discharge Elimination
System (NPDES) permit.
The DREs were set in accordance with
Resource Conservation and Recovery Act
(RCRA) incinerator regulations in 40 CFR,
part 264 subpart O.
Timeline
Remedy Selection: Hydraulic containment
and recovery followed by on-site
incineration of free-product and nonaqueous
organic residuals from the groundwater
treatment system was selected as the
remedy for the Petro Processors Superfund
site. On-site incineration was selected
based on the cost associated with using an
incinerator and the reduction in long-term
threats to human health and the
environment which occurred as a result of
destroying the contaminants.
Tab e 1. Timeine
Date
Activity
1961 - 1980
The Petro Site was used for disposal of petrochemical waste
February 1984
Consent Decree established for site cleanup
1984
Petro Site was placed on the NPL
1987
Remedial construction begins
1989
Consent Decree amended
November 7-11,1994
Trial Burn
November 1994 - December 1995
Incinerator operated under interim standards
December 28.1995
Final ooeratina standards approved for incinerator
Site Loaistics/Contacts
Site Management: RP-lead
Oversight: EPA
Remedial Project Manager:
Cynthia Kaleri
U.S. EPA Region 6
1445 Ross Avenue
Dallas, Texas 75202-2733
(214) 665-6772
State Contact:
Glenn Miller
Louisiana Department of Environmental
Quality
Inactive and Abandoned Sites Division
P.O. Box 82282
Baton Rouge, Louisiana 70884-2282
Site General Contractor:
Bill Dawson
NPC Services, Inc.
3867 Plaza Tower Drive
Baton Rouge, Louisiana 70816
(504) 778-6206
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Solid Waste and Emergency Response
Technology Innovation Office
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Petro Processors Superfund Site
Matrix Description
Matrix Identification
Type of Matrix Processed
Through the Treatment System: Organic
liquid and gas residuals generated during the
treatment of groundwater contaminated by
infiltration from unlined waste lagoons used for
waste disposal.
Contaminant Characterization
Primary Contaminant Groups: Chlorinated • The contaminants of greatest concern
hydrocarbons, PAHs, heavy metals, and oils were hexachlorobutadiene and
hexachlorobenzene.
Matrix Characteristics Affecting Treatment Costs or Performance
Information on matrix characteristics was not available.
Treatment System Description
Primary Treatment Technology
Incineration system including:
Fume waste feed system
Organic liquid waste feed system
Horizontal, direct-fired incinerator
Supplemental Treatment Technology
Pretreatment (liquids):
Agitation
Post-Treatment (air):
Quench tank
HCI absorber/caustic scrubber tower
Particulate scrubber
Entrainment separator
Post-Treatment (water):
pH adjustment
Carbon adsorption
System Description and Operation
Groundwater is recovered from the
Brooklawn site using an existing system of
165 extraction wells. The groundwater is
pumped through phase separators to
remove NAPLs and air strippers to remove
dissolved organics. The treatment system
is designed to treat groundwater with 1,000
to 2,000 mg/L of chlorinated organics.
The NAPL liquid waste is stored in a waste
feed tank, which contains an agitator to
maintain a homogenous mixture, prior
to being fed into the incinerator. The
tank is a pressure vessel rated at 15
psig with a storage capacity of 4,760
gallons, which provides storage capacity
of approximately one day. [2].
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Technology Innovation Office
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Petro Processors Superfund Site
Treatment System Description (Cont.)
System Description and Operation (Cont.l
The tank is padded with nitrogen to
maintain an inert, non-flammable mixture
above the liquid and it is kept at an
operating pressure between 2 and 10
psig. To maintain the correct pressure,
the tank is vented as needed to the
incinerator through a flame arrestor. The
waste tank is equipped with an electric
heating panel to control the viscosity of
the waste at a temperature between 70°F
and 95°F.
The liquid waste is pumped by a
centrifugal pump through a strainer to
remove any solids and into the incinerator
liquid waste feed nozzle. The liquid waste
feed is monitored by a Coriolis meter and
controlled by a flow control valve and a
safety shutoff valve. If an automatic
waste feed cutoff (AWFCO) is initiated,
the pump is shut down, and the feed
control valve and safety shutoff valve are
closed. The liquid waste feed nozzle is
atomized with air supplied by an on-site
air compressor; the atomization air
pressure is maintained above the liquid
waste feed pressure at the nozzle [2].
The vent gas stream produced by the air
strippers is fed to the incinerator through a
combustion air fan and is discharged into
the incinerator as part of the total
combustion air. The flow of the
combustion air fan is controlled such that
the minimum air flow to the incinerator
exceeds the vent gas flow; this is
designed to provide the incinerator with
sufficient air for proper combustion. A
gravity damper allows fresh air to be
pulled into the blower with the vent gas
stream if the burner demands more air
than that supplied by the vent gas stream
[2].
The design maximum vent gas flow rate
is 2,800 standard cubic feet per minute
(scfm); the combustion air fan has a
design capacity of 3,260 scfm. The
combustion air flow is monitored by a flow
meter and controlled by a flow control
valve on the suction line [2].
The incinerator is 30 feet in length, has an
outer diameter of 8.5 feet, and is lined
with 8 inches of firebrick and castable
lining. The incinerator has a firing
capacity of 14 million BTU/hr. A negative
pressure is maintained within the
incinerator in order to prevent fugitive
emissions.
The incinerator is designed to dispose of
vent gases and liquids simultaneously, but
can process either wastestream
separately should an AWFCO occur.
The incinerator operates in both a fume
and liquid-injection mode. While
operating in the fume mode natural gas is
used as a fuel. The liquid-injection mode
includes operation while using liquid
organics recovered from the site to
supplement or replace the natural gas [2].
The incinerator is equipped with two
burners. A low-NOx main burner is used
for firing liquids. The waste and
atomization air are discharged from the
nozzle through small orifices in the nozzle
tip directly into the main burn flame [2].
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Solid Waste and Emergency Response
Technology Innovation Office
129
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Petro Processors Superfund Site
Treatment System Description (Cont.)
System Description and Operation (Cont.l
Natural gas is used as auxiliary fuel for the
incineration system and is fed to the
incinerator through a burner located at the
inlet end of the incinerator chamber, which
is fired tangentially into the main burner
flame [2]. The design liquid waste feed rate
is 1,600 Ib/hr and the design temperature for
liquid-injection operation is 2,000°F to
2,400°F.
The exhaust gas from the incinerator is
channeled to the quench tower, where it is
cooled with water to approximately 175°F.
The quench tank is a vertical, wet-walled,
rubber-lined steel vessel. An emergency
water tank is installed above the quench
tank in the event of a loss of process water.
The RP estimate is estimated that 50% of
the HCI in the exhaust gas is absorbed in
the quench tank.
Following the quench tank, the exhaust gas
enters the HCI absorber/caustic scrubber
tower. The tower is a vertical fiberglass
vessel containing packed sections. Water
recirculated through the HCI absorber
removes approximately 40% of the HCI in
the gas.
The caustic scrubber is designed to remove
approximately 99.9% of the remaining HCI,
97% of the Cl2, 90% of the S02, and some
particulate matter. A blowdown stream from
the caustic scrubber is fed to the HCI
absorber to remove salt and ash from the
caustic scrubber system [2].
Residuals collected in the blowdown
from the APCS is treated by a carbon
adsorption unit which is part of the
groundwater treatment system.
The off-gas leaves the scrubber system
and enters a high-energy particulate
scrubber, where it is split into two
streams. The two streams are then
recombined and are contacted with a
recirculating water stream where water
droplets entrap particulate matter. The
particles are then removed from the
water in the entrainment separator.
Blowdown from the APCS is pumped
into a neutralization system. The
blowdown is treated with lime to bring
the pH into the 6 - 9 range before
discharge under the terms of a NPDES
permit to the Mississippi River.
Combustion gases were drawn through
the incineration system by a variable
speed, induced draft fan and were
exhausted through an 100-foot stack.
The fan has a 75 hp motor and is
designed to handle 4,400 scfm. Design
condition flue gas velocity is 3,800 -
4,000 actual cubic feet per minute
(acfm) at a temperature of 147°F.
The groundwater which was isolated
from the NAPLs in the phase separator
is treated with carbon adsorption before
being discharged under a NPDES
permit.
Table 2. Summary of Operating Parameters
Parameter
Value
Residence Time
2 seconds
System Throughput
980 Ib/hr (liquid)
Kiln Temperature
1,600° (fume mode)
2,000°F - 2,300°F (liquid mode)
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Technology Innovation Office
130
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Petro Processors Superfund Site
Treatment System Performance
Cleanup Goals/Standards
The DRE requirements were set based on • Stack gas particulate concentrations of
RCRA incinerator regulations 40 CFR part less than or equal to 0.04 grains per dry
264, subpart O. standard cubic foot (gr/dscf), dry basis,
corrected to 7% 02 are required for the
A DRE of 99.99% was required for each incinerator,
constituent of concern.
HCI emissions of less than or equal to 4
A 60-minute rolling average stack gas CO Ib/hr are required for the incinerator,
concentration less than or equal to 100 parts
per million by volume (ppmv), dry basis,
corrected to 7% 02 is required for the
incinerator.
Treatment Performance and Compliance
Two trial burns, one for liquid mode
incineration and one for fume mode
incineration, were conducted at Petro.
These trial burns were designed to operate
the incineration system at conditions that
would reflect worst-case destruction and
removal of all constituents of concern.
Tetrachloroethene and monochlorobenzene
were selected as the principal organic
hazardous constituents (POHCs) for the
liquid mode trial burn; 1,1,2-
trichloroethane and trichloroethene were
selected as the POHCs for the fume mode
trial burn. The reported DREs for each
POHC are included in Table 3-A and 3-B.
To date, the incinerator at Petro has
operated within the operating limits
established during the trial burn,
signifying that all cleanup requirements
that have been established are being
met. The AWFCOs and their frequency
of occurrence during the operation of
the incinerator are shown in Table 4-A
and 4-B. Trial burn and typical
operating parameters are shown in
Tables 5-A and 5-B.
Table 3-A. Average Destruction and Removal Efficiencies from Liquid Mode Trial Burn
[3L
Contaminant
Average Organic Liquid
Waste Feed Rate (Ib/hr)
Average Contaminant Rate in
Stack Gas Emissions (g/hr)
Average Contaminant Rate
in Residual (Mg'kg)
DRE(%)
Tetrachloroethene
1,472
NA
NA
99.99999
Vlonochlorobenzene
1,472
NA
NA
99.99999
Table 3-B. Average Destruction and Removal Efficiencies from Fume Mode Trial Burn
[4]_
Contaminant
Average Air Stripper
Flow Rate (qpm)
Average Contaminant Rate in
Stack Gas Emissions (q/hr)
Average Contaminant
Rate in Residual (gq/kq)
DRE(%)
1,1,2-Trichloroethane
200
NA
NA
99.99998
Trichloroethene
200
NA
NA
99.99999
U.S. ENVIRONMENTAL PROTECTION AGENCY
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Technology Innovation Office
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Petro Processors Superfund Site
Treatment System Performance (Cont.)
Table 4-A. Automatic Waste Feed Cutoffs for Liquid Mode Incineration [3,6]
Parameter
Cutoff Limit
Frequency
Maximum organic liquid feed rate1
1,470 Ib/hr
Monthly
Minimum combustion chamber gas temperature2
2,000° F
Monthly
Maximum combustion chamber gas temperature2
2,300° F
Monthly
Minimum caustic scrubber pH1
7.5
Monthly
Minimum HCI absorber recycle flow rate1
130 qpm
Monthly
Minimum caustic scrubber recycle flow rate1
300 gpm
Monthly
Maximum stack gas flow rate1
15,200 Ib/hr
Monthly
Minimum particulate scrubber differential pressure1
35 inches w.c.
Monthly
Maximum combustion chamber pressure2
-0.1 inches H20
Monthly
Maximum stack gas CO concentration (corrected to 7% 02)1
100 ppmv
Monthly
Minimum stack gas 02 concentration1
2% volume dry basis
Monthly
Maximum quench chamber exit gas temperature2
200 °F
Monthly
w.c. = Water column
1 Based on 60-minute rolling average
instantaneous value
Table 4-B. Automatic Waste Feed Cutoffs for Fume Mode Incineration [4,6]
Parameter
Cutoff Limit
Frequency
Maximum air stripper water flow rate1
200 gpm
Monthly
Minimum combustion chamber gas temperature2
1,600° F
Monthly
Minimum caustic scrubber pH1
7.5
Monthly
Minimum HCI absorber recycle flow rate1
130 gpm
Monthly
Minimum caustic scrubber recycle flow rate1
300 gpm
Monthly
Maximum stack gas flow rate1
16,200 Ib/hr
Monthly
Maximum combustion chamber pressure2
-0.1 inches H20
Monthly
Maximum stack gas CO concentration (corrected to 7% 02)1
100 ppmv
Monthly
Minimum stack gas O, concentration1
2% volume dry basis
Monthly
1 Based on 60-minute rolling average
instantaneous value
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Solid Waste and Emergency Response
Technology Innovation Office
132
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Petro Processors Superfund Site
Treatment System Performance (Cont.)
Table 5-A. Operating Parameters for Liquid Mode Incineration [3,6]
Parameter
Actual Value
Trial Burn Value
Contaminated Organic Liquid Waste Feed Rate
980 Ib/hr
1,472 Ib/hr
Fuel-Fired Feed Rate
14 million BTU/hr
14 million BTU/hr
Emission Rate
Particulate matter
HCI
Cl2
Hydrocarbons
NA
NA
NA
NA
0.0264 gr/dscf
0.190 Ib/hr
0.003 Ib/hr
0.7 ppmv
Operating Conditions
Maximum CO concentration in gas (corrected to 7% 02)
Minimum combustion chamber gas temperature
Minimum caustic scrubber pH
Minimum HCI absorber recycle flow rate
Minimum caustic scrubber recycle flow rate
Minimum particulate scrubber differential pressure
Maximum combustion chamber pressure
Quench chamber exit gas temperature
1.6 ppmv
2,042° F
8.2 s.u.
178 gpm
369 gpm
37 inches w.c.
-2.34 inches w.c.
169°F
1.7 ppmv
2,000° F
7.5 s.u.
131 gpm
305 gpm
35 inches w.c.
-1.26 inches w.c.
178°F
w.c. = Water column
Table 5-B. Operating Parameters for Fume Mode Incineration [4,6]
Parameter
Actual Value
Trial Burn Value
Air Stripper Flow Rate
93 gpm
200 gpm
Fuel-Fired Feed Rate
14 million BTU/hr
14 million BTU/hr
Emission Rate
Particulate matter
HCI
Cl2
Hydrocarbons
NA
NA
NA
NA
0.0018 gr/dscf
0.01 Ib/hr
0.07 Ib/hr
Not Available
Operating Conditions
Maximum CO concentration in gas (corrected to 7% 02)
Minimum combustion chamber gas temperature
Maximum combustion chamber pressure
Quench chamber exit gas temperature
1.2 ppmv
1,680° F
-2.443 inches w.c.
156°F
3.8 ppmv
1,600° F
-450 inches w.c.
158°F
w.c. = Water column
Performance Data Completeness
Data are available for concentrations of
contaminants in the groundwater before
treatment.
Data are also available for
concentration of contaminants in the
liquid and gaseous waste that were fed
to the incinerator the two trial burns.
Performance Data Quality
The QA/QC program used throughout the
remedial action met EPA and the State of
Louisiana requirements. All monitoring was
performed using EPA-approved
methods, and the vendor did not note
any exceptions to the QA/QC protocols.
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Solid Waste and Emergency Response
Technology Innovation Office
133
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Petro Processors Superfund Site
Treatment System Cost
Procurement Process
The RPs have installed and are operating the
treatment system, including the incinerator,
at the site.
Cost Data
The estimated treatment cost of $59,221,500
and the projected costs were reported by the
RPs in terms of capital costs and operation
and maintenance costs. To date, the
estimated capital costs for the incinerator are
$44,552,586 and the estimated operation and
maintenance costs are $14,668,908. The
projected cost for the remaining capital
expenditures is $6,971,000. The projected
monthly operation and maintenance costs for
the incinerator are $300,000. The estimated
costs for thermal treatment were about
$4,800,000. To date, a total of 213,000
gallons of organic liquids and fumes have
been incinerated. This corresponds to a total
unit cost of $280 per gallon and a unit cost
for thermal treatment of $21 per gallon.
Tables 6 and 7 show capital costs and
operation and maintenance costs for the
remedy.
Table 6. Capital Costs [7]
WBS Number
Description
Cost to Date
(1/91 -5/97)
Projected Cost
331
01
Mobilization and preparatory work
$18,159,087
NA
331
02
Monitoring, sampling, testing, and analysis
$4,310,840
$520,000
331
03
Sitework
$6,405,230
$150,000
331
05
Surface water collection and control
$2,418,588
$100,000
331
06
Groundwater collection and control
$9,285,089
$3,100,000
331
22
General requirements
$3,973,752
$3,101,000
Total Capital Costs
$44,552,586
$6,971,000
Table 7. Operation and Maintenance Costs {7]
WBS Number
Description
Cost to Date
(4/94 - 4/97)
Projected
Monthly Costs
342
02
Monitoring, sampling, testing, and analysis
$1,596,888
$35,000
342
03
Sitework
$232,520
$6,000
342
14
Thermal treatment
$4,749,582
$115,000
342
18
Disposal
$92,429
$2,500
342
22
General reguirements
$7,997,489
$141,500
Total Operation and Maintenance Costs
$14,668,908
$300,000
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Solid Waste and Emergency Response
Technology Innovation Office
134
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Petro Processors Superfund Site
Treatment System Cost (continued)
Cost Data Quality
Actual and projected capital and operations
and maintenance cost data are available
from the RP for this application.
Observations and Lessons Learned
Observations and Lessons Learned
Site personnel feel that there have been
relatively few problems with the incinerator
thus far. They have attributed this to the
fact that they used all of their allowable pre-
operation, or shakedown, hours to properly
adjust the system in order to successfully
complete the trial burn [5].
References
1) Superfund Site Status Summaries. U.S.
EPA, "Petro Processors of Louisiana, Inc.",
http://www. e pa .g ov/ea rth 1 r6/6sf/petro pro,
May 9, 1997.
1) Remedial Design and Construction Plan.
Petro-Processors. Inc.. "Design &
Construction Specifications: Operating
Specification for the Liquid Mode Operation
of the LTAD Incineration System,
Addendum A, Volume III, Part 5, Book 10 of
17, NPC Services Inc., November 15, 1995.
1) Remedial Design and Construction Plan.
Petro-Processors. Inc. "Design &
Construction Specifications: Operating
Specification for the Liquid Mode Operation
of the LTAD Incineration System,
Addendum A, Volume III, Part 5, Book 1 of
17, NPC Services Inc., November 15, 1995.
1) Remedial Design and Construction
Plan. Petro-Processors. Inc. "Design &
Construction Specifications: Operating
Specification for the Fume Mode
Operation of the LTAD Incineration
System, Addendum A, Volume III, Part
4, Book 1 of 11, NPC Services Inc.,
November 15, 1995.
1) Personal Communication, Ms. Cynthia
Kaleri, April 2, 1997.
1) Personal Communication, Mr. Bryan
McReynolds, July 24, 1997.
1) Personal Communication, Mr. Marty
Munley, July 28, 1997.
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Solid Waste and Emergency Response
Technology Innovation Office
135
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