Base Catalyzed Decomposition (BCD) formerly called Base Catalyzed Dechlorination
description
Transcript of Base Catalyzed Decomposition (BCD) formerly called Base Catalyzed Dechlorination
Base Catalyzed Decomposition (BCD)
formerly called Base Catalyzed Dechlorination
Status & POPs application
Commercial operations: Australia, Mexico for last six years. Systems used for short-term projects in Australia, Spain (2 years) and US
Pilot plant treatment PCCD-and PCDF-soil and waste and at present full-scale plant under construction at Spolana (Czech Republic)
POPs application:All POPs, PCB’s and pesticides
Technology description
Hydrogen DonorPCB (POP) (Hydrocarbon oil) Base
Biphenyl Salt Steam
ClyClx
+ R' - H + NaOH
Carbon Catalyst
>320oC+ NaCl + H2O
Technology description
Principle: Destruction of toxic halogenated + non-halogenated compounds by catalytic transfer hydrogenation.
Process: Mixture hydrocarbon (donor oil) + base (sodium hydroxide) + catalyst formulation of polyalkeneglycol compounds) 300° C Toxic materials pumped into closed treatment vessel.
Toxics decomposition : Atomic hydrogen released from hydrocarbon or
donor oil. Conversion toxic compounds to salts + non-toxic residues.=>carbon, some of hydrogen donor, base, and salt (sodium chloride)
Technology description
Complete destruction of toxic materials without release of any toxics into environment.
Watch: No continuous but a batch process!
New in Japan Nov 04: introduction continuous process for oils with low contamination of PCB’s
BCD Flow Schedule
BCDBCD ReactorReactor
Condenser 1Condenser 2
Chiller
Centrifuge
SolidsSaltCarbon
Base
Catalyst
GasEmissions
Oil
Carbon Trap
Carbon Trap
CarbonTrap
Oil
Nitrogen HydrogenDonor
Recovered Oil
Water
PART I - Adaptation Technology – Country
A. Performance:
1. Minimum pre-treatment:Different types pre-treatment may be necessary:
(A) Removal larger particles by sifting + size reduction by crushing; or
(B) Adjustment of pH and moisture content
For soils often Thermal desorption used as pre-treatment and concentrate into BCD process
PART I: Adaptation Technology - Country
A. Performance:
2. Destruction Efficiency (DE):
DEs of 99.99–99.9999 % for DDT, HCH, PCBs, PCDDs and PCDFs. DEs > 99.999 % and DREs > 99.9999 % for chlordane and HCB.
Reduction of chlorinated organics > 2 mg/kg + non detectable
PART I: Adaptation Technology - Country
A. Performance:
Destruction of HCB & Lindane (Spolana site Czech Rep.) 2004 update
Material Inlet mg/kg Outlet Oil Matrix mg/kg HCB Lindane HCB Lindane
Chemical waste 29,000 1,500 < 1.0 < 1.0Chemical waste 200,000 900 < 2.0 < 2.0Chemical waste 550,000 1,000 < 2.0 < 2.0Chemical waste 270,000 1,000 < 2.0 < 2.0Chemical waste 160,000 1,000 < 2.0 < 2.0Dust 7,60 7 < 2.0 < 2.0Chemical waste 1,598 19,000 < 2.0 < 2.0Conc Aqueous 630 < 2.0 < 2.0 < 2.0Conc Organic 11,000 < 2.0 < 2.0 < 2.0
PART I: Adaptation Technology - Country
A Performance:
Dioxin Destruction
Material Inlet ng/kg I-TEQ Outlet Oil Matrix ng/kg I-TEQChemical waste 209,000 0 ( Reported value)Chemical waste 200,000 4.3Chemical waste 11,000 0.23Chemical waste 47,000 0Chemical waste 35,000 0Dust 1,620,000 0.52Chemical waste 78,000 0Conc Aqueous 96,000 0Conc Organics 876,000 0
PART I: Adaptation Technology - Country
A. Performance:Treatment of Solid Matrices in Upstream Desorber (from pre-treatment step)
Dioxin Removal
Material Inlet ng/kg I-TEQ Outlet ng/kg I-TEQ
Soil 46,500 2.9Brick&Concrete 2,420,000 6.3Concrete 4,780,000 66.0Plaster 3,800 5.6
PART I: Adaptation Technology - Country
A. Performance:
Treatment of Solid Matrices in Upstream Desorber
HCB & Lindane Removal
Material Inlet mg/kg Outlet mg/kg
HCB Lindane HCB LindaneSoil 2,643 1.34 < 1.0 < 1.0Brick&Concr 49,000 11 < 1.0 < 1.0Concrete 5,100 18 < 1.0 < 1.0Plaster 270 < 1.0 < 1.0 < 1.0
PART I: Adaptation Technology - Country
A. Performance:
3. Toxic by-products: ---4. Uncontrolled releases: ---5. Capacity to treat all POPs:
Yes, but PCB treatment of capacitors not possible and solvent washing required for transformer components
6. Throughput: quantity [tons/day, l/day] ca 10 m3 per batch, can treat 3 batches/24 hrs. Last
productivity + throughput increase till 1000 t/y high chlorine content PCB’s/Pests possible in single line
POPs throughput : [POPs waste/total waste in %]:30% and new in Spolana upto 55%, no limit on chlorine
content
PART I: Adaptation Technology - Country
A. Performance:
7. Wastes/residuals: Secondary waste stream volumes: Sludge with water, salt, unused hydrogen donor oil + carbon
residue =>inert and non-toxic Heavy fuel oils can be used once only, with the used oil being
fed to cement kilns after destruction of POP’s. New option: re-use 90-95% of donor oil (refined paraffinic oils) high improvement economics of process and reduction of
wastes to a solids stream of sodium chloride and carbon from the breakdown of the POP molecule.
Off gas treatment:
activated carbon traps to minimize releases of volatile organics in gaseous emissions.
PART II: Adaption Country – TechnologyA. Resource needs: example 1000 t/y
Power requirements: 110-125 kWh Water requirements: cooling water 10-15 m3/h Fuel volumes: Fuel gas 40 m3/h Reagents volumes: Vary 1-20 % by weight of contaminated
medium Weather tight buildings: Hazardous waste personnel requirement: Sampling Requirements/facilities: Peer sampling: Laboratory requirements: Communication systems: Number of (un/skilled) personnel required:
1 skilled chem operator, 1 semi skilled operator
PART II: Adaption Country – Technology
B: Costs for: case related in % of total
1400-1700 US $/t for org. Chlorine 50% & throughput of 150 t/m (Spolana site)
Installation + commissioning: Site preparation: Energy & Telecom installation: Compliance: Reporting: Run without waste: Run with waste: Decommissioning: Landfilling: Transport residues:
PART II: Adaption Country – Technology
C. Impact & D. Risks Discharges to air: 2-5 m3/h 90% Nitrogen rest H2
Discharges to water: none
Discharges to land(fill): Salt residue 900-1100t/1000 t of 50% chlorine
Risks reagents applied: Hydrogen donor, alkali, bicarbonate, catalyst
Risks of technology: Fire risk low( 1995), as only at 1point oil temp is > flashpoint
Operational risks: most automatic + controls
PART II: Adaption Country Technology
E. Constructability & F. Output
Ease of installation & construction of plant: easy fixed recipes
Ease of shipping/transit: container sized
Ease of operation: Ease of processing: Generated waste (% of input waste): Deposited waste at landfill (% of input waste): Waste quality properties (pH, TCLP)
Mexico PCB plant
Olympic Site, Australia
Soil inlet hopper 3000 litre plant
Indirect thermal desorption
BCD Plant - SpolanaActive carbon filter
Water cooled primary
condensers Collection pots for condensate
BCD Reactor
Dumping tank
Simple process Pre-treatment needed with solvent extraction with transformers and capacitors
Proven technology New: re-use 90-95% of donor
oil high improvement economics reduction of production of wastes
ca 10 m3 per batch. –new productivity 1000 t/y (50%) high chlorine content PCB’s/Pests possible in single line
Excellent destruction rates Little space needed
Strength’s Weaknesses