7

3

f 4f

O

SDMS DocID 530304

Snrse -fund Records Crates

BREAK OTHER

erxgt 3 r z l

lt shy raquo m|

Union Cheaioftl Company

South Hope tteino Plant

= bull fraquobull Co

Source Partait Application

Prototypo Experimental Organio

Waste Xnolnerator Systems

and

Fuol Burning Boilers

August amp960

Yx

it

f

I

1

I I

I I I

IY

V

VI

VII

VIII

TABLE OP CONTENTS i

Project Description

Sito Review

Process Discussion and Flow Diagrams

Kampteriampls to bo Inoinsrated

Projected Air Emissions

Air Pollution Regulation Review

Emission Control Review

Appendix

A Calculations

S System Details

r

F Protect Description

Union Chemical Conpany operates chemical processing f a c i l i t i e s

in South Hop Mains These f a c i l i t i s s produce orcanic chemical

formulations for sale and recover organic solvents from waste

streams via a distillation process The flammable s t i l l bottoms

from the recovery process are burned to produce steam for the

facility However more s t i l l bottoms are produced than are

needed for steam generation and some cannot be burned in the

existing boilers thus the need has arisen for a specially designed

inoineration system to process their waste materials

A prototype experimental incineration system has been designed

and will be installed at South Hope to process excess s t i l l bottoms

as well as unrecoverable organic materials from other locations

Best Available air emission control equipment will be installed

to assure compliance with air emission control regulations

The incineration system will burn a maximum of about 4000000

BTUs per hour of hydrocarbons composed of a variety of compounds

as listed in Section IV

Emissions to be oontrolled will consist of inoresnio particulate

matter and gaseous hydrochloric aoid This application covers not

only the experimental incinerator system but a l l other burning

units at Union Chemical Company Table X gives specifios of

their operation

v V -2shy

bullpound2OJ

-111

Combustion Units at Union Chemical Company

H Unit

iJ Ho 1 Boiler

Sr Ho 2 Boiler

Pilot FluidAed Burner

Row Prototype

Puol

Non-halogenhydrocarbons

Non-halogen hydrocarbons

Miscellaneoushydrocarbons

Kiscellaneoua hydrocarbons

2000000

Capacity(BTUhr)

1000000

ltraquo50000

4000000

Operating Schedule

7 days-24 hours

7 daye2^ hours

Daytlmo Experimental

7 days-2k hoursExperimental

Tvnct pn bullProcess Steam

Process Steam

Testing R amp D

Testing R amp D

Only one boiler would be operating at a time

o o

e

mill

-iV

-3shy

I I Site Hovlew

Union Chemical Conpany Is located in the Central Kaine Air

Quality Region which is designated as a Class I I area The near

est Class I area is located approximately 77 kilometers to the

east and will not be affected by the project in South Hope

However the Central Kaine Air Quality Region is preoantly

considered a non-attainment area for otone which is attributed

to out-of-state sources All other criteria pollutants are

within the ambient limits established by the USEPA and

the Mains OKP

The incinerator site i s in South Hope Kaine located on

Kaino Route 17 about 32 miles East-Southeast of Augusta and

8 miles North-Northwest of Rockland The site is located on

the enclosed site plan area topographical map and stata of

Kaine location map

Distampnoe to the summit of Cadillao Mountain

--O 3T Z I -pound 8- degl 1 t mdash -J bull

I

copy o

NOTICE if the la laaa clear than this notice It la dua to tha quality of tha document UNI001

balng filmed - -y bull

raquo k c 1 _ - r 1111 bull--gtbullbull ~ ^

A laquo4

U T t Proems Dlocuoolon

Union Chemical Company provides two basic production sorvleos

at ito plant in South Hope Maine Chemical formulations for

stripping paints and other coatings from furniture and related

items are produced for sale and distribution Dirty organic

solvent streams are also processed to remove contaminants to

allow their recycle and re-use by clients throughout the Northeast

The proposed project w i l l allow Union Chemical Company to

develop a system to increase the utilization of the byproducts

from the organic solvent recovery process Some of thooo materials

are presently burned to produce steam for plant operationi however

as Btated earlier more fuel i s produced than can be utilized In

tho present two boilers and there are materials which cannot be

burned in the present boilers

S t i l l bottoms w i l l go to new bulk fuel tankB at the propouod

Jnolnorator alto and w i l l be stored prior to incineration Thoro

w i l l be throo new fuel tanks installodi two holding combuotlblo

material and the othor non-combuotlble chlorinated material The

two typeo would be mixed in a blender and prepared fuel w i l l be

stored In aday tank prior to incineration The non-combustible

chlorinated material w i l l decompose and burn above 2000degF The

oombustible material i s used to provide the necessary heat for

decomposition of the non-combustible chlorinated compoundsbull

Pronotied FluldlzodPod Incinerator Syotern

The koy to the proposed incineration proceno is the new

fluidized bed oombustion system Plans now require the comburitor

to oporate on a 24 hour per day experimental schedule with the ropt

of the plant to demonstrate i t s r e l i a b i l i t y We expeot normal

maintenance and down time to result In an annual average operating

oohodula on 24 hours per day 7 days per week 45 wooks por yoor

However emlssioiis calculations are based on 8760 hours per year

(52 weeks)

The ineinerator system as described in Figures 1 St 2 and

Table 2 will be made up of several components and will have dry

calcium chloride and ash as by-products The combustible and

non-combustible organic materials will be mixed in a blender and

fod via a day tank to the fluidized bed where incineration will

take place Gases in excess of 2100degF will pass from the burner

via an ash drop out box to an air heat exchanger The heat

exchanger will lower the gas temperature to about 1400degF The

gnn containing some hydrochloric acid when incinerating

chlorinated compounds will then paas to an injection system

whoro dry lime wVll be added The lime will react with tho acid

to form calcium chloride Ash and sand carry over from the drop

out box plus solids generated in the process will be removed

from the PJBB by a cyclone Prior to entering the final gas

aboorption unit quench water will be added in the duct to lower

the gas temperature to i80degF

The gas absorption system will be designed to remove

particulate matter and any residual hydrochloric acid from the

gas stream It will be a high efficiency cross-flow type wet

reactor which will recycle a dilute solution of lime through a

packod bed A small bleed stream from the cross-flow will purge

oontnminants to the burner where they will exit with the dry

oalclum ohloride Details of the gas absorption system will be

found in the appendix bull bull

1 0 laquo D bull n-raquolt bull a m-8shy J O B F I L C NO

CMCCKCO B Y mdash OAT o U bull E j bull

SKcrr OR PROJKCT tVlltM CHZtylCjL Go

000^ aso PROTOTYPE INCINERATOR SYSTEM

3

0 0 - NONE EXHAUST STACK

NEUTRt SYSTEM

GAS ABS SOLIDS UNIT

FLUID OUT BED SOLIDS

jCQMBUSTEf DROP-OUT BLEED RECYLCE AIR IN - 1600 CFM

FUEL IN r 124 LBSMIN

V 1

PROJECTED OPERATION - WORST CASE 1

FUEL - FLAMMABLE COMPOSITE

DATA BASED ON ACTUAL TRIAL RUN

BTULB OF FUEL FEED - 4909 BTUHOUR INPUT - 3535000 ASH CONTENT OF FEED - 157Z

5

I

bull c o bull oOCSIGMCH bull9 - n ix Mgt

raquoCHCCKCO a v _ raquo laquo 2 o tgtA r e -raquolaquolt - raquo m

J O H O _ _ _

ADJECT L^UWA CrtCAjjcyji Co 0013 GRSCP laquoraquorr 3 5 3 laquobull mdash ^ SYSTEM a ogt p

CAD 2traquo LBSMIN EXHAUST STACK

NEUTR SYSTEM

1988degF

AIR IN - 1997 CFM

FUEL IN

107 LBSMIN

PROJECTED OPERATION - WORST CASE 2

t

FUEL - FLAMMABLE COMPOSITE PLUS 21 CHLORINATED ORGAN ICS DATA BASED ON ACTUAL TRIAL RUN BTULB OF FUEL FEED - 6940 BTUHOUR INPUT - 4470000 ASH CONTENT OF FEED - 172

IN THIS CASE - raCHLOROETHYLENE

~ Q m (-gt

-10shy

deg I sect = o laquo =raquo5deg mdash3

3 raquo ZzrTABLE 2 bull =r =-3 3 bull mdash fa

UNION CHEMICAL COMPANY

Fluid Bed System - Projected Operating Data

SITUATION CASE j CASK jZ Proioeted

Ash from fuel 207 lbemin 182 195

Sand carry-over 03 03 03

Aah drop out 119 106 113

HC1 generated None 195 0975

CaO added (335 exoess)None 200 100

CaCl2 gonorated mdashgt 149 297 Unroacted CaO 025 05 Neutralisation Systembull

Solids Removal 101 385 243

KC1 Removal None 193 097

Oats Absorption System i a copySolids Removal 0176 067 042

HC1 Removal None 00198 001

5E VI- Ill i S a bull to

o o

tr copy A l l system components which might be subject to chemical 3 laquobullbull =r =shy

bulla m at 11 attack w i l l be fabricated of corrosion resistant materials The Jentire system w i l l be designed to roquire a minimum of operating

attention and to be relatively maintenance free The system

cannot operate unless a l l pollution oontrol devices are

functioning (eg no bypass modos)

I Y J Watorlalo to be Incinerated

A l l of the materials to be burned in the proposed lncinorator

are organic and inorganio residues from solvent recovery oporationo

or polymer formulators Union Chemical Companys method of

oporation involves d i s t i l l a t i o n of a l l economically recoverable

organic solvents using advanced proceos techniques

The materials to be burned include Ketones Alcohols Esters

Aliphatios Aroma t i c s and Chlorinated compounds A partial l i s t

of these oompounds i s as followsi (US EPA designations are

used)

F002 Spent halogcnuted solvents and s t i l l bottoms

P003 laquo Spent non-haloccnated solvento and s t i l l bottoms

F005 laquobull Spent non halogenated solvents and s t i l l bottoms

F017 raquo Paint residue from industrial painting

K078 - Solvent wastes from paint manufacturing sKtfc-flg K082 - Air pollution control sludges from paint manufacturers

V002 - Acetone

VOflO - Dichloromothane

V112 - Ethyl Acetate

Ymo - Ieobutyl Aloohol

Y15 Methanol

J

deg12shy

VI59 - Methyl Ethyl Ketone

p V161 Kethyl Ioobutyl Ketone

V210 - Tetrachloroethane

V220 - Toluene

V226 - 111 Trlchloroethane

V228 - Trichlorethylene

V239 - Xylene

t bull

raquo V Projected Air Emission

The materiale to Ve incinerated are essentially compounds

composed of carbon hydrogen and oxygen with occasional omall

amounts of chlorine and nitrogen The waste materials also

contain small amounts of inert ash primarily s i l i c a iron

oxide and heavy metal pigments Table I I I present an analysis

1 of ash from combustion of a typical fuel Routine ash analysis

w i l l be performed Uses for the ash are being researched but

present plans are to stabilize them via a stabilex type process

As described in Section VII the a i r emission control system

in tho form of process devices and system operating controls

w i l l result i n over-all highly efficient pollutant removal and

prevention

Table IV l i s t s potential a i r pollutants after the

incineration and chemical reactor processes prior to the wet

cross flow reactor as compared to anticipated emissions after the

oross flow

-=bull fiiSr-srrs

-raquoraquolt raquom|

o- raquo bull fi

a J 3

c3 o o

Yx

it

f

I

1

I I

I I I

IY

V

VI

VII

VIII

TABLE OP CONTENTS i

Project Description

Sito Review

Process Discussion and Flow Diagrams

Kampteriampls to bo Inoinsrated

Projected Air Emissions

Air Pollution Regulation Review

Emission Control Review

Appendix

A Calculations

S System Details

r

F Protect Description

Union Chemical Conpany operates chemical processing f a c i l i t i e s

in South Hop Mains These f a c i l i t i s s produce orcanic chemical

formulations for sale and recover organic solvents from waste

streams via a distillation process The flammable s t i l l bottoms

from the recovery process are burned to produce steam for the

facility However more s t i l l bottoms are produced than are

needed for steam generation and some cannot be burned in the

existing boilers thus the need has arisen for a specially designed

inoineration system to process their waste materials

A prototype experimental incineration system has been designed

and will be installed at South Hope to process excess s t i l l bottoms

as well as unrecoverable organic materials from other locations

Best Available air emission control equipment will be installed

to assure compliance with air emission control regulations

The incineration system will burn a maximum of about 4000000

BTUs per hour of hydrocarbons composed of a variety of compounds

as listed in Section IV

Emissions to be oontrolled will consist of inoresnio particulate

matter and gaseous hydrochloric aoid This application covers not

only the experimental incinerator system but a l l other burning

units at Union Chemical Company Table X gives specifios of

their operation

v V -2shy

bullpound2OJ

-111

Combustion Units at Union Chemical Company

H Unit

iJ Ho 1 Boiler

Sr Ho 2 Boiler

Pilot FluidAed Burner

Row Prototype

Puol

Non-halogenhydrocarbons

Non-halogen hydrocarbons

Miscellaneoushydrocarbons

Kiscellaneoua hydrocarbons

2000000

Capacity(BTUhr)

1000000

ltraquo50000

4000000

Operating Schedule

7 days-24 hours

7 daye2^ hours

Daytlmo Experimental

7 days-2k hoursExperimental

Tvnct pn bullProcess Steam

Process Steam

Testing R amp D

Testing R amp D

Only one boiler would be operating at a time

o o

e

mill

-iV

-3shy

I I Site Hovlew

Union Chemical Conpany Is located in the Central Kaine Air

Quality Region which is designated as a Class I I area The near

est Class I area is located approximately 77 kilometers to the

east and will not be affected by the project in South Hope

However the Central Kaine Air Quality Region is preoantly

considered a non-attainment area for otone which is attributed

to out-of-state sources All other criteria pollutants are

within the ambient limits established by the USEPA and

the Mains OKP

The incinerator site i s in South Hope Kaine located on

Kaino Route 17 about 32 miles East-Southeast of Augusta and

8 miles North-Northwest of Rockland The site is located on

the enclosed site plan area topographical map and stata of

Kaine location map

Distampnoe to the summit of Cadillao Mountain

--O 3T Z I -pound 8- degl 1 t mdash -J bull

I

copy o

NOTICE if the la laaa clear than this notice It la dua to tha quality of tha document UNI001

balng filmed - -y bull

raquo k c 1 _ - r 1111 bull--gtbullbull ~ ^

A laquo4

U T t Proems Dlocuoolon

Union Chemical Company provides two basic production sorvleos

at ito plant in South Hope Maine Chemical formulations for

stripping paints and other coatings from furniture and related

items are produced for sale and distribution Dirty organic

solvent streams are also processed to remove contaminants to

allow their recycle and re-use by clients throughout the Northeast

The proposed project w i l l allow Union Chemical Company to

develop a system to increase the utilization of the byproducts

from the organic solvent recovery process Some of thooo materials

are presently burned to produce steam for plant operationi however

as Btated earlier more fuel i s produced than can be utilized In

tho present two boilers and there are materials which cannot be

burned in the present boilers

S t i l l bottoms w i l l go to new bulk fuel tankB at the propouod

Jnolnorator alto and w i l l be stored prior to incineration Thoro

w i l l be throo new fuel tanks installodi two holding combuotlblo

material and the othor non-combuotlble chlorinated material The

two typeo would be mixed in a blender and prepared fuel w i l l be

stored In aday tank prior to incineration The non-combustible

chlorinated material w i l l decompose and burn above 2000degF The

oombustible material i s used to provide the necessary heat for

decomposition of the non-combustible chlorinated compoundsbull

Pronotied FluldlzodPod Incinerator Syotern

The koy to the proposed incineration proceno is the new

fluidized bed oombustion system Plans now require the comburitor

to oporate on a 24 hour per day experimental schedule with the ropt

of the plant to demonstrate i t s r e l i a b i l i t y We expeot normal

maintenance and down time to result In an annual average operating

oohodula on 24 hours per day 7 days per week 45 wooks por yoor

However emlssioiis calculations are based on 8760 hours per year

(52 weeks)

The ineinerator system as described in Figures 1 St 2 and

Table 2 will be made up of several components and will have dry

calcium chloride and ash as by-products The combustible and

non-combustible organic materials will be mixed in a blender and

fod via a day tank to the fluidized bed where incineration will

take place Gases in excess of 2100degF will pass from the burner

via an ash drop out box to an air heat exchanger The heat

exchanger will lower the gas temperature to about 1400degF The

gnn containing some hydrochloric acid when incinerating

chlorinated compounds will then paas to an injection system

whoro dry lime wVll be added The lime will react with tho acid

to form calcium chloride Ash and sand carry over from the drop

out box plus solids generated in the process will be removed

from the PJBB by a cyclone Prior to entering the final gas

aboorption unit quench water will be added in the duct to lower

the gas temperature to i80degF

The gas absorption system will be designed to remove

particulate matter and any residual hydrochloric acid from the

gas stream It will be a high efficiency cross-flow type wet

reactor which will recycle a dilute solution of lime through a

packod bed A small bleed stream from the cross-flow will purge

oontnminants to the burner where they will exit with the dry

oalclum ohloride Details of the gas absorption system will be

found in the appendix bull bull

1 0 laquo D bull n-raquolt bull a m-8shy J O B F I L C NO

CMCCKCO B Y mdash OAT o U bull E j bull

SKcrr OR PROJKCT tVlltM CHZtylCjL Go

000^ aso PROTOTYPE INCINERATOR SYSTEM

3

0 0 - NONE EXHAUST STACK

NEUTRt SYSTEM

GAS ABS SOLIDS UNIT

FLUID OUT BED SOLIDS

jCQMBUSTEf DROP-OUT BLEED RECYLCE AIR IN - 1600 CFM

FUEL IN r 124 LBSMIN

V 1

PROJECTED OPERATION - WORST CASE 1

FUEL - FLAMMABLE COMPOSITE

DATA BASED ON ACTUAL TRIAL RUN

BTULB OF FUEL FEED - 4909 BTUHOUR INPUT - 3535000 ASH CONTENT OF FEED - 157Z

5

I

bull c o bull oOCSIGMCH bull9 - n ix Mgt

raquoCHCCKCO a v _ raquo laquo 2 o tgtA r e -raquolaquolt - raquo m

J O H O _ _ _

ADJECT L^UWA CrtCAjjcyji Co 0013 GRSCP laquoraquorr 3 5 3 laquobull mdash ^ SYSTEM a ogt p

CAD 2traquo LBSMIN EXHAUST STACK

NEUTR SYSTEM

1988degF

AIR IN - 1997 CFM

FUEL IN

107 LBSMIN

PROJECTED OPERATION - WORST CASE 2

t

FUEL - FLAMMABLE COMPOSITE PLUS 21 CHLORINATED ORGAN ICS DATA BASED ON ACTUAL TRIAL RUN BTULB OF FUEL FEED - 6940 BTUHOUR INPUT - 4470000 ASH CONTENT OF FEED - 172

IN THIS CASE - raCHLOROETHYLENE

~ Q m (-gt

-10shy

deg I sect = o laquo =raquo5deg mdash3

3 raquo ZzrTABLE 2 bull =r =-3 3 bull mdash fa

UNION CHEMICAL COMPANY

Fluid Bed System - Projected Operating Data

SITUATION CASE j CASK jZ Proioeted

Ash from fuel 207 lbemin 182 195

Sand carry-over 03 03 03

Aah drop out 119 106 113

HC1 generated None 195 0975

CaO added (335 exoess)None 200 100

CaCl2 gonorated mdashgt 149 297 Unroacted CaO 025 05 Neutralisation Systembull

Solids Removal 101 385 243

KC1 Removal None 193 097

Oats Absorption System i a copySolids Removal 0176 067 042

HC1 Removal None 00198 001

5E VI- Ill i S a bull to

o o

tr copy A l l system components which might be subject to chemical 3 laquobullbull =r =shy

bulla m at 11 attack w i l l be fabricated of corrosion resistant materials The Jentire system w i l l be designed to roquire a minimum of operating

attention and to be relatively maintenance free The system

cannot operate unless a l l pollution oontrol devices are

functioning (eg no bypass modos)

I Y J Watorlalo to be Incinerated

A l l of the materials to be burned in the proposed lncinorator

are organic and inorganio residues from solvent recovery oporationo

or polymer formulators Union Chemical Companys method of

oporation involves d i s t i l l a t i o n of a l l economically recoverable

organic solvents using advanced proceos techniques

The materials to be burned include Ketones Alcohols Esters

Aliphatios Aroma t i c s and Chlorinated compounds A partial l i s t

of these oompounds i s as followsi (US EPA designations are

used)

F002 Spent halogcnuted solvents and s t i l l bottoms

P003 laquo Spent non-haloccnated solvento and s t i l l bottoms

F005 laquobull Spent non halogenated solvents and s t i l l bottoms

F017 raquo Paint residue from industrial painting

K078 - Solvent wastes from paint manufacturing sKtfc-flg K082 - Air pollution control sludges from paint manufacturers

V002 - Acetone

VOflO - Dichloromothane

V112 - Ethyl Acetate

Ymo - Ieobutyl Aloohol

Y15 Methanol

J

deg12shy

VI59 - Methyl Ethyl Ketone

p V161 Kethyl Ioobutyl Ketone

V210 - Tetrachloroethane

V220 - Toluene

V226 - 111 Trlchloroethane

V228 - Trichlorethylene

V239 - Xylene

t bull

raquo V Projected Air Emission

The materiale to Ve incinerated are essentially compounds

composed of carbon hydrogen and oxygen with occasional omall

amounts of chlorine and nitrogen The waste materials also

contain small amounts of inert ash primarily s i l i c a iron

oxide and heavy metal pigments Table I I I present an analysis

1 of ash from combustion of a typical fuel Routine ash analysis

w i l l be performed Uses for the ash are being researched but

present plans are to stabilize them via a stabilex type process

As described in Section VII the a i r emission control system

in tho form of process devices and system operating controls

w i l l result i n over-all highly efficient pollutant removal and

prevention

Table IV l i s t s potential a i r pollutants after the

incineration and chemical reactor processes prior to the wet

cross flow reactor as compared to anticipated emissions after the

oross flow

-=bull fiiSr-srrs

-raquoraquolt raquom|

o- raquo bull fi

a J 3

c3 o o

F Protect Description

Union Chemical Conpany operates chemical processing f a c i l i t i e s

in South Hop Mains These f a c i l i t i s s produce orcanic chemical

formulations for sale and recover organic solvents from waste

streams via a distillation process The flammable s t i l l bottoms

from the recovery process are burned to produce steam for the

facility However more s t i l l bottoms are produced than are

needed for steam generation and some cannot be burned in the

existing boilers thus the need has arisen for a specially designed

inoineration system to process their waste materials

A prototype experimental incineration system has been designed

and will be installed at South Hope to process excess s t i l l bottoms

as well as unrecoverable organic materials from other locations

Best Available air emission control equipment will be installed

to assure compliance with air emission control regulations

The incineration system will burn a maximum of about 4000000

BTUs per hour of hydrocarbons composed of a variety of compounds

as listed in Section IV

Emissions to be oontrolled will consist of inoresnio particulate

matter and gaseous hydrochloric aoid This application covers not

only the experimental incinerator system but a l l other burning

units at Union Chemical Company Table X gives specifios of

their operation

v V -2shy

bullpound2OJ

-111

Combustion Units at Union Chemical Company

H Unit

iJ Ho 1 Boiler

Sr Ho 2 Boiler

Pilot FluidAed Burner

Row Prototype

Puol

Non-halogenhydrocarbons

Non-halogen hydrocarbons

Miscellaneoushydrocarbons

Kiscellaneoua hydrocarbons

2000000

Capacity(BTUhr)

1000000

ltraquo50000

4000000

Operating Schedule

7 days-24 hours

7 daye2^ hours

Daytlmo Experimental

7 days-2k hoursExperimental

Tvnct pn bullProcess Steam

Process Steam

Testing R amp D

Testing R amp D

Only one boiler would be operating at a time

o o

e

mill

-iV

-3shy

I I Site Hovlew

Union Chemical Conpany Is located in the Central Kaine Air

Quality Region which is designated as a Class I I area The near

est Class I area is located approximately 77 kilometers to the

east and will not be affected by the project in South Hope

However the Central Kaine Air Quality Region is preoantly

considered a non-attainment area for otone which is attributed

to out-of-state sources All other criteria pollutants are

within the ambient limits established by the USEPA and

the Mains OKP

The incinerator site i s in South Hope Kaine located on

Kaino Route 17 about 32 miles East-Southeast of Augusta and

8 miles North-Northwest of Rockland The site is located on

the enclosed site plan area topographical map and stata of

Kaine location map

Distampnoe to the summit of Cadillao Mountain

--O 3T Z I -pound 8- degl 1 t mdash -J bull

I

copy o

NOTICE if the la laaa clear than this notice It la dua to tha quality of tha document UNI001

balng filmed - -y bull

raquo k c 1 _ - r 1111 bull--gtbullbull ~ ^

A laquo4

U T t Proems Dlocuoolon

Union Chemical Company provides two basic production sorvleos

at ito plant in South Hope Maine Chemical formulations for

stripping paints and other coatings from furniture and related

items are produced for sale and distribution Dirty organic

solvent streams are also processed to remove contaminants to

allow their recycle and re-use by clients throughout the Northeast

The proposed project w i l l allow Union Chemical Company to

develop a system to increase the utilization of the byproducts

from the organic solvent recovery process Some of thooo materials

are presently burned to produce steam for plant operationi however

as Btated earlier more fuel i s produced than can be utilized In

tho present two boilers and there are materials which cannot be

burned in the present boilers

S t i l l bottoms w i l l go to new bulk fuel tankB at the propouod

Jnolnorator alto and w i l l be stored prior to incineration Thoro

w i l l be throo new fuel tanks installodi two holding combuotlblo

material and the othor non-combuotlble chlorinated material The

two typeo would be mixed in a blender and prepared fuel w i l l be

stored In aday tank prior to incineration The non-combustible

chlorinated material w i l l decompose and burn above 2000degF The

oombustible material i s used to provide the necessary heat for

decomposition of the non-combustible chlorinated compoundsbull

Pronotied FluldlzodPod Incinerator Syotern

The koy to the proposed incineration proceno is the new

fluidized bed oombustion system Plans now require the comburitor

to oporate on a 24 hour per day experimental schedule with the ropt

of the plant to demonstrate i t s r e l i a b i l i t y We expeot normal

maintenance and down time to result In an annual average operating

oohodula on 24 hours per day 7 days per week 45 wooks por yoor

However emlssioiis calculations are based on 8760 hours per year

(52 weeks)

The ineinerator system as described in Figures 1 St 2 and

Table 2 will be made up of several components and will have dry

calcium chloride and ash as by-products The combustible and

non-combustible organic materials will be mixed in a blender and

fod via a day tank to the fluidized bed where incineration will

take place Gases in excess of 2100degF will pass from the burner

via an ash drop out box to an air heat exchanger The heat

exchanger will lower the gas temperature to about 1400degF The

gnn containing some hydrochloric acid when incinerating

chlorinated compounds will then paas to an injection system

whoro dry lime wVll be added The lime will react with tho acid

to form calcium chloride Ash and sand carry over from the drop

out box plus solids generated in the process will be removed

from the PJBB by a cyclone Prior to entering the final gas

aboorption unit quench water will be added in the duct to lower

the gas temperature to i80degF

The gas absorption system will be designed to remove

particulate matter and any residual hydrochloric acid from the

gas stream It will be a high efficiency cross-flow type wet

reactor which will recycle a dilute solution of lime through a

packod bed A small bleed stream from the cross-flow will purge

oontnminants to the burner where they will exit with the dry

oalclum ohloride Details of the gas absorption system will be

found in the appendix bull bull

1 0 laquo D bull n-raquolt bull a m-8shy J O B F I L C NO

CMCCKCO B Y mdash OAT o U bull E j bull

SKcrr OR PROJKCT tVlltM CHZtylCjL Go

000^ aso PROTOTYPE INCINERATOR SYSTEM

3

0 0 - NONE EXHAUST STACK

NEUTRt SYSTEM

GAS ABS SOLIDS UNIT

FLUID OUT BED SOLIDS

jCQMBUSTEf DROP-OUT BLEED RECYLCE AIR IN - 1600 CFM

FUEL IN r 124 LBSMIN

V 1

PROJECTED OPERATION - WORST CASE 1

FUEL - FLAMMABLE COMPOSITE

DATA BASED ON ACTUAL TRIAL RUN

BTULB OF FUEL FEED - 4909 BTUHOUR INPUT - 3535000 ASH CONTENT OF FEED - 157Z

5

I

bull c o bull oOCSIGMCH bull9 - n ix Mgt

raquoCHCCKCO a v _ raquo laquo 2 o tgtA r e -raquolaquolt - raquo m

J O H O _ _ _

ADJECT L^UWA CrtCAjjcyji Co 0013 GRSCP laquoraquorr 3 5 3 laquobull mdash ^ SYSTEM a ogt p

CAD 2traquo LBSMIN EXHAUST STACK

NEUTR SYSTEM

1988degF

AIR IN - 1997 CFM

FUEL IN

107 LBSMIN

PROJECTED OPERATION - WORST CASE 2

t

FUEL - FLAMMABLE COMPOSITE PLUS 21 CHLORINATED ORGAN ICS DATA BASED ON ACTUAL TRIAL RUN BTULB OF FUEL FEED - 6940 BTUHOUR INPUT - 4470000 ASH CONTENT OF FEED - 172

IN THIS CASE - raCHLOROETHYLENE

~ Q m (-gt

-10shy

deg I sect = o laquo =raquo5deg mdash3

3 raquo ZzrTABLE 2 bull =r =-3 3 bull mdash fa

UNION CHEMICAL COMPANY

Fluid Bed System - Projected Operating Data

SITUATION CASE j CASK jZ Proioeted

Ash from fuel 207 lbemin 182 195

Sand carry-over 03 03 03

Aah drop out 119 106 113

HC1 generated None 195 0975

CaO added (335 exoess)None 200 100

CaCl2 gonorated mdashgt 149 297 Unroacted CaO 025 05 Neutralisation Systembull

Solids Removal 101 385 243

KC1 Removal None 193 097

Oats Absorption System i a copySolids Removal 0176 067 042

HC1 Removal None 00198 001

5E VI- Ill i S a bull to

o o

tr copy A l l system components which might be subject to chemical 3 laquobullbull =r =shy

bulla m at 11 attack w i l l be fabricated of corrosion resistant materials The Jentire system w i l l be designed to roquire a minimum of operating

attention and to be relatively maintenance free The system

cannot operate unless a l l pollution oontrol devices are

functioning (eg no bypass modos)

I Y J Watorlalo to be Incinerated

A l l of the materials to be burned in the proposed lncinorator

are organic and inorganio residues from solvent recovery oporationo

or polymer formulators Union Chemical Companys method of

oporation involves d i s t i l l a t i o n of a l l economically recoverable

organic solvents using advanced proceos techniques

The materials to be burned include Ketones Alcohols Esters

Aliphatios Aroma t i c s and Chlorinated compounds A partial l i s t

of these oompounds i s as followsi (US EPA designations are

used)

F002 Spent halogcnuted solvents and s t i l l bottoms

P003 laquo Spent non-haloccnated solvento and s t i l l bottoms

F005 laquobull Spent non halogenated solvents and s t i l l bottoms

F017 raquo Paint residue from industrial painting

K078 - Solvent wastes from paint manufacturing sKtfc-flg K082 - Air pollution control sludges from paint manufacturers

V002 - Acetone

VOflO - Dichloromothane

V112 - Ethyl Acetate

Ymo - Ieobutyl Aloohol

Y15 Methanol

J

deg12shy

VI59 - Methyl Ethyl Ketone

p V161 Kethyl Ioobutyl Ketone

V210 - Tetrachloroethane

V220 - Toluene

V226 - 111 Trlchloroethane

V228 - Trichlorethylene

V239 - Xylene

t bull

raquo V Projected Air Emission

The materiale to Ve incinerated are essentially compounds

composed of carbon hydrogen and oxygen with occasional omall

amounts of chlorine and nitrogen The waste materials also

contain small amounts of inert ash primarily s i l i c a iron

oxide and heavy metal pigments Table I I I present an analysis

1 of ash from combustion of a typical fuel Routine ash analysis

w i l l be performed Uses for the ash are being researched but

present plans are to stabilize them via a stabilex type process

As described in Section VII the a i r emission control system

in tho form of process devices and system operating controls

w i l l result i n over-all highly efficient pollutant removal and

prevention

Table IV l i s t s potential a i r pollutants after the

incineration and chemical reactor processes prior to the wet

cross flow reactor as compared to anticipated emissions after the

oross flow

-=bull fiiSr-srrs

-raquoraquolt raquom|

o- raquo bull fi

a J 3

c3 o o

v V -2shy

bullpound2OJ

-111

Combustion Units at Union Chemical Company

H Unit

iJ Ho 1 Boiler

Sr Ho 2 Boiler

Pilot FluidAed Burner

Row Prototype

Puol

Non-halogenhydrocarbons

Non-halogen hydrocarbons

Miscellaneoushydrocarbons

Kiscellaneoua hydrocarbons

2000000

Capacity(BTUhr)

1000000

ltraquo50000

4000000

Operating Schedule

7 days-24 hours

7 daye2^ hours

Daytlmo Experimental

7 days-2k hoursExperimental

Tvnct pn bullProcess Steam

Process Steam

Testing R amp D

Testing R amp D

Only one boiler would be operating at a time

o o

e

mill

-iV

-3shy

I I Site Hovlew

Union Chemical Conpany Is located in the Central Kaine Air

Quality Region which is designated as a Class I I area The near

est Class I area is located approximately 77 kilometers to the

east and will not be affected by the project in South Hope

However the Central Kaine Air Quality Region is preoantly

considered a non-attainment area for otone which is attributed

to out-of-state sources All other criteria pollutants are

within the ambient limits established by the USEPA and

the Mains OKP

The incinerator site i s in South Hope Kaine located on

Kaino Route 17 about 32 miles East-Southeast of Augusta and

8 miles North-Northwest of Rockland The site is located on

the enclosed site plan area topographical map and stata of

Kaine location map

Distampnoe to the summit of Cadillao Mountain

--O 3T Z I -pound 8- degl 1 t mdash -J bull

I

copy o

NOTICE if the la laaa clear than this notice It la dua to tha quality of tha document UNI001

balng filmed - -y bull

raquo k c 1 _ - r 1111 bull--gtbullbull ~ ^

A laquo4

U T t Proems Dlocuoolon

Union Chemical Company provides two basic production sorvleos

at ito plant in South Hope Maine Chemical formulations for

stripping paints and other coatings from furniture and related

items are produced for sale and distribution Dirty organic

solvent streams are also processed to remove contaminants to

allow their recycle and re-use by clients throughout the Northeast

The proposed project w i l l allow Union Chemical Company to

develop a system to increase the utilization of the byproducts

from the organic solvent recovery process Some of thooo materials

are presently burned to produce steam for plant operationi however

as Btated earlier more fuel i s produced than can be utilized In

tho present two boilers and there are materials which cannot be

burned in the present boilers

S t i l l bottoms w i l l go to new bulk fuel tankB at the propouod

Jnolnorator alto and w i l l be stored prior to incineration Thoro

w i l l be throo new fuel tanks installodi two holding combuotlblo

material and the othor non-combuotlble chlorinated material The

two typeo would be mixed in a blender and prepared fuel w i l l be

stored In aday tank prior to incineration The non-combustible

chlorinated material w i l l decompose and burn above 2000degF The

oombustible material i s used to provide the necessary heat for

decomposition of the non-combustible chlorinated compoundsbull

Pronotied FluldlzodPod Incinerator Syotern

The koy to the proposed incineration proceno is the new

fluidized bed oombustion system Plans now require the comburitor

to oporate on a 24 hour per day experimental schedule with the ropt

of the plant to demonstrate i t s r e l i a b i l i t y We expeot normal

maintenance and down time to result In an annual average operating

oohodula on 24 hours per day 7 days per week 45 wooks por yoor

However emlssioiis calculations are based on 8760 hours per year

(52 weeks)

The ineinerator system as described in Figures 1 St 2 and

Table 2 will be made up of several components and will have dry

calcium chloride and ash as by-products The combustible and

non-combustible organic materials will be mixed in a blender and

fod via a day tank to the fluidized bed where incineration will

take place Gases in excess of 2100degF will pass from the burner

via an ash drop out box to an air heat exchanger The heat

exchanger will lower the gas temperature to about 1400degF The

gnn containing some hydrochloric acid when incinerating

chlorinated compounds will then paas to an injection system

whoro dry lime wVll be added The lime will react with tho acid

to form calcium chloride Ash and sand carry over from the drop

out box plus solids generated in the process will be removed

from the PJBB by a cyclone Prior to entering the final gas

aboorption unit quench water will be added in the duct to lower

the gas temperature to i80degF

The gas absorption system will be designed to remove

particulate matter and any residual hydrochloric acid from the

gas stream It will be a high efficiency cross-flow type wet

reactor which will recycle a dilute solution of lime through a

packod bed A small bleed stream from the cross-flow will purge

oontnminants to the burner where they will exit with the dry

oalclum ohloride Details of the gas absorption system will be

found in the appendix bull bull

1 0 laquo D bull n-raquolt bull a m-8shy J O B F I L C NO

CMCCKCO B Y mdash OAT o U bull E j bull

SKcrr OR PROJKCT tVlltM CHZtylCjL Go

000^ aso PROTOTYPE INCINERATOR SYSTEM

3

0 0 - NONE EXHAUST STACK

NEUTRt SYSTEM

GAS ABS SOLIDS UNIT

FLUID OUT BED SOLIDS

jCQMBUSTEf DROP-OUT BLEED RECYLCE AIR IN - 1600 CFM

FUEL IN r 124 LBSMIN

V 1

PROJECTED OPERATION - WORST CASE 1

FUEL - FLAMMABLE COMPOSITE

DATA BASED ON ACTUAL TRIAL RUN

BTULB OF FUEL FEED - 4909 BTUHOUR INPUT - 3535000 ASH CONTENT OF FEED - 157Z

5

I

bull c o bull oOCSIGMCH bull9 - n ix Mgt

raquoCHCCKCO a v _ raquo laquo 2 o tgtA r e -raquolaquolt - raquo m

J O H O _ _ _

ADJECT L^UWA CrtCAjjcyji Co 0013 GRSCP laquoraquorr 3 5 3 laquobull mdash ^ SYSTEM a ogt p

CAD 2traquo LBSMIN EXHAUST STACK

NEUTR SYSTEM

1988degF

AIR IN - 1997 CFM

FUEL IN

107 LBSMIN

PROJECTED OPERATION - WORST CASE 2

t

FUEL - FLAMMABLE COMPOSITE PLUS 21 CHLORINATED ORGAN ICS DATA BASED ON ACTUAL TRIAL RUN BTULB OF FUEL FEED - 6940 BTUHOUR INPUT - 4470000 ASH CONTENT OF FEED - 172

IN THIS CASE - raCHLOROETHYLENE

~ Q m (-gt

-10shy

deg I sect = o laquo =raquo5deg mdash3

3 raquo ZzrTABLE 2 bull =r =-3 3 bull mdash fa

UNION CHEMICAL COMPANY

Fluid Bed System - Projected Operating Data

SITUATION CASE j CASK jZ Proioeted

Ash from fuel 207 lbemin 182 195

Sand carry-over 03 03 03

Aah drop out 119 106 113

HC1 generated None 195 0975

CaO added (335 exoess)None 200 100

CaCl2 gonorated mdashgt 149 297 Unroacted CaO 025 05 Neutralisation Systembull

Solids Removal 101 385 243

KC1 Removal None 193 097

Oats Absorption System i a copySolids Removal 0176 067 042

HC1 Removal None 00198 001

5E VI- Ill i S a bull to

o o

tr copy A l l system components which might be subject to chemical 3 laquobullbull =r =shy

bulla m at 11 attack w i l l be fabricated of corrosion resistant materials The Jentire system w i l l be designed to roquire a minimum of operating

attention and to be relatively maintenance free The system

cannot operate unless a l l pollution oontrol devices are

functioning (eg no bypass modos)

I Y J Watorlalo to be Incinerated

A l l of the materials to be burned in the proposed lncinorator

are organic and inorganio residues from solvent recovery oporationo

or polymer formulators Union Chemical Companys method of

oporation involves d i s t i l l a t i o n of a l l economically recoverable

organic solvents using advanced proceos techniques

The materials to be burned include Ketones Alcohols Esters

Aliphatios Aroma t i c s and Chlorinated compounds A partial l i s t

of these oompounds i s as followsi (US EPA designations are

used)

F002 Spent halogcnuted solvents and s t i l l bottoms

P003 laquo Spent non-haloccnated solvento and s t i l l bottoms

F005 laquobull Spent non halogenated solvents and s t i l l bottoms

F017 raquo Paint residue from industrial painting

K078 - Solvent wastes from paint manufacturing sKtfc-flg K082 - Air pollution control sludges from paint manufacturers

V002 - Acetone

VOflO - Dichloromothane

V112 - Ethyl Acetate

Ymo - Ieobutyl Aloohol

Y15 Methanol

J

deg12shy

VI59 - Methyl Ethyl Ketone

p V161 Kethyl Ioobutyl Ketone

V210 - Tetrachloroethane

V220 - Toluene

V226 - 111 Trlchloroethane

V228 - Trichlorethylene

V239 - Xylene

t bull

raquo V Projected Air Emission

The materiale to Ve incinerated are essentially compounds

composed of carbon hydrogen and oxygen with occasional omall

amounts of chlorine and nitrogen The waste materials also

contain small amounts of inert ash primarily s i l i c a iron

oxide and heavy metal pigments Table I I I present an analysis

1 of ash from combustion of a typical fuel Routine ash analysis

w i l l be performed Uses for the ash are being researched but

present plans are to stabilize them via a stabilex type process

As described in Section VII the a i r emission control system

in tho form of process devices and system operating controls

w i l l result i n over-all highly efficient pollutant removal and

prevention

Table IV l i s t s potential a i r pollutants after the

incineration and chemical reactor processes prior to the wet

cross flow reactor as compared to anticipated emissions after the

oross flow

-=bull fiiSr-srrs

-raquoraquolt raquom|

o- raquo bull fi

a J 3

c3 o o

-iV

-3shy

I I Site Hovlew

Union Chemical Conpany Is located in the Central Kaine Air

Quality Region which is designated as a Class I I area The near

est Class I area is located approximately 77 kilometers to the

east and will not be affected by the project in South Hope

However the Central Kaine Air Quality Region is preoantly

considered a non-attainment area for otone which is attributed

to out-of-state sources All other criteria pollutants are

within the ambient limits established by the USEPA and

the Mains OKP

The incinerator site i s in South Hope Kaine located on

Kaino Route 17 about 32 miles East-Southeast of Augusta and

8 miles North-Northwest of Rockland The site is located on

the enclosed site plan area topographical map and stata of

Kaine location map

Distampnoe to the summit of Cadillao Mountain

--O 3T Z I -pound 8- degl 1 t mdash -J bull

I

copy o

NOTICE if the la laaa clear than this notice It la dua to tha quality of tha document UNI001

balng filmed - -y bull

raquo k c 1 _ - r 1111 bull--gtbullbull ~ ^

A laquo4

U T t Proems Dlocuoolon

Union Chemical Company provides two basic production sorvleos

at ito plant in South Hope Maine Chemical formulations for

stripping paints and other coatings from furniture and related

items are produced for sale and distribution Dirty organic

solvent streams are also processed to remove contaminants to

allow their recycle and re-use by clients throughout the Northeast

The proposed project w i l l allow Union Chemical Company to

develop a system to increase the utilization of the byproducts

from the organic solvent recovery process Some of thooo materials

are presently burned to produce steam for plant operationi however

as Btated earlier more fuel i s produced than can be utilized In

tho present two boilers and there are materials which cannot be

burned in the present boilers

S t i l l bottoms w i l l go to new bulk fuel tankB at the propouod

Jnolnorator alto and w i l l be stored prior to incineration Thoro

w i l l be throo new fuel tanks installodi two holding combuotlblo

material and the othor non-combuotlble chlorinated material The

two typeo would be mixed in a blender and prepared fuel w i l l be

stored In aday tank prior to incineration The non-combustible

chlorinated material w i l l decompose and burn above 2000degF The

oombustible material i s used to provide the necessary heat for

decomposition of the non-combustible chlorinated compoundsbull

Pronotied FluldlzodPod Incinerator Syotern

The koy to the proposed incineration proceno is the new

fluidized bed oombustion system Plans now require the comburitor

to oporate on a 24 hour per day experimental schedule with the ropt

of the plant to demonstrate i t s r e l i a b i l i t y We expeot normal

maintenance and down time to result In an annual average operating

oohodula on 24 hours per day 7 days per week 45 wooks por yoor

However emlssioiis calculations are based on 8760 hours per year

(52 weeks)

The ineinerator system as described in Figures 1 St 2 and

Table 2 will be made up of several components and will have dry

calcium chloride and ash as by-products The combustible and

non-combustible organic materials will be mixed in a blender and

fod via a day tank to the fluidized bed where incineration will

take place Gases in excess of 2100degF will pass from the burner

via an ash drop out box to an air heat exchanger The heat

exchanger will lower the gas temperature to about 1400degF The

gnn containing some hydrochloric acid when incinerating

chlorinated compounds will then paas to an injection system

whoro dry lime wVll be added The lime will react with tho acid

to form calcium chloride Ash and sand carry over from the drop

out box plus solids generated in the process will be removed

from the PJBB by a cyclone Prior to entering the final gas

aboorption unit quench water will be added in the duct to lower

the gas temperature to i80degF

The gas absorption system will be designed to remove

particulate matter and any residual hydrochloric acid from the

gas stream It will be a high efficiency cross-flow type wet

reactor which will recycle a dilute solution of lime through a

packod bed A small bleed stream from the cross-flow will purge

oontnminants to the burner where they will exit with the dry

oalclum ohloride Details of the gas absorption system will be

found in the appendix bull bull

1 0 laquo D bull n-raquolt bull a m-8shy J O B F I L C NO

CMCCKCO B Y mdash OAT o U bull E j bull

SKcrr OR PROJKCT tVlltM CHZtylCjL Go

000^ aso PROTOTYPE INCINERATOR SYSTEM

3

0 0 - NONE EXHAUST STACK

NEUTRt SYSTEM

GAS ABS SOLIDS UNIT

FLUID OUT BED SOLIDS

jCQMBUSTEf DROP-OUT BLEED RECYLCE AIR IN - 1600 CFM

FUEL IN r 124 LBSMIN

V 1

PROJECTED OPERATION - WORST CASE 1

FUEL - FLAMMABLE COMPOSITE

DATA BASED ON ACTUAL TRIAL RUN

BTULB OF FUEL FEED - 4909 BTUHOUR INPUT - 3535000 ASH CONTENT OF FEED - 157Z

5

I

bull c o bull oOCSIGMCH bull9 - n ix Mgt

raquoCHCCKCO a v _ raquo laquo 2 o tgtA r e -raquolaquolt - raquo m

J O H O _ _ _

ADJECT L^UWA CrtCAjjcyji Co 0013 GRSCP laquoraquorr 3 5 3 laquobull mdash ^ SYSTEM a ogt p

CAD 2traquo LBSMIN EXHAUST STACK

NEUTR SYSTEM

1988degF

AIR IN - 1997 CFM

FUEL IN

107 LBSMIN

PROJECTED OPERATION - WORST CASE 2

t

FUEL - FLAMMABLE COMPOSITE PLUS 21 CHLORINATED ORGAN ICS DATA BASED ON ACTUAL TRIAL RUN BTULB OF FUEL FEED - 6940 BTUHOUR INPUT - 4470000 ASH CONTENT OF FEED - 172

IN THIS CASE - raCHLOROETHYLENE

~ Q m (-gt

-10shy

deg I sect = o laquo =raquo5deg mdash3

3 raquo ZzrTABLE 2 bull =r =-3 3 bull mdash fa

UNION CHEMICAL COMPANY

Fluid Bed System - Projected Operating Data

SITUATION CASE j CASK jZ Proioeted

Ash from fuel 207 lbemin 182 195

Sand carry-over 03 03 03

Aah drop out 119 106 113

HC1 generated None 195 0975

CaO added (335 exoess)None 200 100

CaCl2 gonorated mdashgt 149 297 Unroacted CaO 025 05 Neutralisation Systembull

Solids Removal 101 385 243

KC1 Removal None 193 097

Oats Absorption System i a copySolids Removal 0176 067 042

HC1 Removal None 00198 001

5E VI- Ill i S a bull to

o o

tr copy A l l system components which might be subject to chemical 3 laquobullbull =r =shy

bulla m at 11 attack w i l l be fabricated of corrosion resistant materials The Jentire system w i l l be designed to roquire a minimum of operating

attention and to be relatively maintenance free The system

cannot operate unless a l l pollution oontrol devices are

functioning (eg no bypass modos)

I Y J Watorlalo to be Incinerated

A l l of the materials to be burned in the proposed lncinorator

are organic and inorganio residues from solvent recovery oporationo

or polymer formulators Union Chemical Companys method of

oporation involves d i s t i l l a t i o n of a l l economically recoverable

organic solvents using advanced proceos techniques

The materials to be burned include Ketones Alcohols Esters

Aliphatios Aroma t i c s and Chlorinated compounds A partial l i s t

of these oompounds i s as followsi (US EPA designations are

used)

F002 Spent halogcnuted solvents and s t i l l bottoms

P003 laquo Spent non-haloccnated solvento and s t i l l bottoms

F005 laquobull Spent non halogenated solvents and s t i l l bottoms

F017 raquo Paint residue from industrial painting

K078 - Solvent wastes from paint manufacturing sKtfc-flg K082 - Air pollution control sludges from paint manufacturers

V002 - Acetone

VOflO - Dichloromothane

V112 - Ethyl Acetate

Ymo - Ieobutyl Aloohol

Y15 Methanol

J

deg12shy

VI59 - Methyl Ethyl Ketone

p V161 Kethyl Ioobutyl Ketone

V210 - Tetrachloroethane

V220 - Toluene

V226 - 111 Trlchloroethane

V228 - Trichlorethylene

V239 - Xylene

t bull

raquo V Projected Air Emission

The materiale to Ve incinerated are essentially compounds

composed of carbon hydrogen and oxygen with occasional omall

amounts of chlorine and nitrogen The waste materials also

contain small amounts of inert ash primarily s i l i c a iron

oxide and heavy metal pigments Table I I I present an analysis

1 of ash from combustion of a typical fuel Routine ash analysis

w i l l be performed Uses for the ash are being researched but

present plans are to stabilize them via a stabilex type process

As described in Section VII the a i r emission control system

in tho form of process devices and system operating controls

w i l l result i n over-all highly efficient pollutant removal and

prevention

Table IV l i s t s potential a i r pollutants after the

incineration and chemical reactor processes prior to the wet

cross flow reactor as compared to anticipated emissions after the

oross flow

-=bull fiiSr-srrs

-raquoraquolt raquom|

o- raquo bull fi

a J 3

c3 o o

NOTICE if the la laaa clear than this notice It la dua to tha quality of tha document UNI001

balng filmed - -y bull

raquo k c 1 _ - r 1111 bull--gtbullbull ~ ^

A laquo4

U T t Proems Dlocuoolon

Union Chemical Company provides two basic production sorvleos

at ito plant in South Hope Maine Chemical formulations for

stripping paints and other coatings from furniture and related

items are produced for sale and distribution Dirty organic

solvent streams are also processed to remove contaminants to

allow their recycle and re-use by clients throughout the Northeast

The proposed project w i l l allow Union Chemical Company to

develop a system to increase the utilization of the byproducts

from the organic solvent recovery process Some of thooo materials

are presently burned to produce steam for plant operationi however

as Btated earlier more fuel i s produced than can be utilized In

tho present two boilers and there are materials which cannot be

burned in the present boilers

S t i l l bottoms w i l l go to new bulk fuel tankB at the propouod

Jnolnorator alto and w i l l be stored prior to incineration Thoro

w i l l be throo new fuel tanks installodi two holding combuotlblo

material and the othor non-combuotlble chlorinated material The

two typeo would be mixed in a blender and prepared fuel w i l l be

stored In aday tank prior to incineration The non-combustible

chlorinated material w i l l decompose and burn above 2000degF The

oombustible material i s used to provide the necessary heat for

decomposition of the non-combustible chlorinated compoundsbull

Pronotied FluldlzodPod Incinerator Syotern

The koy to the proposed incineration proceno is the new

fluidized bed oombustion system Plans now require the comburitor

to oporate on a 24 hour per day experimental schedule with the ropt

of the plant to demonstrate i t s r e l i a b i l i t y We expeot normal

maintenance and down time to result In an annual average operating

oohodula on 24 hours per day 7 days per week 45 wooks por yoor

However emlssioiis calculations are based on 8760 hours per year

(52 weeks)

The ineinerator system as described in Figures 1 St 2 and

Table 2 will be made up of several components and will have dry

calcium chloride and ash as by-products The combustible and

non-combustible organic materials will be mixed in a blender and

fod via a day tank to the fluidized bed where incineration will

take place Gases in excess of 2100degF will pass from the burner

via an ash drop out box to an air heat exchanger The heat

exchanger will lower the gas temperature to about 1400degF The

gnn containing some hydrochloric acid when incinerating

chlorinated compounds will then paas to an injection system

whoro dry lime wVll be added The lime will react with tho acid

to form calcium chloride Ash and sand carry over from the drop

out box plus solids generated in the process will be removed

from the PJBB by a cyclone Prior to entering the final gas

aboorption unit quench water will be added in the duct to lower

the gas temperature to i80degF

The gas absorption system will be designed to remove

particulate matter and any residual hydrochloric acid from the

gas stream It will be a high efficiency cross-flow type wet

reactor which will recycle a dilute solution of lime through a

packod bed A small bleed stream from the cross-flow will purge

oontnminants to the burner where they will exit with the dry

oalclum ohloride Details of the gas absorption system will be

found in the appendix bull bull

1 0 laquo D bull n-raquolt bull a m-8shy J O B F I L C NO

CMCCKCO B Y mdash OAT o U bull E j bull

SKcrr OR PROJKCT tVlltM CHZtylCjL Go

000^ aso PROTOTYPE INCINERATOR SYSTEM

3

0 0 - NONE EXHAUST STACK

NEUTRt SYSTEM

GAS ABS SOLIDS UNIT

FLUID OUT BED SOLIDS

jCQMBUSTEf DROP-OUT BLEED RECYLCE AIR IN - 1600 CFM

FUEL IN r 124 LBSMIN

V 1

PROJECTED OPERATION - WORST CASE 1

FUEL - FLAMMABLE COMPOSITE

DATA BASED ON ACTUAL TRIAL RUN

BTULB OF FUEL FEED - 4909 BTUHOUR INPUT - 3535000 ASH CONTENT OF FEED - 157Z

5

I

bull c o bull oOCSIGMCH bull9 - n ix Mgt

raquoCHCCKCO a v _ raquo laquo 2 o tgtA r e -raquolaquolt - raquo m

J O H O _ _ _

ADJECT L^UWA CrtCAjjcyji Co 0013 GRSCP laquoraquorr 3 5 3 laquobull mdash ^ SYSTEM a ogt p

CAD 2traquo LBSMIN EXHAUST STACK

NEUTR SYSTEM

1988degF

AIR IN - 1997 CFM

FUEL IN

107 LBSMIN

PROJECTED OPERATION - WORST CASE 2

t

FUEL - FLAMMABLE COMPOSITE PLUS 21 CHLORINATED ORGAN ICS DATA BASED ON ACTUAL TRIAL RUN BTULB OF FUEL FEED - 6940 BTUHOUR INPUT - 4470000 ASH CONTENT OF FEED - 172

IN THIS CASE - raCHLOROETHYLENE

~ Q m (-gt

-10shy

deg I sect = o laquo =raquo5deg mdash3

3 raquo ZzrTABLE 2 bull =r =-3 3 bull mdash fa

UNION CHEMICAL COMPANY

Fluid Bed System - Projected Operating Data

SITUATION CASE j CASK jZ Proioeted

Ash from fuel 207 lbemin 182 195

Sand carry-over 03 03 03

Aah drop out 119 106 113

HC1 generated None 195 0975

CaO added (335 exoess)None 200 100

CaCl2 gonorated mdashgt 149 297 Unroacted CaO 025 05 Neutralisation Systembull

Solids Removal 101 385 243

KC1 Removal None 193 097

Oats Absorption System i a copySolids Removal 0176 067 042

HC1 Removal None 00198 001

5E VI- Ill i S a bull to

o o

tr copy A l l system components which might be subject to chemical 3 laquobullbull =r =shy

bulla m at 11 attack w i l l be fabricated of corrosion resistant materials The Jentire system w i l l be designed to roquire a minimum of operating

attention and to be relatively maintenance free The system

cannot operate unless a l l pollution oontrol devices are

functioning (eg no bypass modos)

I Y J Watorlalo to be Incinerated

A l l of the materials to be burned in the proposed lncinorator

are organic and inorganio residues from solvent recovery oporationo

or polymer formulators Union Chemical Companys method of

oporation involves d i s t i l l a t i o n of a l l economically recoverable

organic solvents using advanced proceos techniques

The materials to be burned include Ketones Alcohols Esters

Aliphatios Aroma t i c s and Chlorinated compounds A partial l i s t

of these oompounds i s as followsi (US EPA designations are

used)

F002 Spent halogcnuted solvents and s t i l l bottoms

P003 laquo Spent non-haloccnated solvento and s t i l l bottoms

F005 laquobull Spent non halogenated solvents and s t i l l bottoms

F017 raquo Paint residue from industrial painting

K078 - Solvent wastes from paint manufacturing sKtfc-flg K082 - Air pollution control sludges from paint manufacturers

V002 - Acetone

VOflO - Dichloromothane

V112 - Ethyl Acetate

Ymo - Ieobutyl Aloohol

Y15 Methanol

J

deg12shy

VI59 - Methyl Ethyl Ketone

p V161 Kethyl Ioobutyl Ketone

V210 - Tetrachloroethane

V220 - Toluene

V226 - 111 Trlchloroethane

V228 - Trichlorethylene

V239 - Xylene

t bull

raquo V Projected Air Emission

The materiale to Ve incinerated are essentially compounds

composed of carbon hydrogen and oxygen with occasional omall

amounts of chlorine and nitrogen The waste materials also

contain small amounts of inert ash primarily s i l i c a iron

oxide and heavy metal pigments Table I I I present an analysis

1 of ash from combustion of a typical fuel Routine ash analysis

w i l l be performed Uses for the ash are being researched but

present plans are to stabilize them via a stabilex type process

As described in Section VII the a i r emission control system

in tho form of process devices and system operating controls

w i l l result i n over-all highly efficient pollutant removal and

prevention

Table IV l i s t s potential a i r pollutants after the

incineration and chemical reactor processes prior to the wet

cross flow reactor as compared to anticipated emissions after the

oross flow

-=bull fiiSr-srrs

-raquoraquolt raquom|

o- raquo bull fi

a J 3

c3 o o

U T t Proems Dlocuoolon

Union Chemical Company provides two basic production sorvleos

at ito plant in South Hope Maine Chemical formulations for

stripping paints and other coatings from furniture and related

items are produced for sale and distribution Dirty organic

solvent streams are also processed to remove contaminants to

allow their recycle and re-use by clients throughout the Northeast

The proposed project w i l l allow Union Chemical Company to

develop a system to increase the utilization of the byproducts

from the organic solvent recovery process Some of thooo materials

are presently burned to produce steam for plant operationi however

as Btated earlier more fuel i s produced than can be utilized In

tho present two boilers and there are materials which cannot be

burned in the present boilers

S t i l l bottoms w i l l go to new bulk fuel tankB at the propouod

Jnolnorator alto and w i l l be stored prior to incineration Thoro

w i l l be throo new fuel tanks installodi two holding combuotlblo

material and the othor non-combuotlble chlorinated material The

two typeo would be mixed in a blender and prepared fuel w i l l be

stored In aday tank prior to incineration The non-combustible

chlorinated material w i l l decompose and burn above 2000degF The

oombustible material i s used to provide the necessary heat for

decomposition of the non-combustible chlorinated compoundsbull

Pronotied FluldlzodPod Incinerator Syotern

The koy to the proposed incineration proceno is the new

fluidized bed oombustion system Plans now require the comburitor

to oporate on a 24 hour per day experimental schedule with the ropt

of the plant to demonstrate i t s r e l i a b i l i t y We expeot normal

maintenance and down time to result In an annual average operating

oohodula on 24 hours per day 7 days per week 45 wooks por yoor

However emlssioiis calculations are based on 8760 hours per year

(52 weeks)

The ineinerator system as described in Figures 1 St 2 and

Table 2 will be made up of several components and will have dry

calcium chloride and ash as by-products The combustible and

non-combustible organic materials will be mixed in a blender and

fod via a day tank to the fluidized bed where incineration will

take place Gases in excess of 2100degF will pass from the burner

via an ash drop out box to an air heat exchanger The heat

exchanger will lower the gas temperature to about 1400degF The

gnn containing some hydrochloric acid when incinerating

chlorinated compounds will then paas to an injection system

whoro dry lime wVll be added The lime will react with tho acid

to form calcium chloride Ash and sand carry over from the drop

out box plus solids generated in the process will be removed

from the PJBB by a cyclone Prior to entering the final gas

aboorption unit quench water will be added in the duct to lower

the gas temperature to i80degF

The gas absorption system will be designed to remove

particulate matter and any residual hydrochloric acid from the

gas stream It will be a high efficiency cross-flow type wet

reactor which will recycle a dilute solution of lime through a

packod bed A small bleed stream from the cross-flow will purge

oontnminants to the burner where they will exit with the dry

oalclum ohloride Details of the gas absorption system will be

found in the appendix bull bull

1 0 laquo D bull n-raquolt bull a m-8shy J O B F I L C NO

CMCCKCO B Y mdash OAT o U bull E j bull

SKcrr OR PROJKCT tVlltM CHZtylCjL Go

000^ aso PROTOTYPE INCINERATOR SYSTEM

3

0 0 - NONE EXHAUST STACK

NEUTRt SYSTEM

GAS ABS SOLIDS UNIT

FLUID OUT BED SOLIDS

jCQMBUSTEf DROP-OUT BLEED RECYLCE AIR IN - 1600 CFM

FUEL IN r 124 LBSMIN

V 1

PROJECTED OPERATION - WORST CASE 1

FUEL - FLAMMABLE COMPOSITE

DATA BASED ON ACTUAL TRIAL RUN

BTULB OF FUEL FEED - 4909 BTUHOUR INPUT - 3535000 ASH CONTENT OF FEED - 157Z

5

I

bull c o bull oOCSIGMCH bull9 - n ix Mgt

raquoCHCCKCO a v _ raquo laquo 2 o tgtA r e -raquolaquolt - raquo m

J O H O _ _ _

ADJECT L^UWA CrtCAjjcyji Co 0013 GRSCP laquoraquorr 3 5 3 laquobull mdash ^ SYSTEM a ogt p

CAD 2traquo LBSMIN EXHAUST STACK

NEUTR SYSTEM

1988degF

AIR IN - 1997 CFM

FUEL IN

107 LBSMIN

PROJECTED OPERATION - WORST CASE 2

t

FUEL - FLAMMABLE COMPOSITE PLUS 21 CHLORINATED ORGAN ICS DATA BASED ON ACTUAL TRIAL RUN BTULB OF FUEL FEED - 6940 BTUHOUR INPUT - 4470000 ASH CONTENT OF FEED - 172

IN THIS CASE - raCHLOROETHYLENE

~ Q m (-gt

-10shy

deg I sect = o laquo =raquo5deg mdash3

3 raquo ZzrTABLE 2 bull =r =-3 3 bull mdash fa

UNION CHEMICAL COMPANY

Fluid Bed System - Projected Operating Data

SITUATION CASE j CASK jZ Proioeted

Ash from fuel 207 lbemin 182 195

Sand carry-over 03 03 03

Aah drop out 119 106 113

HC1 generated None 195 0975

CaO added (335 exoess)None 200 100

CaCl2 gonorated mdashgt 149 297 Unroacted CaO 025 05 Neutralisation Systembull

Solids Removal 101 385 243

KC1 Removal None 193 097

Oats Absorption System i a copySolids Removal 0176 067 042

HC1 Removal None 00198 001

5E VI- Ill i S a bull to

o o

tr copy A l l system components which might be subject to chemical 3 laquobullbull =r =shy

bulla m at 11 attack w i l l be fabricated of corrosion resistant materials The Jentire system w i l l be designed to roquire a minimum of operating

attention and to be relatively maintenance free The system

cannot operate unless a l l pollution oontrol devices are

functioning (eg no bypass modos)

I Y J Watorlalo to be Incinerated

A l l of the materials to be burned in the proposed lncinorator

are organic and inorganio residues from solvent recovery oporationo

or polymer formulators Union Chemical Companys method of

oporation involves d i s t i l l a t i o n of a l l economically recoverable

organic solvents using advanced proceos techniques

The materials to be burned include Ketones Alcohols Esters

Aliphatios Aroma t i c s and Chlorinated compounds A partial l i s t

of these oompounds i s as followsi (US EPA designations are

used)

F002 Spent halogcnuted solvents and s t i l l bottoms

P003 laquo Spent non-haloccnated solvento and s t i l l bottoms

F005 laquobull Spent non halogenated solvents and s t i l l bottoms

F017 raquo Paint residue from industrial painting

K078 - Solvent wastes from paint manufacturing sKtfc-flg K082 - Air pollution control sludges from paint manufacturers

V002 - Acetone

VOflO - Dichloromothane

V112 - Ethyl Acetate

Ymo - Ieobutyl Aloohol

Y15 Methanol

J

deg12shy

VI59 - Methyl Ethyl Ketone

p V161 Kethyl Ioobutyl Ketone

V210 - Tetrachloroethane

V220 - Toluene

V226 - 111 Trlchloroethane

V228 - Trichlorethylene

V239 - Xylene

t bull

raquo V Projected Air Emission

The materiale to Ve incinerated are essentially compounds

composed of carbon hydrogen and oxygen with occasional omall

amounts of chlorine and nitrogen The waste materials also

contain small amounts of inert ash primarily s i l i c a iron

oxide and heavy metal pigments Table I I I present an analysis

1 of ash from combustion of a typical fuel Routine ash analysis

w i l l be performed Uses for the ash are being researched but

present plans are to stabilize them via a stabilex type process

As described in Section VII the a i r emission control system

in tho form of process devices and system operating controls

w i l l result i n over-all highly efficient pollutant removal and

prevention

Table IV l i s t s potential a i r pollutants after the

incineration and chemical reactor processes prior to the wet

cross flow reactor as compared to anticipated emissions after the

oross flow

-=bull fiiSr-srrs

-raquoraquolt raquom|

o- raquo bull fi

a J 3

c3 o o

maintenance and down time to result In an annual average operating

oohodula on 24 hours per day 7 days per week 45 wooks por yoor

However emlssioiis calculations are based on 8760 hours per year

(52 weeks)

The ineinerator system as described in Figures 1 St 2 and

Table 2 will be made up of several components and will have dry

calcium chloride and ash as by-products The combustible and

non-combustible organic materials will be mixed in a blender and

fod via a day tank to the fluidized bed where incineration will

take place Gases in excess of 2100degF will pass from the burner

via an ash drop out box to an air heat exchanger The heat

exchanger will lower the gas temperature to about 1400degF The

gnn containing some hydrochloric acid when incinerating

chlorinated compounds will then paas to an injection system

whoro dry lime wVll be added The lime will react with tho acid

to form calcium chloride Ash and sand carry over from the drop

out box plus solids generated in the process will be removed

from the PJBB by a cyclone Prior to entering the final gas

aboorption unit quench water will be added in the duct to lower

the gas temperature to i80degF

The gas absorption system will be designed to remove

particulate matter and any residual hydrochloric acid from the

gas stream It will be a high efficiency cross-flow type wet

reactor which will recycle a dilute solution of lime through a

packod bed A small bleed stream from the cross-flow will purge

oontnminants to the burner where they will exit with the dry

oalclum ohloride Details of the gas absorption system will be

found in the appendix bull bull

1 0 laquo D bull n-raquolt bull a m-8shy J O B F I L C NO

CMCCKCO B Y mdash OAT o U bull E j bull

SKcrr OR PROJKCT tVlltM CHZtylCjL Go

000^ aso PROTOTYPE INCINERATOR SYSTEM

3

0 0 - NONE EXHAUST STACK

NEUTRt SYSTEM

GAS ABS SOLIDS UNIT

FLUID OUT BED SOLIDS

jCQMBUSTEf DROP-OUT BLEED RECYLCE AIR IN - 1600 CFM

FUEL IN r 124 LBSMIN

V 1

PROJECTED OPERATION - WORST CASE 1

FUEL - FLAMMABLE COMPOSITE

DATA BASED ON ACTUAL TRIAL RUN

BTULB OF FUEL FEED - 4909 BTUHOUR INPUT - 3535000 ASH CONTENT OF FEED - 157Z

5

I

bull c o bull oOCSIGMCH bull9 - n ix Mgt

raquoCHCCKCO a v _ raquo laquo 2 o tgtA r e -raquolaquolt - raquo m

J O H O _ _ _

ADJECT L^UWA CrtCAjjcyji Co 0013 GRSCP laquoraquorr 3 5 3 laquobull mdash ^ SYSTEM a ogt p

CAD 2traquo LBSMIN EXHAUST STACK

NEUTR SYSTEM

1988degF

AIR IN - 1997 CFM

FUEL IN

107 LBSMIN

PROJECTED OPERATION - WORST CASE 2

t

FUEL - FLAMMABLE COMPOSITE PLUS 21 CHLORINATED ORGAN ICS DATA BASED ON ACTUAL TRIAL RUN BTULB OF FUEL FEED - 6940 BTUHOUR INPUT - 4470000 ASH CONTENT OF FEED - 172

IN THIS CASE - raCHLOROETHYLENE

~ Q m (-gt

-10shy

deg I sect = o laquo =raquo5deg mdash3

3 raquo ZzrTABLE 2 bull =r =-3 3 bull mdash fa

UNION CHEMICAL COMPANY

Fluid Bed System - Projected Operating Data

SITUATION CASE j CASK jZ Proioeted

Ash from fuel 207 lbemin 182 195

Sand carry-over 03 03 03

Aah drop out 119 106 113

HC1 generated None 195 0975

CaO added (335 exoess)None 200 100

CaCl2 gonorated mdashgt 149 297 Unroacted CaO 025 05 Neutralisation Systembull

Solids Removal 101 385 243

KC1 Removal None 193 097

Oats Absorption System i a copySolids Removal 0176 067 042

HC1 Removal None 00198 001

5E VI- Ill i S a bull to

o o

tr copy A l l system components which might be subject to chemical 3 laquobullbull =r =shy

bulla m at 11 attack w i l l be fabricated of corrosion resistant materials The Jentire system w i l l be designed to roquire a minimum of operating

attention and to be relatively maintenance free The system

cannot operate unless a l l pollution oontrol devices are

functioning (eg no bypass modos)

I Y J Watorlalo to be Incinerated

A l l of the materials to be burned in the proposed lncinorator

are organic and inorganio residues from solvent recovery oporationo

or polymer formulators Union Chemical Companys method of

oporation involves d i s t i l l a t i o n of a l l economically recoverable

organic solvents using advanced proceos techniques

The materials to be burned include Ketones Alcohols Esters

Aliphatios Aroma t i c s and Chlorinated compounds A partial l i s t

of these oompounds i s as followsi (US EPA designations are

used)

F002 Spent halogcnuted solvents and s t i l l bottoms

P003 laquo Spent non-haloccnated solvento and s t i l l bottoms

F005 laquobull Spent non halogenated solvents and s t i l l bottoms

F017 raquo Paint residue from industrial painting

K078 - Solvent wastes from paint manufacturing sKtfc-flg K082 - Air pollution control sludges from paint manufacturers

V002 - Acetone

VOflO - Dichloromothane

V112 - Ethyl Acetate

Ymo - Ieobutyl Aloohol

Y15 Methanol

J

deg12shy

VI59 - Methyl Ethyl Ketone

p V161 Kethyl Ioobutyl Ketone

V210 - Tetrachloroethane

V220 - Toluene

V226 - 111 Trlchloroethane

V228 - Trichlorethylene

V239 - Xylene

t bull

raquo V Projected Air Emission

The materiale to Ve incinerated are essentially compounds

composed of carbon hydrogen and oxygen with occasional omall

amounts of chlorine and nitrogen The waste materials also

contain small amounts of inert ash primarily s i l i c a iron

oxide and heavy metal pigments Table I I I present an analysis

1 of ash from combustion of a typical fuel Routine ash analysis

w i l l be performed Uses for the ash are being researched but

present plans are to stabilize them via a stabilex type process

As described in Section VII the a i r emission control system

in tho form of process devices and system operating controls

w i l l result i n over-all highly efficient pollutant removal and

prevention

Table IV l i s t s potential a i r pollutants after the

incineration and chemical reactor processes prior to the wet

cross flow reactor as compared to anticipated emissions after the

oross flow

-=bull fiiSr-srrs

-raquoraquolt raquom|

o- raquo bull fi

a J 3

c3 o o

1 0 laquo D bull n-raquolt bull a m-8shy J O B F I L C NO

CMCCKCO B Y mdash OAT o U bull E j bull

SKcrr OR PROJKCT tVlltM CHZtylCjL Go

000^ aso PROTOTYPE INCINERATOR SYSTEM

3

0 0 - NONE EXHAUST STACK

NEUTRt SYSTEM

GAS ABS SOLIDS UNIT

FLUID OUT BED SOLIDS

jCQMBUSTEf DROP-OUT BLEED RECYLCE AIR IN - 1600 CFM

FUEL IN r 124 LBSMIN

V 1

PROJECTED OPERATION - WORST CASE 1

FUEL - FLAMMABLE COMPOSITE

DATA BASED ON ACTUAL TRIAL RUN

BTULB OF FUEL FEED - 4909 BTUHOUR INPUT - 3535000 ASH CONTENT OF FEED - 157Z

5

I

bull c o bull oOCSIGMCH bull9 - n ix Mgt

raquoCHCCKCO a v _ raquo laquo 2 o tgtA r e -raquolaquolt - raquo m

J O H O _ _ _

ADJECT L^UWA CrtCAjjcyji Co 0013 GRSCP laquoraquorr 3 5 3 laquobull mdash ^ SYSTEM a ogt p

CAD 2traquo LBSMIN EXHAUST STACK

NEUTR SYSTEM

1988degF

AIR IN - 1997 CFM

FUEL IN

107 LBSMIN

PROJECTED OPERATION - WORST CASE 2

t

FUEL - FLAMMABLE COMPOSITE PLUS 21 CHLORINATED ORGAN ICS DATA BASED ON ACTUAL TRIAL RUN BTULB OF FUEL FEED - 6940 BTUHOUR INPUT - 4470000 ASH CONTENT OF FEED - 172

IN THIS CASE - raCHLOROETHYLENE

~ Q m (-gt

-10shy

deg I sect = o laquo =raquo5deg mdash3

3 raquo ZzrTABLE 2 bull =r =-3 3 bull mdash fa

UNION CHEMICAL COMPANY

Fluid Bed System - Projected Operating Data

SITUATION CASE j CASK jZ Proioeted

Ash from fuel 207 lbemin 182 195

Sand carry-over 03 03 03

Aah drop out 119 106 113

HC1 generated None 195 0975

CaO added (335 exoess)None 200 100

CaCl2 gonorated mdashgt 149 297 Unroacted CaO 025 05 Neutralisation Systembull

Solids Removal 101 385 243

KC1 Removal None 193 097

Oats Absorption System i a copySolids Removal 0176 067 042

HC1 Removal None 00198 001

5E VI- Ill i S a bull to

o o

tr copy A l l system components which might be subject to chemical 3 laquobullbull =r =shy

bulla m at 11 attack w i l l be fabricated of corrosion resistant materials The Jentire system w i l l be designed to roquire a minimum of operating

attention and to be relatively maintenance free The system

cannot operate unless a l l pollution oontrol devices are

functioning (eg no bypass modos)

I Y J Watorlalo to be Incinerated

A l l of the materials to be burned in the proposed lncinorator

are organic and inorganio residues from solvent recovery oporationo

or polymer formulators Union Chemical Companys method of

oporation involves d i s t i l l a t i o n of a l l economically recoverable

organic solvents using advanced proceos techniques

The materials to be burned include Ketones Alcohols Esters

Aliphatios Aroma t i c s and Chlorinated compounds A partial l i s t

of these oompounds i s as followsi (US EPA designations are

used)

F002 Spent halogcnuted solvents and s t i l l bottoms

P003 laquo Spent non-haloccnated solvento and s t i l l bottoms

F005 laquobull Spent non halogenated solvents and s t i l l bottoms

F017 raquo Paint residue from industrial painting

K078 - Solvent wastes from paint manufacturing sKtfc-flg K082 - Air pollution control sludges from paint manufacturers

V002 - Acetone

VOflO - Dichloromothane

V112 - Ethyl Acetate

Ymo - Ieobutyl Aloohol

Y15 Methanol

J

deg12shy

VI59 - Methyl Ethyl Ketone

p V161 Kethyl Ioobutyl Ketone

V210 - Tetrachloroethane

V220 - Toluene

V226 - 111 Trlchloroethane

V228 - Trichlorethylene

V239 - Xylene

t bull

raquo V Projected Air Emission

The materiale to Ve incinerated are essentially compounds

composed of carbon hydrogen and oxygen with occasional omall

amounts of chlorine and nitrogen The waste materials also

contain small amounts of inert ash primarily s i l i c a iron

oxide and heavy metal pigments Table I I I present an analysis

1 of ash from combustion of a typical fuel Routine ash analysis

w i l l be performed Uses for the ash are being researched but

present plans are to stabilize them via a stabilex type process

As described in Section VII the a i r emission control system

in tho form of process devices and system operating controls

w i l l result i n over-all highly efficient pollutant removal and

prevention

Table IV l i s t s potential a i r pollutants after the

incineration and chemical reactor processes prior to the wet

cross flow reactor as compared to anticipated emissions after the

oross flow

-=bull fiiSr-srrs

-raquoraquolt raquom|

o- raquo bull fi

a J 3

c3 o o

I

bull c o bull oOCSIGMCH bull9 - n ix Mgt

raquoCHCCKCO a v _ raquo laquo 2 o tgtA r e -raquolaquolt - raquo m

J O H O _ _ _

ADJECT L^UWA CrtCAjjcyji Co 0013 GRSCP laquoraquorr 3 5 3 laquobull mdash ^ SYSTEM a ogt p

CAD 2traquo LBSMIN EXHAUST STACK

NEUTR SYSTEM

1988degF

AIR IN - 1997 CFM

FUEL IN

107 LBSMIN

PROJECTED OPERATION - WORST CASE 2

t

FUEL - FLAMMABLE COMPOSITE PLUS 21 CHLORINATED ORGAN ICS DATA BASED ON ACTUAL TRIAL RUN BTULB OF FUEL FEED - 6940 BTUHOUR INPUT - 4470000 ASH CONTENT OF FEED - 172

IN THIS CASE - raCHLOROETHYLENE

~ Q m (-gt

-10shy

deg I sect = o laquo =raquo5deg mdash3

3 raquo ZzrTABLE 2 bull =r =-3 3 bull mdash fa

UNION CHEMICAL COMPANY

Fluid Bed System - Projected Operating Data

SITUATION CASE j CASK jZ Proioeted

Ash from fuel 207 lbemin 182 195

Sand carry-over 03 03 03

Aah drop out 119 106 113

HC1 generated None 195 0975

CaO added (335 exoess)None 200 100

CaCl2 gonorated mdashgt 149 297 Unroacted CaO 025 05 Neutralisation Systembull

Solids Removal 101 385 243

KC1 Removal None 193 097

Oats Absorption System i a copySolids Removal 0176 067 042

HC1 Removal None 00198 001

5E VI- Ill i S a bull to

o o

tr copy A l l system components which might be subject to chemical 3 laquobullbull =r =shy

bulla m at 11 attack w i l l be fabricated of corrosion resistant materials The Jentire system w i l l be designed to roquire a minimum of operating

attention and to be relatively maintenance free The system

cannot operate unless a l l pollution oontrol devices are

functioning (eg no bypass modos)

I Y J Watorlalo to be Incinerated

A l l of the materials to be burned in the proposed lncinorator

are organic and inorganio residues from solvent recovery oporationo

or polymer formulators Union Chemical Companys method of

oporation involves d i s t i l l a t i o n of a l l economically recoverable

organic solvents using advanced proceos techniques

The materials to be burned include Ketones Alcohols Esters

Aliphatios Aroma t i c s and Chlorinated compounds A partial l i s t

of these oompounds i s as followsi (US EPA designations are

used)

F002 Spent halogcnuted solvents and s t i l l bottoms

P003 laquo Spent non-haloccnated solvento and s t i l l bottoms

F005 laquobull Spent non halogenated solvents and s t i l l bottoms

F017 raquo Paint residue from industrial painting

K078 - Solvent wastes from paint manufacturing sKtfc-flg K082 - Air pollution control sludges from paint manufacturers

V002 - Acetone

VOflO - Dichloromothane

V112 - Ethyl Acetate

Ymo - Ieobutyl Aloohol

Y15 Methanol

J

deg12shy

VI59 - Methyl Ethyl Ketone

p V161 Kethyl Ioobutyl Ketone

V210 - Tetrachloroethane

V220 - Toluene

V226 - 111 Trlchloroethane

V228 - Trichlorethylene

V239 - Xylene

t bull

raquo V Projected Air Emission

The materiale to Ve incinerated are essentially compounds

composed of carbon hydrogen and oxygen with occasional omall

amounts of chlorine and nitrogen The waste materials also

contain small amounts of inert ash primarily s i l i c a iron

oxide and heavy metal pigments Table I I I present an analysis

1 of ash from combustion of a typical fuel Routine ash analysis

w i l l be performed Uses for the ash are being researched but

present plans are to stabilize them via a stabilex type process

As described in Section VII the a i r emission control system

in tho form of process devices and system operating controls

w i l l result i n over-all highly efficient pollutant removal and

prevention

Table IV l i s t s potential a i r pollutants after the

incineration and chemical reactor processes prior to the wet

cross flow reactor as compared to anticipated emissions after the

oross flow

-=bull fiiSr-srrs

-raquoraquolt raquom|

o- raquo bull fi

a J 3

c3 o o

~ Q m (-gt

-10shy

deg I sect = o laquo =raquo5deg mdash3

3 raquo ZzrTABLE 2 bull =r =-3 3 bull mdash fa

UNION CHEMICAL COMPANY

Fluid Bed System - Projected Operating Data

SITUATION CASE j CASK jZ Proioeted

Ash from fuel 207 lbemin 182 195

Sand carry-over 03 03 03

Aah drop out 119 106 113

HC1 generated None 195 0975

CaO added (335 exoess)None 200 100

CaCl2 gonorated mdashgt 149 297 Unroacted CaO 025 05 Neutralisation Systembull

Solids Removal 101 385 243

KC1 Removal None 193 097

Oats Absorption System i a copySolids Removal 0176 067 042

HC1 Removal None 00198 001

5E VI- Ill i S a bull to

o o

tr copy A l l system components which might be subject to chemical 3 laquobullbull =r =shy

bulla m at 11 attack w i l l be fabricated of corrosion resistant materials The Jentire system w i l l be designed to roquire a minimum of operating

attention and to be relatively maintenance free The system

cannot operate unless a l l pollution oontrol devices are

functioning (eg no bypass modos)

I Y J Watorlalo to be Incinerated

A l l of the materials to be burned in the proposed lncinorator

are organic and inorganio residues from solvent recovery oporationo

or polymer formulators Union Chemical Companys method of

oporation involves d i s t i l l a t i o n of a l l economically recoverable

organic solvents using advanced proceos techniques

The materials to be burned include Ketones Alcohols Esters

Aliphatios Aroma t i c s and Chlorinated compounds A partial l i s t

of these oompounds i s as followsi (US EPA designations are

used)

F002 Spent halogcnuted solvents and s t i l l bottoms

P003 laquo Spent non-haloccnated solvento and s t i l l bottoms

F005 laquobull Spent non halogenated solvents and s t i l l bottoms

F017 raquo Paint residue from industrial painting

K078 - Solvent wastes from paint manufacturing sKtfc-flg K082 - Air pollution control sludges from paint manufacturers

V002 - Acetone

VOflO - Dichloromothane

V112 - Ethyl Acetate

Ymo - Ieobutyl Aloohol

Y15 Methanol

J

deg12shy

VI59 - Methyl Ethyl Ketone

p V161 Kethyl Ioobutyl Ketone

V210 - Tetrachloroethane

V220 - Toluene

V226 - 111 Trlchloroethane

V228 - Trichlorethylene

V239 - Xylene

t bull

raquo V Projected Air Emission

The materiale to Ve incinerated are essentially compounds

composed of carbon hydrogen and oxygen with occasional omall

amounts of chlorine and nitrogen The waste materials also

contain small amounts of inert ash primarily s i l i c a iron

oxide and heavy metal pigments Table I I I present an analysis

1 of ash from combustion of a typical fuel Routine ash analysis

w i l l be performed Uses for the ash are being researched but

present plans are to stabilize them via a stabilex type process

As described in Section VII the a i r emission control system

in tho form of process devices and system operating controls

w i l l result i n over-all highly efficient pollutant removal and

prevention

Table IV l i s t s potential a i r pollutants after the

incineration and chemical reactor processes prior to the wet

cross flow reactor as compared to anticipated emissions after the

oross flow

-=bull fiiSr-srrs

-raquoraquolt raquom|

o- raquo bull fi

a J 3

c3 o o

5E VI- Ill i S a bull to

o o

tr copy A l l system components which might be subject to chemical 3 laquobullbull =r =shy

bulla m at 11 attack w i l l be fabricated of corrosion resistant materials The Jentire system w i l l be designed to roquire a minimum of operating

attention and to be relatively maintenance free The system

cannot operate unless a l l pollution oontrol devices are

functioning (eg no bypass modos)

I Y J Watorlalo to be Incinerated

A l l of the materials to be burned in the proposed lncinorator

are organic and inorganio residues from solvent recovery oporationo

or polymer formulators Union Chemical Companys method of

oporation involves d i s t i l l a t i o n of a l l economically recoverable

organic solvents using advanced proceos techniques

The materials to be burned include Ketones Alcohols Esters

Aliphatios Aroma t i c s and Chlorinated compounds A partial l i s t

of these oompounds i s as followsi (US EPA designations are

used)

F002 Spent halogcnuted solvents and s t i l l bottoms

P003 laquo Spent non-haloccnated solvento and s t i l l bottoms

F005 laquobull Spent non halogenated solvents and s t i l l bottoms

F017 raquo Paint residue from industrial painting

K078 - Solvent wastes from paint manufacturing sKtfc-flg K082 - Air pollution control sludges from paint manufacturers

V002 - Acetone

VOflO - Dichloromothane

V112 - Ethyl Acetate

Ymo - Ieobutyl Aloohol

Y15 Methanol

J

deg12shy

VI59 - Methyl Ethyl Ketone

p V161 Kethyl Ioobutyl Ketone

V210 - Tetrachloroethane

V220 - Toluene

V226 - 111 Trlchloroethane

V228 - Trichlorethylene

V239 - Xylene

t bull

raquo V Projected Air Emission

The materiale to Ve incinerated are essentially compounds

composed of carbon hydrogen and oxygen with occasional omall

amounts of chlorine and nitrogen The waste materials also

contain small amounts of inert ash primarily s i l i c a iron

oxide and heavy metal pigments Table I I I present an analysis

1 of ash from combustion of a typical fuel Routine ash analysis

w i l l be performed Uses for the ash are being researched but

present plans are to stabilize them via a stabilex type process

As described in Section VII the a i r emission control system

in tho form of process devices and system operating controls

w i l l result i n over-all highly efficient pollutant removal and

prevention

Table IV l i s t s potential a i r pollutants after the

incineration and chemical reactor processes prior to the wet

cross flow reactor as compared to anticipated emissions after the

oross flow

-=bull fiiSr-srrs

-raquoraquolt raquom|

o- raquo bull fi

a J 3

c3 o o

J

deg12shy

VI59 - Methyl Ethyl Ketone

p V161 Kethyl Ioobutyl Ketone

V210 - Tetrachloroethane

V220 - Toluene

V226 - 111 Trlchloroethane

V228 - Trichlorethylene

V239 - Xylene

t bull

raquo V Projected Air Emission

The materiale to Ve incinerated are essentially compounds

composed of carbon hydrogen and oxygen with occasional omall

amounts of chlorine and nitrogen The waste materials also

contain small amounts of inert ash primarily s i l i c a iron

oxide and heavy metal pigments Table I I I present an analysis

1 of ash from combustion of a typical fuel Routine ash analysis

w i l l be performed Uses for the ash are being researched but

present plans are to stabilize them via a stabilex type process

As described in Section VII the a i r emission control system

in tho form of process devices and system operating controls

w i l l result i n over-all highly efficient pollutant removal and

prevention

Table IV l i s t s potential a i r pollutants after the

incineration and chemical reactor processes prior to the wet

cross flow reactor as compared to anticipated emissions after the

oross flow

-=bull fiiSr-srrs

-raquoraquolt raquom|

o- raquo bull fi

a J 3

c3 o o

t

Chromium

Copper

Tin

Cadmium

Cobalt

Nickel

Lead

Zino

13shy

TABLE HI

Incinerator Aahlaquo

674

57

iff 153

19

25

72

1230 ^

411

Results in mgAg dry weight

LT trade Less than

POLLUTANT bull

V i raquo i

IV

PARTICULATE

SULFUR DIOXIDE

HYDROCARBONS

CARBON MONOXIDE

HYDROCHLORIC ACID

NO

SABLE IV

POTENTIAL (BEFORE AB50RB0R)

113 TONSAEAR

NONE

NEGLIGIBLE

NOT EXPECTED

ANTICIPATED (AFTER AboORBOR)

226 TONSYEAR

NONE

NEGLIGIBLE

NOT EXPECTED

NEGLIGIBLE raquo NO MEASURABLE AMOUNT IN REGULATORY UNITS

= 2 5 -J bull

2 r bull e bdquobull

bull1

VI Air Pollution Regulation Review

In addition to the Clean Air Act and ite amendments other

applicable regulatory requirements have been reviewed in the

preparation of this application

Waino Revised Statutes Title 38 Chapter 4 Section 582

dofinos the Union Chomlcal Company Incinerator ae a Class VII

unit burning Typos 5 and 6 waste fuels

As the experimental nature of this system will result in

larger production systems BACT (best available control

technology) will ultimately be required The proposed equipment

and process are considered to satisfy that definition

The Union Chemical Compaay prototype experimental incinerator

system will have an allowable particulate emission of 020 grains

per SDCP of exhaust gas

The Incinerator will be limited to the burning of

hydrocarbons as listed in Seotion IV and its design will assure

that particulate matter will be the only pollutant measurable in

rogulatory terms to be controlled

None of the projected emissions from the hydrocarbons listed

qunllfloB for additional emission controls as defined by National

Emission Standards for Hazardous Air Pollutants Only traces of

SO (oulfur dioxide) CO (carbon monoxide) HC1 (hydrochloric

acid) or hydrocarbons are anticipated to be detected in the

system exhaust gas Pilot tests have shown the content of

orranlo chlorldoo in the gas stream to bo undetectable in parts

per million as analyzed by a gas chromatography However should

experimental data on those conwtituentB suggest the need

additional controls will be implemented

-15shy

The burner syotom will be adjacent to a storage building an

chown in the enclosed plot plan The building will be 20 foet by

50 feet by 20 feet high For this reason the burner system exhauot

stack will be 60 feet in height above the concrete pad This

conforms to USEPA recommended Oood Engineering Practice end

nluo puts the exhaust above Bomo 50 foot high hemlock trees

located about 100 feet from the burner

YII Emlooion Control Review

The proposed prototype experimental incinerator system aJt o Union Chemical is a Class VII unit burning types 5 and 6 waute

fuol The organio compounds will be destroyed in the combuution

process which will result in a zone temperature of 2200degF for

a duration of approximately two seconds This will aooure complete

combuntion of a l l hydrocarbons and chlorinated organics (9999

The hot gases will pass through a drop out box and heat

exchanger

The resultant gases will bo at 1400degF These gaseB will

be treated by injection of powdered lime whioh will reaot with any

of the following gasesi T

HC1

so2

HP

ItBr

Tha resultant calcium compoundo along with any inorganic aoh

from the burnor and any bod sand carried oyer with the combuution

gnnoo will enter a high efficiency Flohor-Klontorman XQ Cyclone

for romoval of the majority of tho total suspended particulate

(For detailB eeo manufactured literature) Aeh and calcium

mdash pound 3- degB =raquo 2-pound 5T=l

mo

erja araquo c o

=bull z |o l

s as - = =16-

Q raquo bull B V bull

chloride collected at this point are expected to be uuoful by- lln products and not solid waste requiring disposal a laquobull ==bull

After the cyclone system the gaeos at about 1500degF w i l l be bull =r =bull 3 3 bull trade ftI

cooled by water spray to about 180degF This water spray w i l l alao

initiate a nucleation process resulting in the agglomeration of

smaller particles into larger easier to remove particlos The

180degF gas w i l l be reacted in a wet cross-flow absorption unit |

with a dilute lime slurry which w i l l remove particulates and any

reoidual HC1 or SO The cross-flow reactor w i l l depend on nucloation

and impaction with the liquid for removal in excess of 95 (Soo

enclosed manufacturers information) j

The reactor system w i l l be inter-locked with the fuel j

supply to the fluid bod burner so that should the liquid i

recycle pump f a i l fuel would immediately shut off Emergency

water w i l l also flow to the reaotor In this caue as well as 1

whon the reactor inlet temperature goeo above 190degF With this

control scheme i t is not possible for unburned hydrocarbons

or particulate in excess of allowable limits to escape from o the system Nor in i t poonible to operate the incinerator o without operating the reactor bdquo

Bleed from the reactor w i l l be returned to the

combustion chamber (fluid bed) where i t w i l l be reprocessed

Resultant dry solids w i l l be removed by the oyolone system

and beooms marketable by-products

3 E pound laquo

bull17shy

g-Sf

2 bullgt raquoraquo

I VIIIi Apponflta

Alaquo Calculations

B Control System Details

o

o

Union Chemical Company - Burner System Calculations agt =r 5 3=3 raquo craquo

it Ash from fuel) (167 Cass 1 170 Case )

Case 1 124 lbsmln x 167 bull 207 lbsmin aoh

Case 2 - 107 lbsmln x 170 bull 182 lbsoin ash

1 Sand carry over

Case i - 03 lbsmln

Case 2 - 03 lbsmln

3lt Ash drop outi (assume 50 drop out)

Case 1 - 237 lbsmln x 5 - 119 lbsmln

Case 2 - 212 lbsmln x $ - 106 lbsmln

4 CaO Addedi (based on 195 lbsmln -HC1 generated)

Case 1 - 0

Case 2 - 200 lbsmln lime (33 exoeso)

5raquo CaCl2 generatedplus unreaoted CaOi

Case 1 - 0

Case 2 ~ 347 lbsmln

6 Neutralization System Solids Removal a o(oyolone effioiency - 85) o

Case 1 - (119) 85 - 101 lbsmin removed bdquo

119 lbsmln - 101 - 018 lbsmln left in

gas stream

Case 2 - (106 bull 347) 85 - 365 lbsmin removed

453 - 3laquo85 bullgt 068 lbsmin left in gas stream

7 Neutralization System HC1 Removal 1 (Reaotion 99)

Cane 1 - 0

Case 2 - 195 lbsminHC1 x 099 bull iraquo93 Ibemln

Ml

US

Potential TJP Emissions (50 Case 1 50 Case 2)

iof raquoi i ^ h i ^ ^ f ^ T f y V f ^ I 1 1 3 T o n a V s a r p o t n t i a l - gt s - F

Emissions

v bull Cas Absorption Systea Solids Removallaquo

(Use 98 efficiency)

I Case 1 shy 098 x 018 lbsmin shy OI76 lbsmin removed

018 shy 0176 shy 0004 lbsmin left A

dr

o 10

Case 2 shy 098 x 068 lbsmin shy 067 lbsmin removed

068 shy O67 shy 001 lbsmin left

Cas Absorption System KC1 Removal1

(Use 99 efficiency)

Case 1 - 0

Case 2 shy 99 x 002 lbsmln shy OOI98 removed

11 Projected

002 shy 00198 shy 00002 lbsmin HC1 left

Particulate Air Emissions a

Case 1 laquobull 0004 lbsmln x lfrfrp winday x -6S riavq

2000 l b s t o n

bull 1051 tonsyear

Case 2 shy P01 lbB mln x 14U0 tainday x2000 l b s t o n

bull bull 2628 tonsyear bull Projected Average raquo 5(1051) bull 5(2628) raquo

davs

le^O tonsyoar

Rounding off errors result in 042 tons per year

differences in calculations Use 226 TPY as

projected emissions

12 Projooted HC1 Emlooionsi

Case 2 - P 0pound02_JLbflmln x 44o m^ndav^LJLS^-^Uai 2000 lbston

bull 0026 tonsyear

13 Emission Conoontrationi

o raquobull laquogt e -raquoraquo s

-20 shy

C 0 bull deg

Corroted

-

Corrlaquoot8dlaquo

PtOQltraquo lbg nJn x 7000 e r a A b a 7000 ACKK

raquo 0004 greACFM

0004 grs x l g 0 ^ g g g b shy 0 0 0 i t 8

001 mjpm raquo 7ooo n ^ 0 t 0 1 i 9 6400 ACfM

18j_ 70 bull

001 lbsmin x 180 bull 460deg shy bdquobdquo bdquo rt shy 46o 0013 graSCP

gt i

f

i fc

Material Burned C c ^ j f f r f r f f i - r 7- r1gt bullraquo w ^

i fgtraquoth of Run t- A laquobull raquo r

) Funl Coed ogt bulllt bull -shy

)bull Wator Evaporated bull

Avorage Total Air In lt~fT~gt

Average Over Fire Air bull bullbull bull bull i Avnroge Bod Air _ Avarnge Bod Temperature 7 K t

Avornge Vapor Space Temp

j _Ayornlaquoe Duot Temperature __________

Avnrnre Stack Temp _______________

Avornge Stack C02 Kshy

DTU RelenoodKour In Bed

DTO neionsedKour In VaporSpace _______ nTotnl BTU ReleaoedKour V 1 fr

BWfJallon of Feed _______________________

DTDLb of Feed KfO

Ash Content of Feed K

^rVi ^Lr- strA - mdash r

raquobull bull

bull 0

Tent Date t gt shy X JZ__ -22 shy I bull - Material Burned mdash1 r r shy ^ rc

bull ^ngth of Run t

_ 2_|

Fuel Oned X V raquor ^ V

j Wator Evaporated 2 o = 3 |

= Avorage Total Air In f) C t bullmdash shy a bull jf - Average Ovor Fire Air

I- Average Bod Air ____________________

bull Average Bed Temporature gt 4

v Average Vapor Space Temp lt

^Average Duot Temperaturec i

Average Stack Tempi

bull Average Stack CO-

BTU RoleaoedKour In Bed DTU ReleaeedHour In Vapor Space _____

laquo Total BTU ReleasedHour 1 -f C r

BTUOallon of Feed

BTUtb of Feed ^ bull 9

Ash Content of Feed

o 7 o7 deg ir br~ o

7shy r

ampfea$ampir

VI Air Pollution Regulation Review

In addition to the Clean Air Act and ite amendments other

applicable regulatory requirements have been reviewed in the

preparation of this application

Waino Revised Statutes Title 38 Chapter 4 Section 582

dofinos the Union Chomlcal Company Incinerator ae a Class VII

unit burning Typos 5 and 6 waste fuels

As the experimental nature of this system will result in

larger production systems BACT (best available control

technology) will ultimately be required The proposed equipment

and process are considered to satisfy that definition

The Union Chemical Compaay prototype experimental incinerator

system will have an allowable particulate emission of 020 grains

per SDCP of exhaust gas

The Incinerator will be limited to the burning of

hydrocarbons as listed in Seotion IV and its design will assure

that particulate matter will be the only pollutant measurable in

rogulatory terms to be controlled

None of the projected emissions from the hydrocarbons listed

qunllfloB for additional emission controls as defined by National

Emission Standards for Hazardous Air Pollutants Only traces of

SO (oulfur dioxide) CO (carbon monoxide) HC1 (hydrochloric

acid) or hydrocarbons are anticipated to be detected in the

system exhaust gas Pilot tests have shown the content of

orranlo chlorldoo in the gas stream to bo undetectable in parts

per million as analyzed by a gas chromatography However should

experimental data on those conwtituentB suggest the need

additional controls will be implemented

-15shy

The burner syotom will be adjacent to a storage building an

chown in the enclosed plot plan The building will be 20 foet by

50 feet by 20 feet high For this reason the burner system exhauot

stack will be 60 feet in height above the concrete pad This

conforms to USEPA recommended Oood Engineering Practice end

nluo puts the exhaust above Bomo 50 foot high hemlock trees

located about 100 feet from the burner

YII Emlooion Control Review

The proposed prototype experimental incinerator system aJt o Union Chemical is a Class VII unit burning types 5 and 6 waute

fuol The organio compounds will be destroyed in the combuution

process which will result in a zone temperature of 2200degF for

a duration of approximately two seconds This will aooure complete

combuntion of a l l hydrocarbons and chlorinated organics (9999

The hot gases will pass through a drop out box and heat

exchanger

The resultant gases will bo at 1400degF These gaseB will

be treated by injection of powdered lime whioh will reaot with any

of the following gasesi T

HC1

so2

HP

ItBr

Tha resultant calcium compoundo along with any inorganic aoh

from the burnor and any bod sand carried oyer with the combuution

gnnoo will enter a high efficiency Flohor-Klontorman XQ Cyclone

for romoval of the majority of tho total suspended particulate

(For detailB eeo manufactured literature) Aeh and calcium

mdash pound 3- degB =raquo 2-pound 5T=l

mo

erja araquo c o

=bull z |o l

s as - = =16-

Q raquo bull B V bull

chloride collected at this point are expected to be uuoful by- lln products and not solid waste requiring disposal a laquobull ==bull

After the cyclone system the gaeos at about 1500degF w i l l be bull =r =bull 3 3 bull trade ftI

cooled by water spray to about 180degF This water spray w i l l alao

initiate a nucleation process resulting in the agglomeration of

smaller particles into larger easier to remove particlos The

180degF gas w i l l be reacted in a wet cross-flow absorption unit |

with a dilute lime slurry which w i l l remove particulates and any

reoidual HC1 or SO The cross-flow reactor w i l l depend on nucloation

and impaction with the liquid for removal in excess of 95 (Soo

enclosed manufacturers information) j

The reactor system w i l l be inter-locked with the fuel j

supply to the fluid bod burner so that should the liquid i

recycle pump f a i l fuel would immediately shut off Emergency

water w i l l also flow to the reaotor In this caue as well as 1

whon the reactor inlet temperature goeo above 190degF With this

control scheme i t is not possible for unburned hydrocarbons

or particulate in excess of allowable limits to escape from o the system Nor in i t poonible to operate the incinerator o without operating the reactor bdquo

Bleed from the reactor w i l l be returned to the

combustion chamber (fluid bed) where i t w i l l be reprocessed

Resultant dry solids w i l l be removed by the oyolone system

and beooms marketable by-products

3 E pound laquo

bull17shy

g-Sf

2 bullgt raquoraquo

I VIIIi Apponflta

Alaquo Calculations

B Control System Details

o

o

Union Chemical Company - Burner System Calculations agt =r 5 3=3 raquo craquo

it Ash from fuel) (167 Cass 1 170 Case )

Case 1 124 lbsmln x 167 bull 207 lbsmin aoh

Case 2 - 107 lbsmln x 170 bull 182 lbsoin ash

1 Sand carry over

Case i - 03 lbsmln

Case 2 - 03 lbsmln

3lt Ash drop outi (assume 50 drop out)

Case 1 - 237 lbsmln x 5 - 119 lbsmln

Case 2 - 212 lbsmln x $ - 106 lbsmln

4 CaO Addedi (based on 195 lbsmln -HC1 generated)

Case 1 - 0

Case 2 - 200 lbsmln lime (33 exoeso)

5raquo CaCl2 generatedplus unreaoted CaOi

Case 1 - 0

Case 2 ~ 347 lbsmln

6 Neutralization System Solids Removal a o(oyolone effioiency - 85) o

Case 1 - (119) 85 - 101 lbsmin removed bdquo

119 lbsmln - 101 - 018 lbsmln left in

gas stream

Case 2 - (106 bull 347) 85 - 365 lbsmin removed

453 - 3laquo85 bullgt 068 lbsmin left in gas stream

7 Neutralization System HC1 Removal 1 (Reaotion 99)

Cane 1 - 0

Case 2 - 195 lbsminHC1 x 099 bull iraquo93 Ibemln

Ml

US

Potential TJP Emissions (50 Case 1 50 Case 2)

iof raquoi i ^ h i ^ ^ f ^ T f y V f ^ I 1 1 3 T o n a V s a r p o t n t i a l - gt s - F

Emissions

v bull Cas Absorption Systea Solids Removallaquo

(Use 98 efficiency)

I Case 1 shy 098 x 018 lbsmin shy OI76 lbsmin removed

018 shy 0176 shy 0004 lbsmin left A

dr

o 10

Case 2 shy 098 x 068 lbsmin shy 067 lbsmin removed

068 shy O67 shy 001 lbsmin left

Cas Absorption System KC1 Removal1

(Use 99 efficiency)

Case 1 - 0

Case 2 shy 99 x 002 lbsmln shy OOI98 removed

11 Projected

002 shy 00198 shy 00002 lbsmin HC1 left

Particulate Air Emissions a

Case 1 laquobull 0004 lbsmln x lfrfrp winday x -6S riavq

2000 l b s t o n

bull 1051 tonsyear

Case 2 shy P01 lbB mln x 14U0 tainday x2000 l b s t o n

bull bull 2628 tonsyear bull Projected Average raquo 5(1051) bull 5(2628) raquo

davs

le^O tonsyoar

Rounding off errors result in 042 tons per year

differences in calculations Use 226 TPY as

projected emissions

12 Projooted HC1 Emlooionsi

Case 2 - P 0pound02_JLbflmln x 44o m^ndav^LJLS^-^Uai 2000 lbston

bull 0026 tonsyear

13 Emission Conoontrationi

o raquobull laquogt e -raquoraquo s

-20 shy

C 0 bull deg

Corroted

-

Corrlaquoot8dlaquo

PtOQltraquo lbg nJn x 7000 e r a A b a 7000 ACKK

raquo 0004 greACFM

0004 grs x l g 0 ^ g g g b shy 0 0 0 i t 8

001 mjpm raquo 7ooo n ^ 0 t 0 1 i 9 6400 ACfM

18j_ 70 bull

001 lbsmin x 180 bull 460deg shy bdquobdquo bdquo rt shy 46o 0013 graSCP

gt i

f

i fc

Material Burned C c ^ j f f r f r f f i - r 7- r1gt bullraquo w ^

i fgtraquoth of Run t- A laquobull raquo r

) Funl Coed ogt bulllt bull -shy

)bull Wator Evaporated bull

Avorage Total Air In lt~fT~gt

Average Over Fire Air bull bullbull bull bull i Avnroge Bod Air _ Avarnge Bod Temperature 7 K t

Avornge Vapor Space Temp

j _Ayornlaquoe Duot Temperature __________

Avnrnre Stack Temp _______________

Avornge Stack C02 Kshy

DTU RelenoodKour In Bed

DTO neionsedKour In VaporSpace _______ nTotnl BTU ReleaoedKour V 1 fr

BWfJallon of Feed _______________________

DTDLb of Feed KfO

Ash Content of Feed K

^rVi ^Lr- strA - mdash r

raquobull bull

bull 0

Tent Date t gt shy X JZ__ -22 shy I bull - Material Burned mdash1 r r shy ^ rc

bull ^ngth of Run t

_ 2_|

Fuel Oned X V raquor ^ V

j Wator Evaporated 2 o = 3 |

= Avorage Total Air In f) C t bullmdash shy a bull jf - Average Ovor Fire Air

I- Average Bod Air ____________________

bull Average Bed Temporature gt 4

v Average Vapor Space Temp lt

^Average Duot Temperaturec i

Average Stack Tempi

bull Average Stack CO-

BTU RoleaoedKour In Bed DTU ReleaeedHour In Vapor Space _____

laquo Total BTU ReleasedHour 1 -f C r

BTUOallon of Feed

BTUtb of Feed ^ bull 9

Ash Content of Feed

o 7 o7 deg ir br~ o

7shy r

ampfea$ampir

-15shy

The burner syotom will be adjacent to a storage building an

chown in the enclosed plot plan The building will be 20 foet by

50 feet by 20 feet high For this reason the burner system exhauot

stack will be 60 feet in height above the concrete pad This

conforms to USEPA recommended Oood Engineering Practice end

nluo puts the exhaust above Bomo 50 foot high hemlock trees

located about 100 feet from the burner

YII Emlooion Control Review

The proposed prototype experimental incinerator system aJt o Union Chemical is a Class VII unit burning types 5 and 6 waute

fuol The organio compounds will be destroyed in the combuution

process which will result in a zone temperature of 2200degF for

a duration of approximately two seconds This will aooure complete

combuntion of a l l hydrocarbons and chlorinated organics (9999

The hot gases will pass through a drop out box and heat

exchanger

The resultant gases will bo at 1400degF These gaseB will

be treated by injection of powdered lime whioh will reaot with any

of the following gasesi T

HC1

so2

HP

ItBr

Tha resultant calcium compoundo along with any inorganic aoh

from the burnor and any bod sand carried oyer with the combuution

gnnoo will enter a high efficiency Flohor-Klontorman XQ Cyclone

for romoval of the majority of tho total suspended particulate

(For detailB eeo manufactured literature) Aeh and calcium

mdash pound 3- degB =raquo 2-pound 5T=l

mo

erja araquo c o

=bull z |o l

s as - = =16-

Q raquo bull B V bull

chloride collected at this point are expected to be uuoful by- lln products and not solid waste requiring disposal a laquobull ==bull

After the cyclone system the gaeos at about 1500degF w i l l be bull =r =bull 3 3 bull trade ftI

cooled by water spray to about 180degF This water spray w i l l alao

initiate a nucleation process resulting in the agglomeration of

smaller particles into larger easier to remove particlos The

180degF gas w i l l be reacted in a wet cross-flow absorption unit |

with a dilute lime slurry which w i l l remove particulates and any

reoidual HC1 or SO The cross-flow reactor w i l l depend on nucloation

and impaction with the liquid for removal in excess of 95 (Soo

enclosed manufacturers information) j

The reactor system w i l l be inter-locked with the fuel j

supply to the fluid bod burner so that should the liquid i

recycle pump f a i l fuel would immediately shut off Emergency

water w i l l also flow to the reaotor In this caue as well as 1

whon the reactor inlet temperature goeo above 190degF With this

control scheme i t is not possible for unburned hydrocarbons

or particulate in excess of allowable limits to escape from o the system Nor in i t poonible to operate the incinerator o without operating the reactor bdquo

Bleed from the reactor w i l l be returned to the

combustion chamber (fluid bed) where i t w i l l be reprocessed

Resultant dry solids w i l l be removed by the oyolone system

and beooms marketable by-products

3 E pound laquo

bull17shy

g-Sf

2 bullgt raquoraquo

I VIIIi Apponflta

Alaquo Calculations

B Control System Details

o

o

Union Chemical Company - Burner System Calculations agt =r 5 3=3 raquo craquo

it Ash from fuel) (167 Cass 1 170 Case )

Case 1 124 lbsmln x 167 bull 207 lbsmin aoh

Case 2 - 107 lbsmln x 170 bull 182 lbsoin ash

1 Sand carry over

Case i - 03 lbsmln

Case 2 - 03 lbsmln

3lt Ash drop outi (assume 50 drop out)

Case 1 - 237 lbsmln x 5 - 119 lbsmln

Case 2 - 212 lbsmln x $ - 106 lbsmln

4 CaO Addedi (based on 195 lbsmln -HC1 generated)

Case 1 - 0

Case 2 - 200 lbsmln lime (33 exoeso)

5raquo CaCl2 generatedplus unreaoted CaOi

Case 1 - 0

Case 2 ~ 347 lbsmln

6 Neutralization System Solids Removal a o(oyolone effioiency - 85) o

Case 1 - (119) 85 - 101 lbsmin removed bdquo

119 lbsmln - 101 - 018 lbsmln left in

gas stream

Case 2 - (106 bull 347) 85 - 365 lbsmin removed

453 - 3laquo85 bullgt 068 lbsmin left in gas stream

7 Neutralization System HC1 Removal 1 (Reaotion 99)

Cane 1 - 0

Case 2 - 195 lbsminHC1 x 099 bull iraquo93 Ibemln

Ml

US

Potential TJP Emissions (50 Case 1 50 Case 2)

iof raquoi i ^ h i ^ ^ f ^ T f y V f ^ I 1 1 3 T o n a V s a r p o t n t i a l - gt s - F

Emissions

v bull Cas Absorption Systea Solids Removallaquo

(Use 98 efficiency)

I Case 1 shy 098 x 018 lbsmin shy OI76 lbsmin removed

018 shy 0176 shy 0004 lbsmin left A

dr

o 10

Case 2 shy 098 x 068 lbsmin shy 067 lbsmin removed

068 shy O67 shy 001 lbsmin left

Cas Absorption System KC1 Removal1

(Use 99 efficiency)

Case 1 - 0

Case 2 shy 99 x 002 lbsmln shy OOI98 removed

11 Projected

002 shy 00198 shy 00002 lbsmin HC1 left

Particulate Air Emissions a

Case 1 laquobull 0004 lbsmln x lfrfrp winday x -6S riavq

2000 l b s t o n

bull 1051 tonsyear

Case 2 shy P01 lbB mln x 14U0 tainday x2000 l b s t o n

bull bull 2628 tonsyear bull Projected Average raquo 5(1051) bull 5(2628) raquo

davs

le^O tonsyoar

Rounding off errors result in 042 tons per year

differences in calculations Use 226 TPY as

projected emissions

12 Projooted HC1 Emlooionsi

Case 2 - P 0pound02_JLbflmln x 44o m^ndav^LJLS^-^Uai 2000 lbston

bull 0026 tonsyear

13 Emission Conoontrationi

o raquobull laquogt e -raquoraquo s

-20 shy

C 0 bull deg

Corroted

-

Corrlaquoot8dlaquo

PtOQltraquo lbg nJn x 7000 e r a A b a 7000 ACKK

raquo 0004 greACFM

0004 grs x l g 0 ^ g g g b shy 0 0 0 i t 8

001 mjpm raquo 7ooo n ^ 0 t 0 1 i 9 6400 ACfM

18j_ 70 bull

001 lbsmin x 180 bull 460deg shy bdquobdquo bdquo rt shy 46o 0013 graSCP

gt i

f

i fc

Material Burned C c ^ j f f r f r f f i - r 7- r1gt bullraquo w ^

i fgtraquoth of Run t- A laquobull raquo r

) Funl Coed ogt bulllt bull -shy

)bull Wator Evaporated bull

Avorage Total Air In lt~fT~gt

Average Over Fire Air bull bullbull bull bull i Avnroge Bod Air _ Avarnge Bod Temperature 7 K t

Avornge Vapor Space Temp

j _Ayornlaquoe Duot Temperature __________

Avnrnre Stack Temp _______________

Avornge Stack C02 Kshy

DTU RelenoodKour In Bed

DTO neionsedKour In VaporSpace _______ nTotnl BTU ReleaoedKour V 1 fr

BWfJallon of Feed _______________________

DTDLb of Feed KfO

Ash Content of Feed K

^rVi ^Lr- strA - mdash r

raquobull bull

bull 0

Tent Date t gt shy X JZ__ -22 shy I bull - Material Burned mdash1 r r shy ^ rc

bull ^ngth of Run t

_ 2_|

Fuel Oned X V raquor ^ V

j Wator Evaporated 2 o = 3 |

= Avorage Total Air In f) C t bullmdash shy a bull jf - Average Ovor Fire Air

I- Average Bod Air ____________________

bull Average Bed Temporature gt 4

v Average Vapor Space Temp lt

^Average Duot Temperaturec i

Average Stack Tempi

bull Average Stack CO-

BTU RoleaoedKour In Bed DTU ReleaeedHour In Vapor Space _____

laquo Total BTU ReleasedHour 1 -f C r

BTUOallon of Feed

BTUtb of Feed ^ bull 9

Ash Content of Feed

o 7 o7 deg ir br~ o

7shy r

ampfea$ampir

erja araquo c o

=bull z |o l

s as - = =16-

Q raquo bull B V bull

chloride collected at this point are expected to be uuoful by- lln products and not solid waste requiring disposal a laquobull ==bull

After the cyclone system the gaeos at about 1500degF w i l l be bull =r =bull 3 3 bull trade ftI

cooled by water spray to about 180degF This water spray w i l l alao

initiate a nucleation process resulting in the agglomeration of

smaller particles into larger easier to remove particlos The

180degF gas w i l l be reacted in a wet cross-flow absorption unit |

with a dilute lime slurry which w i l l remove particulates and any

reoidual HC1 or SO The cross-flow reactor w i l l depend on nucloation

and impaction with the liquid for removal in excess of 95 (Soo

enclosed manufacturers information) j

The reactor system w i l l be inter-locked with the fuel j

supply to the fluid bod burner so that should the liquid i

recycle pump f a i l fuel would immediately shut off Emergency

water w i l l also flow to the reaotor In this caue as well as 1

whon the reactor inlet temperature goeo above 190degF With this

control scheme i t is not possible for unburned hydrocarbons

or particulate in excess of allowable limits to escape from o the system Nor in i t poonible to operate the incinerator o without operating the reactor bdquo

Bleed from the reactor w i l l be returned to the

combustion chamber (fluid bed) where i t w i l l be reprocessed

Resultant dry solids w i l l be removed by the oyolone system

and beooms marketable by-products

3 E pound laquo

bull17shy

g-Sf

2 bullgt raquoraquo

I VIIIi Apponflta

Alaquo Calculations

B Control System Details

o

o

Union Chemical Company - Burner System Calculations agt =r 5 3=3 raquo craquo

it Ash from fuel) (167 Cass 1 170 Case )

Case 1 124 lbsmln x 167 bull 207 lbsmin aoh

Case 2 - 107 lbsmln x 170 bull 182 lbsoin ash

1 Sand carry over

Case i - 03 lbsmln

Case 2 - 03 lbsmln

3lt Ash drop outi (assume 50 drop out)

Case 1 - 237 lbsmln x 5 - 119 lbsmln

Case 2 - 212 lbsmln x $ - 106 lbsmln

4 CaO Addedi (based on 195 lbsmln -HC1 generated)

Case 1 - 0

Case 2 - 200 lbsmln lime (33 exoeso)

5raquo CaCl2 generatedplus unreaoted CaOi

Case 1 - 0

Case 2 ~ 347 lbsmln

6 Neutralization System Solids Removal a o(oyolone effioiency - 85) o

Case 1 - (119) 85 - 101 lbsmin removed bdquo

119 lbsmln - 101 - 018 lbsmln left in

gas stream

Case 2 - (106 bull 347) 85 - 365 lbsmin removed

453 - 3laquo85 bullgt 068 lbsmin left in gas stream

7 Neutralization System HC1 Removal 1 (Reaotion 99)

Cane 1 - 0

Case 2 - 195 lbsminHC1 x 099 bull iraquo93 Ibemln

Ml

US

Potential TJP Emissions (50 Case 1 50 Case 2)

iof raquoi i ^ h i ^ ^ f ^ T f y V f ^ I 1 1 3 T o n a V s a r p o t n t i a l - gt s - F

Emissions

v bull Cas Absorption Systea Solids Removallaquo

(Use 98 efficiency)

I Case 1 shy 098 x 018 lbsmin shy OI76 lbsmin removed

018 shy 0176 shy 0004 lbsmin left A

dr

o 10

Case 2 shy 098 x 068 lbsmin shy 067 lbsmin removed

068 shy O67 shy 001 lbsmin left

Cas Absorption System KC1 Removal1

(Use 99 efficiency)

Case 1 - 0

Case 2 shy 99 x 002 lbsmln shy OOI98 removed

11 Projected

002 shy 00198 shy 00002 lbsmin HC1 left

Particulate Air Emissions a

Case 1 laquobull 0004 lbsmln x lfrfrp winday x -6S riavq

2000 l b s t o n

bull 1051 tonsyear

Case 2 shy P01 lbB mln x 14U0 tainday x2000 l b s t o n

bull bull 2628 tonsyear bull Projected Average raquo 5(1051) bull 5(2628) raquo

davs

le^O tonsyoar

Rounding off errors result in 042 tons per year

differences in calculations Use 226 TPY as

projected emissions

12 Projooted HC1 Emlooionsi

Case 2 - P 0pound02_JLbflmln x 44o m^ndav^LJLS^-^Uai 2000 lbston

bull 0026 tonsyear

13 Emission Conoontrationi

o raquobull laquogt e -raquoraquo s

-20 shy

C 0 bull deg

Corroted

-

Corrlaquoot8dlaquo

PtOQltraquo lbg nJn x 7000 e r a A b a 7000 ACKK

raquo 0004 greACFM

0004 grs x l g 0 ^ g g g b shy 0 0 0 i t 8

001 mjpm raquo 7ooo n ^ 0 t 0 1 i 9 6400 ACfM

18j_ 70 bull

001 lbsmin x 180 bull 460deg shy bdquobdquo bdquo rt shy 46o 0013 graSCP

gt i

f

i fc

Material Burned C c ^ j f f r f r f f i - r 7- r1gt bullraquo w ^

i fgtraquoth of Run t- A laquobull raquo r

) Funl Coed ogt bulllt bull -shy

)bull Wator Evaporated bull

Avorage Total Air In lt~fT~gt

Average Over Fire Air bull bullbull bull bull i Avnroge Bod Air _ Avarnge Bod Temperature 7 K t

Avornge Vapor Space Temp

j _Ayornlaquoe Duot Temperature __________

Avnrnre Stack Temp _______________

Avornge Stack C02 Kshy

DTU RelenoodKour In Bed

DTO neionsedKour In VaporSpace _______ nTotnl BTU ReleaoedKour V 1 fr

BWfJallon of Feed _______________________

DTDLb of Feed KfO

Ash Content of Feed K

^rVi ^Lr- strA - mdash r

raquobull bull

bull 0

Tent Date t gt shy X JZ__ -22 shy I bull - Material Burned mdash1 r r shy ^ rc

bull ^ngth of Run t

_ 2_|

Fuel Oned X V raquor ^ V

j Wator Evaporated 2 o = 3 |

= Avorage Total Air In f) C t bullmdash shy a bull jf - Average Ovor Fire Air

I- Average Bod Air ____________________

bull Average Bed Temporature gt 4

v Average Vapor Space Temp lt

^Average Duot Temperaturec i

Average Stack Tempi

bull Average Stack CO-

BTU RoleaoedKour In Bed DTU ReleaeedHour In Vapor Space _____

laquo Total BTU ReleasedHour 1 -f C r

BTUOallon of Feed

BTUtb of Feed ^ bull 9

Ash Content of Feed

o 7 o7 deg ir br~ o

7shy r

ampfea$ampir

3 E pound laquo

bull17shy

g-Sf

2 bullgt raquoraquo

I VIIIi Apponflta

Alaquo Calculations

B Control System Details

o

o

Union Chemical Company - Burner System Calculations agt =r 5 3=3 raquo craquo

it Ash from fuel) (167 Cass 1 170 Case )

Case 1 124 lbsmln x 167 bull 207 lbsmin aoh

Case 2 - 107 lbsmln x 170 bull 182 lbsoin ash

1 Sand carry over

Case i - 03 lbsmln

Case 2 - 03 lbsmln

3lt Ash drop outi (assume 50 drop out)

Case 1 - 237 lbsmln x 5 - 119 lbsmln

Case 2 - 212 lbsmln x $ - 106 lbsmln

4 CaO Addedi (based on 195 lbsmln -HC1 generated)

Case 1 - 0

Case 2 - 200 lbsmln lime (33 exoeso)

5raquo CaCl2 generatedplus unreaoted CaOi

Case 1 - 0

Case 2 ~ 347 lbsmln

6 Neutralization System Solids Removal a o(oyolone effioiency - 85) o

Case 1 - (119) 85 - 101 lbsmin removed bdquo

119 lbsmln - 101 - 018 lbsmln left in

gas stream

Case 2 - (106 bull 347) 85 - 365 lbsmin removed

453 - 3laquo85 bullgt 068 lbsmin left in gas stream

7 Neutralization System HC1 Removal 1 (Reaotion 99)

Cane 1 - 0

Case 2 - 195 lbsminHC1 x 099 bull iraquo93 Ibemln

Ml

US

Potential TJP Emissions (50 Case 1 50 Case 2)

iof raquoi i ^ h i ^ ^ f ^ T f y V f ^ I 1 1 3 T o n a V s a r p o t n t i a l - gt s - F

Emissions

v bull Cas Absorption Systea Solids Removallaquo

(Use 98 efficiency)

I Case 1 shy 098 x 018 lbsmin shy OI76 lbsmin removed

018 shy 0176 shy 0004 lbsmin left A

dr

o 10

Case 2 shy 098 x 068 lbsmin shy 067 lbsmin removed

068 shy O67 shy 001 lbsmin left

Cas Absorption System KC1 Removal1

(Use 99 efficiency)

Case 1 - 0

Case 2 shy 99 x 002 lbsmln shy OOI98 removed

11 Projected

002 shy 00198 shy 00002 lbsmin HC1 left

Particulate Air Emissions a

Case 1 laquobull 0004 lbsmln x lfrfrp winday x -6S riavq

2000 l b s t o n

bull 1051 tonsyear

Case 2 shy P01 lbB mln x 14U0 tainday x2000 l b s t o n

bull bull 2628 tonsyear bull Projected Average raquo 5(1051) bull 5(2628) raquo

davs

le^O tonsyoar

Rounding off errors result in 042 tons per year

differences in calculations Use 226 TPY as

projected emissions

12 Projooted HC1 Emlooionsi

Case 2 - P 0pound02_JLbflmln x 44o m^ndav^LJLS^-^Uai 2000 lbston

bull 0026 tonsyear

13 Emission Conoontrationi

o raquobull laquogt e -raquoraquo s

-20 shy

C 0 bull deg

Corroted

-

Corrlaquoot8dlaquo

PtOQltraquo lbg nJn x 7000 e r a A b a 7000 ACKK

raquo 0004 greACFM

0004 grs x l g 0 ^ g g g b shy 0 0 0 i t 8

001 mjpm raquo 7ooo n ^ 0 t 0 1 i 9 6400 ACfM

18j_ 70 bull

001 lbsmin x 180 bull 460deg shy bdquobdquo bdquo rt shy 46o 0013 graSCP

gt i

f

i fc

Material Burned C c ^ j f f r f r f f i - r 7- r1gt bullraquo w ^

i fgtraquoth of Run t- A laquobull raquo r

) Funl Coed ogt bulllt bull -shy

)bull Wator Evaporated bull

Avorage Total Air In lt~fT~gt

Average Over Fire Air bull bullbull bull bull i Avnroge Bod Air _ Avarnge Bod Temperature 7 K t

Avornge Vapor Space Temp

j _Ayornlaquoe Duot Temperature __________

Avnrnre Stack Temp _______________

Avornge Stack C02 Kshy

DTU RelenoodKour In Bed

DTO neionsedKour In VaporSpace _______ nTotnl BTU ReleaoedKour V 1 fr

BWfJallon of Feed _______________________

DTDLb of Feed KfO

Ash Content of Feed K

^rVi ^Lr- strA - mdash r

raquobull bull

bull 0

Tent Date t gt shy X JZ__ -22 shy I bull - Material Burned mdash1 r r shy ^ rc

bull ^ngth of Run t

_ 2_|

Fuel Oned X V raquor ^ V

j Wator Evaporated 2 o = 3 |

= Avorage Total Air In f) C t bullmdash shy a bull jf - Average Ovor Fire Air

I- Average Bod Air ____________________

bull Average Bed Temporature gt 4

v Average Vapor Space Temp lt

^Average Duot Temperaturec i

Average Stack Tempi

bull Average Stack CO-

BTU RoleaoedKour In Bed DTU ReleaeedHour In Vapor Space _____

laquo Total BTU ReleasedHour 1 -f C r

BTUOallon of Feed

BTUtb of Feed ^ bull 9

Ash Content of Feed

o 7 o7 deg ir br~ o

7shy r

ampfea$ampir

Union Chemical Company - Burner System Calculations agt =r 5 3=3 raquo craquo

it Ash from fuel) (167 Cass 1 170 Case )

Case 1 124 lbsmln x 167 bull 207 lbsmin aoh

Case 2 - 107 lbsmln x 170 bull 182 lbsoin ash

1 Sand carry over

Case i - 03 lbsmln

Case 2 - 03 lbsmln

3lt Ash drop outi (assume 50 drop out)

Case 1 - 237 lbsmln x 5 - 119 lbsmln

Case 2 - 212 lbsmln x $ - 106 lbsmln

4 CaO Addedi (based on 195 lbsmln -HC1 generated)

Case 1 - 0

Case 2 - 200 lbsmln lime (33 exoeso)

5raquo CaCl2 generatedplus unreaoted CaOi

Case 1 - 0

Case 2 ~ 347 lbsmln

6 Neutralization System Solids Removal a o(oyolone effioiency - 85) o

Case 1 - (119) 85 - 101 lbsmin removed bdquo

119 lbsmln - 101 - 018 lbsmln left in

gas stream

Case 2 - (106 bull 347) 85 - 365 lbsmin removed

453 - 3laquo85 bullgt 068 lbsmin left in gas stream

7 Neutralization System HC1 Removal 1 (Reaotion 99)

Cane 1 - 0

Case 2 - 195 lbsminHC1 x 099 bull iraquo93 Ibemln

Ml

US

Potential TJP Emissions (50 Case 1 50 Case 2)

iof raquoi i ^ h i ^ ^ f ^ T f y V f ^ I 1 1 3 T o n a V s a r p o t n t i a l - gt s - F

Emissions

v bull Cas Absorption Systea Solids Removallaquo

(Use 98 efficiency)

I Case 1 shy 098 x 018 lbsmin shy OI76 lbsmin removed

018 shy 0176 shy 0004 lbsmin left A

dr

o 10

Case 2 shy 098 x 068 lbsmin shy 067 lbsmin removed

068 shy O67 shy 001 lbsmin left

Cas Absorption System KC1 Removal1

(Use 99 efficiency)

Case 1 - 0

Case 2 shy 99 x 002 lbsmln shy OOI98 removed

11 Projected

002 shy 00198 shy 00002 lbsmin HC1 left

Particulate Air Emissions a

Case 1 laquobull 0004 lbsmln x lfrfrp winday x -6S riavq

2000 l b s t o n

bull 1051 tonsyear

Case 2 shy P01 lbB mln x 14U0 tainday x2000 l b s t o n

bull bull 2628 tonsyear bull Projected Average raquo 5(1051) bull 5(2628) raquo

davs

le^O tonsyoar

Rounding off errors result in 042 tons per year

differences in calculations Use 226 TPY as

projected emissions

12 Projooted HC1 Emlooionsi

Case 2 - P 0pound02_JLbflmln x 44o m^ndav^LJLS^-^Uai 2000 lbston

bull 0026 tonsyear

13 Emission Conoontrationi

o raquobull laquogt e -raquoraquo s

-20 shy

C 0 bull deg

Corroted

-

Corrlaquoot8dlaquo

PtOQltraquo lbg nJn x 7000 e r a A b a 7000 ACKK

raquo 0004 greACFM

0004 grs x l g 0 ^ g g g b shy 0 0 0 i t 8

001 mjpm raquo 7ooo n ^ 0 t 0 1 i 9 6400 ACfM

18j_ 70 bull

001 lbsmin x 180 bull 460deg shy bdquobdquo bdquo rt shy 46o 0013 graSCP

gt i

f

i fc

Material Burned C c ^ j f f r f r f f i - r 7- r1gt bullraquo w ^

i fgtraquoth of Run t- A laquobull raquo r

) Funl Coed ogt bulllt bull -shy

)bull Wator Evaporated bull

Avorage Total Air In lt~fT~gt

Average Over Fire Air bull bullbull bull bull i Avnroge Bod Air _ Avarnge Bod Temperature 7 K t

Avornge Vapor Space Temp

j _Ayornlaquoe Duot Temperature __________

Avnrnre Stack Temp _______________

Avornge Stack C02 Kshy

DTU RelenoodKour In Bed

DTO neionsedKour In VaporSpace _______ nTotnl BTU ReleaoedKour V 1 fr

BWfJallon of Feed _______________________

DTDLb of Feed KfO

Ash Content of Feed K

^rVi ^Lr- strA - mdash r

raquobull bull

bull 0

Tent Date t gt shy X JZ__ -22 shy I bull - Material Burned mdash1 r r shy ^ rc

bull ^ngth of Run t

_ 2_|

Fuel Oned X V raquor ^ V

j Wator Evaporated 2 o = 3 |

= Avorage Total Air In f) C t bullmdash shy a bull jf - Average Ovor Fire Air

I- Average Bod Air ____________________

bull Average Bed Temporature gt 4

v Average Vapor Space Temp lt

^Average Duot Temperaturec i

Average Stack Tempi

bull Average Stack CO-

BTU RoleaoedKour In Bed DTU ReleaeedHour In Vapor Space _____

laquo Total BTU ReleasedHour 1 -f C r

BTUOallon of Feed

BTUtb of Feed ^ bull 9

Ash Content of Feed

o 7 o7 deg ir br~ o

7shy r

ampfea$ampir

Potential TJP Emissions (50 Case 1 50 Case 2)

iof raquoi i ^ h i ^ ^ f ^ T f y V f ^ I 1 1 3 T o n a V s a r p o t n t i a l - gt s - F

Emissions

v bull Cas Absorption Systea Solids Removallaquo

(Use 98 efficiency)

I Case 1 shy 098 x 018 lbsmin shy OI76 lbsmin removed

018 shy 0176 shy 0004 lbsmin left A

dr

o 10

Case 2 shy 098 x 068 lbsmin shy 067 lbsmin removed

068 shy O67 shy 001 lbsmin left

Cas Absorption System KC1 Removal1

(Use 99 efficiency)

Case 1 - 0

Case 2 shy 99 x 002 lbsmln shy OOI98 removed

11 Projected

002 shy 00198 shy 00002 lbsmin HC1 left

Particulate Air Emissions a

Case 1 laquobull 0004 lbsmln x lfrfrp winday x -6S riavq

2000 l b s t o n

bull 1051 tonsyear

Case 2 shy P01 lbB mln x 14U0 tainday x2000 l b s t o n

bull bull 2628 tonsyear bull Projected Average raquo 5(1051) bull 5(2628) raquo

davs

le^O tonsyoar

Rounding off errors result in 042 tons per year

differences in calculations Use 226 TPY as

projected emissions

12 Projooted HC1 Emlooionsi

Case 2 - P 0pound02_JLbflmln x 44o m^ndav^LJLS^-^Uai 2000 lbston

bull 0026 tonsyear

13 Emission Conoontrationi

o raquobull laquogt e -raquoraquo s

-20 shy

C 0 bull deg

Corroted

-

Corrlaquoot8dlaquo

PtOQltraquo lbg nJn x 7000 e r a A b a 7000 ACKK

raquo 0004 greACFM

0004 grs x l g 0 ^ g g g b shy 0 0 0 i t 8

001 mjpm raquo 7ooo n ^ 0 t 0 1 i 9 6400 ACfM

18j_ 70 bull

001 lbsmin x 180 bull 460deg shy bdquobdquo bdquo rt shy 46o 0013 graSCP

gt i

f

i fc

Material Burned C c ^ j f f r f r f f i - r 7- r1gt bullraquo w ^

i fgtraquoth of Run t- A laquobull raquo r

) Funl Coed ogt bulllt bull -shy

)bull Wator Evaporated bull

Avorage Total Air In lt~fT~gt

Average Over Fire Air bull bullbull bull bull i Avnroge Bod Air _ Avarnge Bod Temperature 7 K t

Avornge Vapor Space Temp

j _Ayornlaquoe Duot Temperature __________

Avnrnre Stack Temp _______________

Avornge Stack C02 Kshy

DTU RelenoodKour In Bed

DTO neionsedKour In VaporSpace _______ nTotnl BTU ReleaoedKour V 1 fr

BWfJallon of Feed _______________________

DTDLb of Feed KfO

Ash Content of Feed K

^rVi ^Lr- strA - mdash r

raquobull bull

bull 0

Tent Date t gt shy X JZ__ -22 shy I bull - Material Burned mdash1 r r shy ^ rc

bull ^ngth of Run t

_ 2_|

Fuel Oned X V raquor ^ V

j Wator Evaporated 2 o = 3 |

= Avorage Total Air In f) C t bullmdash shy a bull jf - Average Ovor Fire Air

I- Average Bod Air ____________________

bull Average Bed Temporature gt 4

v Average Vapor Space Temp lt

^Average Duot Temperaturec i

Average Stack Tempi

bull Average Stack CO-

BTU RoleaoedKour In Bed DTU ReleaeedHour In Vapor Space _____

laquo Total BTU ReleasedHour 1 -f C r

BTUOallon of Feed

BTUtb of Feed ^ bull 9

Ash Content of Feed

o 7 o7 deg ir br~ o

7shy r

ampfea$ampir

-20 shy

C 0 bull deg

Corroted

-

Corrlaquoot8dlaquo

PtOQltraquo lbg nJn x 7000 e r a A b a 7000 ACKK

raquo 0004 greACFM

0004 grs x l g 0 ^ g g g b shy 0 0 0 i t 8

001 mjpm raquo 7ooo n ^ 0 t 0 1 i 9 6400 ACfM

18j_ 70 bull

001 lbsmin x 180 bull 460deg shy bdquobdquo bdquo rt shy 46o 0013 graSCP

gt i

f

i fc

Material Burned C c ^ j f f r f r f f i - r 7- r1gt bullraquo w ^

i fgtraquoth of Run t- A laquobull raquo r

) Funl Coed ogt bulllt bull -shy

)bull Wator Evaporated bull

Avorage Total Air In lt~fT~gt

Average Over Fire Air bull bullbull bull bull i Avnroge Bod Air _ Avarnge Bod Temperature 7 K t

Avornge Vapor Space Temp

j _Ayornlaquoe Duot Temperature __________

Avnrnre Stack Temp _______________

Avornge Stack C02 Kshy

DTU RelenoodKour In Bed

DTO neionsedKour In VaporSpace _______ nTotnl BTU ReleaoedKour V 1 fr

BWfJallon of Feed _______________________

DTDLb of Feed KfO

Ash Content of Feed K

^rVi ^Lr- strA - mdash r

raquobull bull

bull 0

Tent Date t gt shy X JZ__ -22 shy I bull - Material Burned mdash1 r r shy ^ rc

bull ^ngth of Run t

_ 2_|

Fuel Oned X V raquor ^ V

j Wator Evaporated 2 o = 3 |

= Avorage Total Air In f) C t bullmdash shy a bull jf - Average Ovor Fire Air

I- Average Bod Air ____________________

bull Average Bed Temporature gt 4

v Average Vapor Space Temp lt

^Average Duot Temperaturec i

Average Stack Tempi

bull Average Stack CO-

BTU RoleaoedKour In Bed DTU ReleaeedHour In Vapor Space _____

laquo Total BTU ReleasedHour 1 -f C r

BTUOallon of Feed

BTUtb of Feed ^ bull 9

Ash Content of Feed

o 7 o7 deg ir br~ o

7shy r

ampfea$ampir

Material Burned C c ^ j f f r f r f f i - r 7- r1gt bullraquo w ^

i fgtraquoth of Run t- A laquobull raquo r

) Funl Coed ogt bulllt bull -shy

)bull Wator Evaporated bull

Avorage Total Air In lt~fT~gt

Average Over Fire Air bull bullbull bull bull i Avnroge Bod Air _ Avarnge Bod Temperature 7 K t

Avornge Vapor Space Temp

j _Ayornlaquoe Duot Temperature __________

Avnrnre Stack Temp _______________

Avornge Stack C02 Kshy

DTU RelenoodKour In Bed

DTO neionsedKour In VaporSpace _______ nTotnl BTU ReleaoedKour V 1 fr

BWfJallon of Feed _______________________

DTDLb of Feed KfO

Ash Content of Feed K

^rVi ^Lr- strA - mdash r

raquobull bull

bull 0

Tent Date t gt shy X JZ__ -22 shy I bull - Material Burned mdash1 r r shy ^ rc

bull ^ngth of Run t

_ 2_|

Fuel Oned X V raquor ^ V

j Wator Evaporated 2 o = 3 |

= Avorage Total Air In f) C t bullmdash shy a bull jf - Average Ovor Fire Air

I- Average Bod Air ____________________

bull Average Bed Temporature gt 4

v Average Vapor Space Temp lt

^Average Duot Temperaturec i

Average Stack Tempi

bull Average Stack CO-

BTU RoleaoedKour In Bed DTU ReleaeedHour In Vapor Space _____

laquo Total BTU ReleasedHour 1 -f C r

BTUOallon of Feed

BTUtb of Feed ^ bull 9

Ash Content of Feed

o 7 o7 deg ir br~ o

7shy r

ampfea$ampir

bull 0

Tent Date t gt shy X JZ__ -22 shy I bull - Material Burned mdash1 r r shy ^ rc

bull ^ngth of Run t

_ 2_|

Fuel Oned X V raquor ^ V

j Wator Evaporated 2 o = 3 |

= Avorage Total Air In f) C t bullmdash shy a bull jf - Average Ovor Fire Air

I- Average Bod Air ____________________

bull Average Bed Temporature gt 4

v Average Vapor Space Temp lt

^Average Duot Temperaturec i

Average Stack Tempi

bull Average Stack CO-

BTU RoleaoedKour In Bed DTU ReleaeedHour In Vapor Space _____

laquo Total BTU ReleasedHour 1 -f C r

BTUOallon of Feed

BTUtb of Feed ^ bull 9

Ash Content of Feed

o 7 o7 deg ir br~ o

7shy r

ampfea$ampir