.

1 1 3

3 '3

5

James F. Mar t in ENSCO/Pyro tech Frank1 in , TN

ABSTRACT

USE OF A MOBILE WASTE INCINERATION SYSTEM FOR A SITE CLEAN-UP

Operational plans for a program t o clean up an abandoned waste s i t e by us in mobile i n c i n e r a t i o n equipment are discussed. A descr ip t ion o f a

t r a i l e r mounted and can be se t on a s i t e i n a matter o f days The inc inerat ions system i s unique i n t h a t the energy from the inc ine ra t i on process i s recovered and as used t o d r i ve the system prime mover and exhaust gas clean-up equl pment

mobi iJ e waste i n c i n e r a t i o n system i s presented. It i s preassembled,

NATURE OF SITE

The s i t e t h a t i s t o be cleaned-up consists o f two lagoons i d e n t i f i e d as the Se tage Pond and the O i l Pond. The approximate areas o f the ponds are 1 .! and 0 6 acre ( .61 and .24 hectare) respect ively. L iqu id wastes, cons i s t i ng o f o i l s , greases, and b i l g e tank wastes were pumped i n t o the p i t s over a pe r iod o f years. The s i t e l ayou t i s shown i n Figure 1.

An unused p i t and numerous groundwater monitor ing we l l s are also on s i t e . It had been determined t h a t t he p o t e n t i a i ex i s ted f o r the leakage o f contaminants i n t o the l o c a l ground water supply. However, no hazardous ma te r la l s had been i d e n t i f i e d i n previous sampling studies.

The Septa e Pond has an average depth of 2.2 ft (0.67111).

content water, very heavy sludge, and black compacted sand. The 011 Pond has an average depth o f 5.1 f t (1.6m). It i s general ly s t r a t i f i e d i n t o l aye rs from top t o bottom consis t ing o f grease, h igh s o l i d s content water, very heaV sludge, and black compacted sand. The O i l Pond has an average depth o f 5.1 f t (1.6m). It i s l i k e w i s e s t r a t i f i e d i n t o l aye rs consis t ing o f surface o i l , o i l y sludge, o i l y water, bottom sludge, and bottom sand. A l a y e r depth p r o f i l e o f the o i l pond i s shown i n Figure 2.

I t i s generally s t r a t i f i e 8 i n t o l a y e r s from top t o bottom consis t ing o f grease, h iqh s o l i d s

CHOICE OF INCINERATION

Analysls o f mater la l samples from the ponds ind i ca ted t h a t the heat ing value o f a l l the organic waste could be estlmated a t 2 x 10.10 BTU (2 x 10 10 kJ). The t o t a l energy required t o b r i n g a l l t he mater ia l i n the l a oon

x 10 10 KJ). This temperature combined w i t h the residence t ime o f the i n c i n e r a t i o n system would ensure a dest ruct ion e f f i c i e n c y o f 99.9%. An analys is o f the pond contents i s shown i n Table I.

area t o a temperature i n excess o f 1500 deg F (815 dec C) was 5 x 10 10 B 3 u (5

107

Cost estimates for on-si t e incineration w i t h estimates conventional treatment. A mobile system was competitive w i t h the cost of hau l ing the materials t o a secura 1

On-site incineration appeared t o be an attractive approach t o contamination problem. The material could be rendered inert

n hauling the problem from one location and dumping i t a t

DESCRIPTION OF EQUIPMENT

The Mobile Waste Processing system consists of five integrated. trcailer assembl ies :

(1 1 Sol ids Incineration ( 2 ) L i q u i d s Incineratorlkfterburner ( 3 ) Wasie Heat Boiler ( 4 ) Pol lu t ion Control and Prime Mover ( 5 ) Process Control /Chemical Laboratory

The arrangement o f the equipment i s shown i n Figure 3. diagram is shown i n Figure 4.

A schm&tic f lm

The s o l i d s incineration module consists of a sol ids preparation and charging equ discharge system. The charging system i s compr char i n g hopper w i t h integral ram feeder. Duri

intermittently operated ram feed mechanism loc the material i n t o the k i l n . The rotary k i l n i s a refr carbon steel pipe mounted horizontally on a t ra i ler t runnion drive mechanism. Sol i d s residence t complete mixing and detoxification of the sol incineration i s discharged in to the k i l n end bree ash discharge chute. A water cooled screw con ash t o a storage b i n where i t i s samples for p being sent t o a landfill

soli 9 s are placed on the belt co

The 1 iqu id incinerator/afterburner is a large refract0 sized t o provide a combustion gas residence time of 2 exceeding 2200 degrees F. Waste o i l or other hazardous i n the primary burner t h a t completes the incinerator/a

liquids are burned i n a h i g h temperature environment tha t appraack'es tk abatic flame temperature of the fuel. T h i s burner has the cap

urn h ighly chlorinated material w i t h low BTU value. The prim products mix w i t h the k i l n off gas and additional air i n the a f design of the system allows a range of combinations of k i l n aff waste, and contaminated water t o be destroyed. The variations are governed by the thermal inputs imposed by the various potential waste streams.

\ 1

1 no AVO

n 3

II

A t r a i l e r mounted f i re tube boi ler i s provided to recover heat i n the off gas from the k i l n . The waste heat boi ler provides the steam required fo r the system prime mover. A boi ler feed water treatment package i s included to assure minimal boi ler fouling and subsequent boi ler maintenance. A dear a tor i s rovided for oxygen removal and feed water heating. was& boiler a r e drawn through an Inconel elbow where the hot s t e m is, sprayed w i t h quench recirculation water. The off gases a re cooled t o saturatlon before reaching the e x i t of the quench elbow. A FRP sump box ac ts as a 3mp tank for uency recirculation pumps and provides additional residence time fc r

Off gases from t R e

the gases 1 o cool.

The steam from the boiler i s used t o drive a scrubber/ijector system located on another t r a i l e r . The steam e jec tor scrubber ac ts not only a s the System prime mover, b u t also as a f inal pollution control device. The uenched par t iculate laden gases a re drawn through the e jec tor nozzle. Tie turbulence created by the unique nozzle and mixing tube arrangement causes e f f i c i en t par t iculate capture in to the submicron range. A typical performance curve is shown i n Figure 5. The water, a f t e r removal of agglomerated particulate. i s recycled t o the steam e jec tor scrubber. The sol ids a re collected, i n filters as a sludge, tes ted f o r potential contaminates, and landfil led.

A chemical laboratory i s provided w i t h the system. The laboratory is primarily used t o provide chemical and heating value analysis of the waste material t o be incinerated. taken and analyzed f o r contaminates via the laboratory's gas chromatograph and atomic absorption spectrophotometer. T h i s ve r i f i e s complete detoxification of the waste e f f luent streams pr ior t o land f i l l i n g or other disposal.

A control room is also located i n the laboratory van. The incinerator combusti on process and ancl 1 1 ary processes a re monitored and control 1 ed by an integrated system of analog and digi ta l readouts, single loop controllers, and a computer system. The computer system i s employed i n a multifunction role, providing data acquisit ion and display a s well a s operational process control Single loop control lers a r e uti1 ized t o regulate combustion a i r flow, fuel flow and boiler drum ievel S ingle parameter readouts, mounted on a graphic panel, a r e used t o monitor process temperatures, waste water flow quench water flow, and scrubber water flow. conditioning electronics , therefore, measurement s ignals a r e direct ly wired t o it. These si nal s include thermocouple mill ivol ts, pressure transmitter

analysers. Si nal scaling t o engineering units a s accomplished through dlgital

such a s combustion efflciency and gas flows are a lso generated, &splayed, and logged by the computer.

Samples of the eff luent waste streams are also

The system has a b u i l t - i n signal

mil 1 lamps, an, 3 mil 1 iamp/mill ivol t signals from the four combusti on gas

processing as 8 irected by a portion of the software. Calculated arameters

REMOVAL OF MATERIALS AND EQUIPMENT FEED

The surface o i l i s removed from the O i l Pond by skimner pumps. in to a small storage and blend tank. oi l and the mixture i s fed t o the burner on the rotary k i l n .

I t is pumped Clean fuel o i l i s mixed w i t h the waste

3

-J 109

The o i l y water i s pumped t o another storage tank r e i t i s combined w i t h water from the septage pond. This water i s pumped i n t o the k i l n and i s used t o moderate the k i l n o u t l e t gas temperature. The organic content o f the water i s consumed i n the combustion process as i t passes through the flame zane.

The unpumpable septabe sludge i s removed w i t h a clamshell intermediate storage hopper. The mater ia l i s metered onto conveyor and i s dropped i n t o the ram feeder on the f r o n t face o f the k i l n .

The pumpable sludge from the O i l Pond i s pumped d i r e c t l y t o introduced t o the combustion zone through a steam dr iven l a cav i t y pump i s used t o move the sludge t o the v i c i n i t y o f the k i l n .

The bottom and d ike sand i s removed from the ponds w i t h small ealntk equipment. As t h e pond bottoms are exposed a f i q u i d and 9

sect ions are measured and staked. The contami OR i n t o modular containers f o r t ran rt t o the k i l n f e tw. There i t i s f e d i n t o the k i l n i n the same manner as the sewage sludge.

k i l n . It i s A ppogressive

A f te r the sand i s decontaminated i n t h e r o t a r y k i l n , i t d r ash hopper. hopper. There i t may be he ld f o r t e s t i n g and the r e s u l t i n g o i l - f r e e sand i s returned t o the pond area.

It i s moved by an enclosed screw conveyor t o

The f l ow o f t he various feed streams i s summarized i n Figure 6.

PERFORMANCE OF EQUIPMENT

The design capac i t ies o f the mobile i nc ine ra t i on system are 11. Thewsae are nominal capac i t ies based on avemge heat in mater ia ls a t t h i s s i t e . The actual capac i t ies w i l l vary de content o f the mater ia ls .

Mobile equipment s i m i l a r t o t h i s system has been demonstr approved T r i a l Burn on polychlor inatebiphenol (PCB). Thi dest ruct ion e f f i c i e n c e s i n excess o f 99.9999% as i s requi re substance inc ine ra t i on ru les. Results o f t h i s t e s t i n g

SUWARY

The s ta tus o f the set-up of a mobile i nc ine ra t i on system on a s p e c i f i s i t e has been described, w i l l be reported.

Operation r e s u l t s and perform

1

+ .

FIGURE I .. SITE MAP SHOWING LAYOUT O F DISPOSAL EQUIPMENT

c

J

n n h i n

3 4

1. CONTROL ROOM 81 LABORATORY

2. ROTARY KILN TRAILER 3. AFTERBURNER TRAILER 4. HEAT RECOVERY T R A I L E R 5. QUENCH & SCRUBBER TRAILER

SCALE: I '.I= 100'

..

.

112

n z 0

a

J 0

-

v, w

7

z >- id L

z

E' f ' ti I. . f;

.i

LAYER

TABLE I

ANALYSIS OF CONTENTS OF PONDS

HEATING VALUE

Wax

O i l

Sludge

Sept ic Sludge

16,100 BTU/Lb

19,6000 BTU/Lb

7,7000 BTU/Lb

544 BTU/Lb

' .

CHLORINE CONTENT

C1 2200 ppm

C1 3000 ppm

C1 2000 ppm

C1 8 0 ppm

!

I

I

I

I I

114

FIGURE 4 SCHEMATIC FLOW DIAGRAM OF MWP-2000ER

I - C1 c2 -

TACi

-

EJECTOR SCRUBBER

SECONDARY COMBUSTOR WASTE HEAT

RECIRC. TANK

SLUOCE 4 ss

m CONCENTRATOR

d\ I c4

L L T E R

L2 INflLTRATlON AIR

ROTARY KILN v / L I

i L1 t

CONCENTRATED SALT soLunw

b SAMPLING POINTS FOR TRIAL BURN

0

FIGURE 5

PERFORMANCE OF STEAM JET- EJ ECTOR SCRUBBER

I 1 1 1 I 1 I I I I I I I I I I I .C6 .06 .07 .08 .09 .IO .I2 .I4 .I5 .I6 .20 . .24 0.0001 I

STEAM RATE, I b/l b GAS

-71

It

' .

b OUTSIDE FUEL SUPPLY

?

t -

WASTE GAS OIL

STORAGE STEAM 4

STORAGE (HEATED 1

+ A

FIGURE 6

'I

PROCESS FLOW DIAGRAM

z AQUEOUS ROTARY-

STORAGE KILN

I NC I N E R ATOR b L I Q U I D S

-

. * + WASTE HEAT QUENCH e STEAM SECONDARY

FURNACE

'TjTl- STORAGE

WATER

T R E AT M ENT

WATER

'SOLIDS WITHDRAWAL BY FRONTEND LOADERS

TABLE 11

DESIGN CAPACITIES FOR SYDNEY MLNES

Solids

Sludges

Contaminated Liquid Fuel.

Contaminated Water

3800 1727 300

1000 4 5 4 14,100

120 55 19,600

2500 1136

118

TABLE I11

SUMMARY OF ACTUAL DESTRUCTION TEST PARAMETERS ON PCB TRIAL BURN

Parameter

Waste Feed Rate (Lbs/Min) PCB Conc. in Feed (Lb/Lb) PCB Feed Rate (Lb/Min) Fuel Feed Rate (Lb/Min) Heat Input (BTU/Hr) Oxygen Conc. ( % )

Carbon Monoxide Conc. (ppm) Carbon Dioxide Conc. ( % )

NOxConc . (ppm) Combustion Efficiency ( % )

Residence Time (Sec) Destruction Temp. ( O F )

Excess Oxygen . (%)

HCL Conc. (ppm) HCL, Rwnoved . (%)

Stack Flow Rate (dscfm) PCB Output Rate (Lb/Min) Destruction Efficiency ( % )

Particulate Conc. (Gr/DSCF)

EPA Required Value

Actual Average

8.69 0.416 3.62 5.07 7.3~10 6

36.7 3.8

18.1 6690

99.9 99.9979 2.0 3.48

2132223.2 2274 3 . 12.3

101 99+ 99.63

999 6

99.9999 99.999943 2.06~10

0.08 0.025

119 . . , . . . .

KILN FEED

Stream Sludge

Lbs/Hr 1000 PCT H20 20 PCT Ash 0 PCT Carbon 74 PCT Hydrogen 5.7

PCT Chlorine .3 PCT Sulfur 0 PCT Oxygen 0

WHV BTU/Lb 14131.9

Solids

3800 10 90

0 0 0 0 0 0

0

Air T

Liquid Water

120 250D 15323 0 0

83 13 0 0 0 0

19635

KILN EXIT GAS

Stream Exit Gas Solids

' Lbs/Hr TempOF Lbs/Hr H20 Lbs/Hr Ash' Lbs/Hr C02 Lbs/Hr N2 Lbs/Hr HCL Lbs/Hr 02 Lbs/Hr SO2

19324 1776 3732

0 3096

11784 . 3 707

0

3420 1550

3420

. . . .

Kiln Heat Load MMBTU/Hr 15.48 * Stoichi Gas Density Lbs/Cu. Ft. -015 Gas Velocity Ft/Sec 14.4 Kiln Heat Loss BTU/Hs 1,000,000 Soli

SECONDARY COMBUSTOR EXIT GAS

Stream

Lbs/Hr Temp F Lbs/Hr H20 Lbs'/Hr Ash Lb s / Hr C02 Lbs/Hr N2 Lbs/Hr HCL Lbs/Hr SO2 Lbs/Hr 02

Exit Gas

19523 1589 3732

0 3096 11945

3 0

787

Gas Density Lbs/Cu. Ft. .019 Stoichiometry 1.25 Gec. Heat Loss BTU/Hr 1,000,000 Gas Residence Time Secs. 4.65

Stream

Lbs/Hr Temp F Lbs/Hr H20 Lbs/Hr Ash Lbs/Hr C02 Lbs/Hr N2 Lbs/Hr HCL Lbs/Hr SO2 Lbs/Hr 02

BOILER AND QUENCH

Boiler Exit

16259 423 3732

0 3096 11945

3 0

747

Steam Produced Lbs/Hr 8219 Efficiency pct 70

Quench Exit

16134 . 150

3607 '

0 3096. 11945

3 0

747

Stack

12526 166

0 0

3096 11945

3 0

747

Boiler.Make-up H20 GPM 16.42 Steam to Jet Lbs/Hr 3226

121

i'

--* .

.. .

122