Field-scale rotary kiln incineration: Oxygen responses at the kiln,afterburner, and stack

There currently exists a need for better characterization and simulation of the processes that occur during the incineration of hazardous wastes in the environment of a rotary kiln. Addressing this need, a comprehensive research program was formed with the goal of developing a rudimentary predictive capability for rotary kiln incineration of hazardous wastes. This comprehensive program is headed by Louisiana State University and includes interaction with the University of Utah and also various industrial participants. Such cooperation allows use of laboratory, pilot, and field scale equipment. While laboratory scale experiments provide the necessary decoupling of complex phenomena and a high degree of experimental control, and pilot scale studies provide more realism at the expense of experimental control, the problems of scale-up make generalization of results to field scale units very tenuous. The unique aspect of the LSU program is the coupling of the laboratory and pilot scale units with afield scale unit in order to overcome these generalizations. In this study, plastic packs containing a mixture of toluene and sorbent were fed to a field-scale rotary kiln incinerator at a rate of one pack every 10 minutes. Selected continuous gas samples and temperatures were obtained from the exit of the rotary kiln, from the afterburner, and from the stack. These measurements were obtained during various operating conditions. These data provide, for the first time, an ability to compare conditions in the kiln to simultaneous conditions in the afterburner and stack. This paper outlines several new experimental features of our field-scale tests conducted in October 1990. Oxygen responses from the kiln, the afterburner, and the stack are compared during various operating conditions.     

Organic compound destruction and removal efficiency (DRE) for plasma incinerator off-gases using an electrically heated secondary combustion chamber

The United States Department of Energy (DOE) sponsored a series pilot-scale plasma incineration tests of simulated mixed wastes at the MSE Technology Applications, Inc. technology development test facility in Butte, MT. One of the objectives of the test series was to assess the ability of an electrically heated afterburner to destroy organic compounds that may be present in the off-gases resulting from plasma incineration of mixed wastes. The anticipated benefit of an electrically heated afterburner was to decrease total off-gas volume by 50% or more, relative to fossil fuel-fired afterburners. For the present test series, feeds of interest to the DOE Mixed Waste Focus Area (MWFA) were processed in a plasma centrifugal furnace while metering selected organic compounds upstream of the electrically heated afterburner. The plasma furnace was equipped with a transferred-mode torch and was operated under oxidizing conditions (10–15% oxygen at the stack). Feeds consisted of various mixtures of soil, plastics, Portland cement, silicate fines, diesel fuel, and scrap metals. Benzene, chloroform, and 1,1,1-trichloroethane were selected for injection as simulates of organics likely to be present in DOE mixed wastes, and because of their relative rankings on the US Environmental Protection Agency (EPA) thermal stability index. The organic compounds were injected into the off-gas system at a nominal concentration of 2000 ppmv. The afterburner outlet gas stream was periodically sampled, and analyzed by gas chromatography/mass spectrometry. For the electrically heated afterburner, at operating temperatures of 1800–1980°F (982–1082°C), organic compound destruction and removal efficiencies (DREs) for benzene, chloroform, and 1,1,1-trichloroethane were found to be >99.99%. The electrically heated afterburner was also operated at temperatures well below the design operating temperature, in order to assess the sensitivity of the afterburner to temperature swings. At 1300–1320°F (704–716°C) DREs for benzene and 1,1,1-trichloroethane were still >99.99%, while the DRE for chloroform was slightly degraded to 99.977%. At 820–850°F (438–454°C) the DRE for 1,1,1-trichloroethane remained >99.99%, while the DREs for benzene and chloroform were substantially degraded, in the order expected from the EPA thermal stability index. For comparison, analogous tests were performed using a conventional natural gas fired afterburner, with similar results. The natural gas fired afterburner yielded DREs greater than 99.99% for 1,1,1-trichloroethane, chloroform, and benzene, when operated at 1600–1820°F (871–993°C) and 1350°F (732°C). Similarly to the electrically heated afterburner, at 850°F (454°C) DREs were substantially degraded for chloroform and benzene. At normal operating temperatures both the electrically heated afterburner and the natural gas fired afterburner gave acceptable DREs (>99.99%), for the three injected organic compounds. DREs remained acceptable for both units even when operated at substantially reduced temperatures.     

Soil washing treatability tests for pesticide-contaminated soil

The 1987 Sand Creek Operable Unit 5 record of decision (ROD) identified soil washing as the selected technology to remediate soils contaminated with high levels of organochlorine pesticides, herbicides, and metals. Initial treatability tests conducted to assess the applicability of soil washing technology did not effectively evaluate the removal of the elevated contaminant concentrations that were found. To further evaluate the applicability of soil washing at this industrial site, a second more comprehensive pilot-scale treatability test was conducted. Twenty-three test runs were conducted over a two-week period in late September 1992, using a pilot-scale soil washing device called the volume reduction unit (VRU). The experimental design evaluated the effects of two wash temperatures, two pH levels, three surfactants, four surfactant concentrations, and two liquid-to-soil ratios on the contaminant removal efficiency of the soil washing process. Site soils from layers at three different depths were used in the study. Results from the pilot-scale treatability test indicated that the VRU could achieve contaminant reduction efficiencies of 97 percent for heptachlor and greater than 91 percent for dieldrin in the uppermost contaminated soils (surface to 1-ft. depth). Residual concentrations of heptachlor and dieldrin in the treated soil ranged from 50 ppm to less than 1.6 ppm, and 6.8 ppm to less than 1.6 ppm, respectively. However, the analytical method detection limit of 1.6 ppm was not low enough to provide residual concentration data at the risk-based action levels of 0.55 ppm for heptachlor and 0.15 ppm for dieldrin.     

Selecting state-of-the-art incinerators for complex aqueous wastes

The Rocky Mountain Arsenal (RMA) in Adams County, Colorado has been identified as a priority site on the Superfund National Priority List. The Program Manager's Office of RMA announced in early 1990 its intention to implement installation of a state-of-the-art incineration plant to treat the most complex and controversial waste stream on the site. Established in 1942, RMA served as an Army manufacturing center for chemical agents such as mustard gas, white phosphorus, napalm, and GB nerve agent. Parts of the site were also leased to Shell Oil Company, which manufactured pesticides and other agricultural chemicals at this location between 1952 and 1982. To support these activities, the Army operated a ninety-three-acre surface impoundment called Basin F for collection and evaporation of chemical wastewaters. As a result of the wide variety of wastes received and concentrated at Basin F and early treatment attempts, its contents became one of the most unusual chemical cocktails known to man. By the time a formal interim response action for remediation was initiated in 1985, the composition of the Basin consisted of a multi-phase fluid and sludge, including super-saturated levels of inorganic salts; 30 percent or more organics such as pesticides, military agent by-products, degradation products, and solvents; high levels of ammonia compounds and bound nitrogen; and percent levels of copper, arsenic, and other metals. Selection of a remedial alternative involved twelve years of characterizationstudies and eleven years of treatability testing programs encompassing the universe of containment; encapsulation; stabilization; component separation; and thermal, electrical, chemical, and biological degradation technologies. The program resulted in the selection of a state-of-the-art down-fired liquid incinerator for destruction of aqueous organic contaminants in metallic salt matrices. The treatability demonstration, and the technical justification for selection of the T-Thermal submerged quench incinerator for this application, is the subject of this article.     

Incineration treatment of arsenic-contaminated soil

An incineration test program was conducted at the U.S. Environmental Protection Agency's Incineration Research Facility to evaluate the potential of incineration as a treatment option for contaminated soils at the Baird and McGuire Superfund site in Holbrook, Massachusetts. The purpose of these tests was to evaluate the incinerability of these soils in terms of the fate of arsenic and lead and the destruction of organic contaminants during the incineration process. The test program consisted of a series of bench-scale experiments with a muffle furnace and a series of incineration tests in a pilot-scale rotary kiln incinerator system. The study reported in this paper was funded by the Environmental Protection Agency under Contract 68–C9–0038 to Acurex Corporation. It has been subjected to the Agency's review and has been approved for publication. Mention of trade names or commercial products does not constitute endorsement or recommendation for use.     

Assessing detoxification and degradation of wood preserving and petroleum wastes in contaminated soil

This study was undertaken to evaluate in-situ soil bioremediation processes, including degradation and detoxification, for two types of wood preserving wastes and two types of petroleum refining wastes at high concentrations in an unacclimated soil. The soil solid phase, water soluble fractions of the soil, and column leachates were evaluated. Two bioassays, a mutagenic potential asay (Ames assay) and an aqueous toxicity assay (Microtox^™ assay) were used to evaluate detoxification; high performance liquid chromatography was used to evaluate chemical concentration and degradation for eight polynuclear aromatic hydrocarbons (PAHs). The group of non-carcinogenic PAHs studied demonstrated greater degradation, ranging from 54–90% of mass added for the four wastes; the carcinogenic group of PAHs studied exhibited degradation ranging from 24–53% of mass added. Although no mutagenicity was observed in waste/soil mixtures after one year of treatment, Microtox^™ toxicity was observed in water soluble fractions and in leachate samples. An integration of information concerning degradation of hazardous constituents with bioassay information represents an approach for designing treatability studies and for evaluating the effectiveness of in-situ bioremediation of contaminated soil/waste systems. When combined with information from waste, site and soil characterization studies, the data generated in treatability studies may be used in predictive mathematical models to: (1) evaluate the effectiveness of use of on-site bioremediation for treatment of wastes in soil systems; (2) develop appropriate containment structures to prevent unacceptable waste transport from the treatment zone; and (3) design performance monitoring strategies.     

On-site remediation of PCB contamination using transportable incineration systems

Many Superfund or hazardous waste sites prove to be excellent candidates for remediation using transportable incineration. Transportable incineration has been selected as the alternative of choice to remediate numerous sites throughout the United States. There are a number of firms that provide mobile and transportable incineration equipment and services. A variety of treatment systems are available, including rotary kilns, fluidized beds, and infrared incinerators. Roy F. Weston, Inc., has been instrumental in the development, design, permitting, construction, performance testing, and operation of hazardous and toxic waste thermal treatment systems. Weston owns and operates two high-temperature transportable incineration systems (TISs). The first system is Weston's seven-ton-per-hour (tph) TIS-5. The second is the TIS-20, with a design capacity of up to 30 tph. These units are typical rotary kiln incinerators, the most flexible, adaptable type of incineration unit. This article discusses Weston's use of these incinerators to remediate soils at sites contaminated with polychlorinated biphenyls (PCBs).     

Treatment of hazardous waste incineration wastewater

This article outlines the general design concepts and new chemistry necessary to achieve truly cost-effective management of an important part of the hazardous waste incineration system—i.e., the unit operations needed to treat wastewater generated by rotary kiln incinerators burning wastes containing halogens and heavy metals.     

Review of environmental aspects and waste management of stone cutting and fabrication industries

Iran is the second largest stockholder of construction stones with 10 % of world production ;and there are more than 4000 stone cutting and fabrication industries (SCFIs). In the processing of raw stones, a considerable part of stone is turned into waste. Generated wastes include excess parts of different stones and sludge. The present paper reviews the state of SCFIs waste management using multiple data sources including site, analysis of effluent and sludge samples, and conducting interviews with people who are involved in 286 SCFIs in Qom and Tabriz. The results revealed that currently almost 35 to 52.5 % of raw stones were converted to solid wastes depending on stone cutting and processing methods, type of stones and their quality, which seemed a high percentage. Also, the effluents between 0.8 and 2.8 m³ were generated per ton of processed stone. Based on the analysis of heavy metals with atomic absorption spectroscopy, sludge samples contained a considerable amount of Pb, Cu, Cr, and Cd. It was also found that the lack of specific recycling, reuse and disposal programs and suitable supervision has led to uncontrolled disposal of stone wastes and sludge in different areas. However, there are good opportunities for reuse and recycling of the SCFIs wastes.     

Circulating fluidized bed incineration of industrial solid wastes

A pilot scale test facility of a circulating fluidized bed incinerator was established to generate design and operation data and help assess the technical feasibility for industrial applications. The use of high turbulence in the combustion zone and feeding an acid-capturer directly into the incinerator to absorb acid gases eliminates the costly afterburner and scrubber. This paper presents some systematic incineration tests of uniform industrial wastes such as paper mill sludge cake, rubber waste and petroleum coke. Sludge cakes with high moisture and low heating values can be treated to a low emission level by co-firing with coal. The high superficial gas velocity has improved combustion efficiency but increases NO_x emissions. However, sulphur content has almost no influence on sulphur retention. The problems of CO/NO_x emissions and circulation stability are also discussed.     

Evaluation of white‐rot fungi for the remediation of creosote‐contaminated soil

Application of fungal‐based bioaugmentation was evaluated for the remediation of creosote‐contaminated soil at a wood‐preserving site in West Virginia. Soil at the site contained creosote‐range polycyclic aromatic hydrocarbons (PAHs) at concentrations in some areas that exceed industrial risk‐based levels. Two white‐rot fungi (Pleurotus ostreatus and Irpex lacteus) were evaluated for remediation effectiveness in a two‐month bench‐scale treatability test. Both fungi produced similar results, with up to 67.3 percent degradation of total PAHs in 56 days. Pilot‐scale testing was performed at the site using Pleurotus ostreatus grown on two local substrate mixtures. During the 276‐day field trial, total PAHs were degraded by up to 93.2 percent, with all individual PAHs except one achieving industrial risk‐based concentrations. It was recommended that fungal‐based remediation be applied to all contaminated soil at the site. © 2002 Wiley Periodicals, Inc.     

Recycling MSWI bottom and fly ash as raw materials for Portland cement

Municipal solid waste incineration (MSWI) ash is rich in heavy metals and salts. The disposal of MSWI ash without proper treatment may cause serious environmental problems. Recently, the local cement industry in Taiwan has played an important role in the management of solid wastes because it can utilize various kinds of wastes as either fuels or raw materials. The objective of this study is to assess the possibility of MSWI ash reuse as a raw material for cement production. The ash was first washed with water and acid to remove the chlorides, which could cause serious corrosion in the cement kiln. Various amounts of pre-washed ash were added to replace the clay component of the raw materials for cement production. The allowable limits of chloride in the fly ash and bottom ash were found to be 1.75% and 3.50% respectively. The results indicate that cement production can be a feasible alternative for MSWI ash management. It is also evident that the addition of either fly ash or bottom ash did not have any effect on the compressive strength of the clinker. Cement products conformed to the Chinese National Standard (CNS) of Type II Portland cement with one exception, the setting time of the clinker was much longer.     

A simple and convenient empirical survey method with a soil electrical conductivity meter for incineration residue-derived soil contamination

To facilitate field surveys for identifying areas of incineration residue-derived soil contamination, a simple and convenient method with a soil electrical conductivity meter was examined. First, the leaching test specified by Notification No. 13 of the Ministry of the Environment, 1973, was conducted on 506 samples of 11 types of wastes and compost, and the relationship between the concentrations of toxic elements [total Hg (T-Hg), Cd, Pb, Cr⁶⁺, and As] and values of electrical conductivity (EC) was examined. The results showed that bottom ash and fly ash were wastes with high EC values and that these wastes indicated higher levels of toxic elements. Second, an estimation method for the soil EC value of contaminated soil (ECc) was proposed based on the EC values of noncontaminated soil, and its usefulness was examined. The results of field surveys conducted at sites whose soils were suspected of contamination by dioxins and other pollutants derived from incineration residues showed that the contaminated spots and areas were identified by using ECc values. Moreover, comparison of the elemental contents of soils in terms of Cr, Ni, Zn, Na, K, Ca, Fe, Mn, and others, in addition to the above-mentioned toxic elements (excluding Cr⁶⁺), with those of the potential sources of pollution was verified to be effective for identifying the source of soil contamination.     

Liquefaction process for a hydrothermally treated waste mixture containing plastics

Most landfilled plastic waste is a mixture or is in the form of composites with incombustible wastes such as glass, metals, and ceramics. After hydrothermal treatment, including a steam-explosion process, the separation of mixed waste (MW) into organic and inorganic substances becomes easy. However, the effect of hydrothermal pretreatment on the subsequent liquefaction of organic substances from MW is not obvious. In this study, the effects on the liquefaction of polystyrene and high-density polyethylene are discussed. Moreover, optimum conditions for the liquefaction of organic substances from hydrothermally treated MW are identified. By means of this hydrothermal pretreatment, including the steam-explosion process, polystyrene and high-density polyethylene can be significantly converted to oil by liquefaction at 300°–400°C. In comparison with liquefaction of hydrothermally pretreated mixed waste (HMW) at 300°–400°C with a batch type reactor, the yield of oil increases significantly on liquefaction using a semi-batch type reactor. It is considered that the radical chain and termination reactions among the radicals from HMW were inhibited in the semi-batch type reactor. On liquefaction of HMW in a semi-batch reactor, the conversion of HMW to oil was enhanced on increasing the liquefaction temperature to 350°C and the holding time to 60 min. Chemical Feedstock Recycling & Other Innovative Recycling Techniques 6     

Environmental performance of construction waste: Comparing three scenarios from a case study in Catalonia,Spain

The main objective of this paper is to evaluate environmental impacts of construction wastes in terms of the LIFE 98 ENV/E/351 project. Construction wastes are classified in accordance with the Life Program Environment Directive of the European Commission. Three different scenarios to current waste management from a case study in Catalonia (Spain) have been compared: landfilling, recycling and incineration, and these scenarios were evaluated by means of Life Cycle Assessment. The recommendations of the Catalan Waste Catalogue and the European Waste Catalogue have been taken into account. Also, the influence of transport has been evaluated.Results show that in terms of the Global Warming Potential, the most environmentally friendly treatment was recycling, followed by incineration and lastly landfilling. According to the influence of treatment plants location on the GWP indicator, we observe that incineration and recycling of construction wastes are better than landfilling, even for long distances from the building site to the plants. This is true for most wastes except for the stony types, than should be recycled close to the building site.In summary, data from construction waste of a Catalan case study was evaluated using the well established method of LCA to determine the environmental impacts.     

Application of risk management techniques for the remediation of an old mining site in Greece

This article summarizes the project and risk management of a remediation/reclamation project in Lavrion, Greece. In Thoricos the disposal of mining and metallurgical wastes in the past resulted in the contamination with heavy metals and acid mine drainage. The objective of this reclamation project was to transform this coastal zone from a contaminated site to an area suitable for recreation purposes. A separate risk assessment study was performed to provide the basis of determining the relevant environmental contamination and to rate the alternative remedial schemes involved. The study used both existing data available from comprehensive studies, as well as newly collected field data. For considering environmental risk, the isolation and minimization of risk option was selected, and a reclamation scheme, based on environmental criteria, was applied which was comprised of in situ neutralization, stabilization and cover of the potentially acid generating wastes and contaminated soils with a low permeability geochemical barrier. Additional measures were specifically applied in the areas where highly sulphidic wastes existed constituting active acid generation sources, which included the encapsulation of wastes in HDPE liners installed on clay layers.     

Removal,Handling, and Thermal Desorption Treatment Techniques for Manufactured Gas Plant Wastes

Due to the nature of contamination typically found at former MGP (manufactured gas plant) sites, excavation and thermal desorption of MGP wastes has proven to be an effective method for the remediation of MGP‐contaminated soil. The use of on‐site thermal desorption enables MGP sites to be quickly remediated at a low cost. Tar pits, holders, and other underground storage structures typically contain coal tar residuals and waste from former operations, and the areas around these structures are often significantly contaminated. Thus, excavation techniques, odor and vapor management, and material preparation for the treatment method are important factors to consider when developing a site remediation strategy. This article reviews typical excavation and handling methods associated with the remediation of former MGP sites and discusses the treatment of MGP wastes using on‐site thermal desorption technology. © 2001 John Wiley & Sons, Inc.     

Treatment of Sydney N.S. tar pond sludge in a pilot‐scale rotary kiln

Tar pond wastes from Sydney, Nova Scotia, containing 50 ppm or more of polychlorinated biphenyls (PCBs) were treated in a pilot‐scale rotary kiln. In order to use the existing feed system attached to the rotary kiln, the wastes were first oven‐dried. Stack gas sampling was conducted during the test, which included measurement of volatile organic compounds (VOCs), polycyclic aromatic hydrocarbons (PAHs), semi‐volatile organic compounds (SVOCs), HCl, and metals. The purpose of this study was to determine emissions from treatment of the tar pond waste using rotary kiln technology. It was found that the dried sludge could sustain combustion in the kiln without any supporting fuel. The emissions of polychlorinated dibenzodioxins/furans (PCDD/Fs) were higher than the Canadian Council of Ministers of the Environment (CCME) air emissions guidelines, and the reasons for this are discussed. © 2008 Wiley Periodicals, Inc.     

Triad case study: Rattlesnake Creek

The U.S. Army Corps of Engineers (US ACE) is responsible for conducting the cleanup of radiological contaminated properties as part of the Formerly Utilized Sites Remedial Action Program. One property is the Rattlesnake Creek (RSC) portion of the Ashland sites. The RSC stream sediments are contaminated with thorium‐230, radium‐226, and uranium. The US ACE is closing RSC using protocols contained within the Multi‐Agency Radiation Survey and Site Investigation Manual (MARSSIM). At RSC, the US ACE developed site‐specific derived concentration guideline level (DCGL) cleanup requirements consistent with the MARSSIM guidance. Because of uncertainty about the distribution of contamination within the creek, the US ACE used the Triad approach to collect data and design remedial actions. Systematic planning helped target the areas of concern, develop a conceptual site model, and identify data gaps to be addressed before remediation plans were finalized. Preremediation sampling and analysis plans were designed to be explicitly consistent with final status survey requirements, allowing data sets to support both excavation planning needs and closure requirements in areas where contamination was not encountered above DCGL standards. Judicious use of real‐ time technologies such as X‐ray fluorescence and gamma walkover surveys minimized expensive off‐ site alpha spectrometry analyses, and at the same time provided the ability to respond to unexpected field conditions. © 2004 Wiley Periodicals, Inc.     

Treatment technology for remediation of wood preserving sites: Overview

This is the first in a series of five articles describing the applicability, performance, and cost of technologies for the remediation of contaminated soil and water at wood preserving sites. Site‐specific treatability studies conducted under the supervision of the United States Environmental Protection Agency (US EPA), National Risk Management Research Laboratory (NRMRL), from 1995 through 1997 constitute much of the basis for the evaluations presented, although data from other treatability studies, literature sources, and actual site remediations have also been included to provide a more comprehensive evaluation of remediation technologies. This article provides an overview of the wood preserving sites studied, including contaminant levels, and a summary of the performance of the technologies evaluated. The subsequent articles discuss the performance of each technology in more detail. Three articles discuss technologies for the treatment of soils, including solidification/stabilization, biological treatment, solvent extraction and soil washing. One article discusses technologies for the treatment of liquids, water and nonaqueous phase liquids (NAPLS), including biological treatment, carbon adsorption, photolytic oxidation, and hydraulic containment. The reader should be aware that other technologies including, but not limited to, incineration, thermal desorption, and base catalyzed dehalogenation, also have application for treating contaminants on wood preserving sites. They are not discussed in these five articles since the focus was to evaluate lesser known and hopefully lower cost approaches. However, the reader should include consideration of these other technologies as part of any evaluation or screening of technologies applicable to remediation of wood preserving sites.