U N I O N I C M E M I C A L - I C D M P A N Y I N C .

( 2 D 7 ) 7 B 5 - 2 B Z 5 U N I O N , M A I N E 0 4 8 6 2

xiddencluR": to .application f o r License f o r

Hazardous aaste F a c i l i t y by union Chemical

Co., Inc. 1-31-34

•2108003

Addendum to Application for License f o r

Hazardous Waste F a c i l i t y by Union Chemical

Co., Inc. 1-31-84

FIVE SECTIONS

SECTION TITLE

I Union Chemical's Portion of test Burn Plan

I I GCA's Portion of test Burn Plan '

I I I Raw Data sheets kept by Incinerator Operators

during test burn

I V Final Report/Evalvation of test burn by DEP's

Representature at the test burn

V GCA Program Results of test burn

- 1

Test Burn Plan f o r Union Chemical

F l u i d Bed Incinerator

Incinerator Design Information

The Phoenix Model 32 f l u i d i z e d bed incinerator at Union

Chemical was designed and constructed by Union Chemical personnel.

The i n c i n e r a t i o n u n i t consists of the following major pieces of

equipment i n series, as i l l u s t r a t e d i n figure 32.

Combustion Chamber

Ash drop chamber

D i l u t i o n a i r reactor

Cyclone

Quench tower and acid n e u t r a l i z a t i o n u n i t

Induced d r a f t blower

Wet scrubber packed with polypropylene T e l l e r e t t e s

Exhaust stack

The combustion chamber i s v e r t i c a l , r i s i n g to a height of

24 f e e t . The f l u i d i z e d bed section i s 32 inches i n diameter,

increasing to a diameter of 42 inches i n the freeboard space

above the bed. The f l u i d i z e d medium is a f i n e mesh o l i v i n e

sand. The f l u i d i a e d bed i s 24 inches high when quiescent,

and 30 to 32 inches high when f l u i d i z e d . The bed i s f l u i d i z e d

by a 2830 scfm forced d r a f t Twin City Fan blower rated at 4 l

inches w.c. The blower i s equipped with a silencer and i s

housed to provide fu r t h e r noise protection. The blower also

feeds i n t o the freeboard above the bed: the proportion of a i r

flowing to the bed and to the freeboard i s controlled by dampers.

The combustion a i r i s not preheated p r i o r to introduction to the

combustion chamber zones. The combustion chamber i s equipped

w ith a sight glass i n order to observe the flame i n the free

board space. The combustion chamber is li n e d with four inches

of Harbison-Walker acid resistant castable r e f r a c t o r y , rated at

2800 F plus three inche of H.W. insu l a t i n g r e f r a c t o r y . The ~>.̂

combustion chamber i s equipped with an i n j e c t o r f o r l i q u i d s of

Union Chemical proprietary design, a rota r y valve port f o r feeding

$S solid—wa-s-tes ( f i g . 31) and an inconel spray nozzle f o r c o - f i r i n g contaminated water. S t a l a c t i t e s forming on. the i n j e c t o r during

MEYER ROTO-FLO AIR LOCK FEEDERS

. . . are designed for use with pneumatic conveying systems, dust control equipment or as volumetric -feejjers_ in the process industries.

F U N C T I O N : Thebasic use of the Roto-Flo is as an airlock. In this capacity, w y - f . ' . it wil l seal the system against loss of air or gas, thereby main

* * • taining operating pressures for maximum efficiency. Roto-Flo Units are also widely used as volumetric metering devices to

,•„ * feed *a wide variety of materials at an even flow-cate into i . processing systems and eliminate clogging. In many operations,

use of a Roto-Flo Airlock reduces the hazards of high pres.. "sures by serving as an explosive check.

CONSTRUCTION: Roto-Flo housings are of close grain cast iron construction. ; Cast steel, bronze, stainless steel and aluminum for special ' • applications is available on order. Rotors are machined to

precise tolerances and statically balanced to insure smooth operation and free flow. Overall design simplifies installation and keeps maintenance to a minimum.

A P P L I C A T I O N : Roto-Flo rotary airlock feeders have unlimited application in industry. They are widely used with materials handling storage bins, silos, dust collectors, rotary dryers, air classifiers and all types of pneumatic conveying or processing systems. Manufacturers of mobile pneumatic material handling equipment

* such as car unloaders, insulation blowers, bulk packaging machinery, etc., utilize Roto-Flo units as O.E.M. components.

Any material that is finely ground or granular, dry and free % flowing such as sugar, cement, non-metallic minerals, grains,

plastics, dust, soap flakes, coffee, etc., can generally be handled by a Roto-Flo Rotary Airlock feeder.

Roto-Flo Airlock Feeders are available for blow-thru and drop-thru applications. There are 4 basic rotor styles with 4, 6 and 8 vane construction (see p. 4) to meet specific applications. Sizes and types available are shown below:

STYLE ROTOR VANES

BLOW DROP SIZE THRU THRU

4x4

6x6

8x8

10x10

12x12

12x21

14x14

16x21

18x18

22x22

Pel le t adapters and square to round transi

C O N S T R U C T I O N a n d F E A T U R E S tions available as standard options.

Full flow tapered inlet and

outlet.

Heavy duty flanges are pre-drilled and tapped to Seal strips are optional simplify installation. and can be supplied in

Neoprene, Teflon, Urethane, Stainless Steel, or

Brass and are bolted on

for easy change or ad Close tolerance machining

justment. for air tight sealing,

(rated at 12 PSIG). Six vane open end high capac i ty ro tors are standard. Four or eight vane rotors available per Self aligning cartridge type customer order. Rotors ball bearing pre-lubricatalso available with bev ed and sealed for life — elled and/or hard faced one fixed, one floating to edges. allow for heat expansion.

Housing and head plates

are of close grain cast

iron construction stand

ard for structural stabil

ity. (Feeders made of oth

er metals and special ai- Oversize shaft for maximum

loys available on specific torque. (Safety torque limorder.) iter or shear pin sprocket

can be supplied with drives.)

Removable Inspection plate (optional) (see photo—Model SDL)

Rigid motor mounting plate Externally adjusted packbosses on all sizes. ing glands on type HD to

prevent bearing contamination. Available with air

Special interior coatings purge shaft seal (optional) such as nickel, chrome, rubber, teflon, etc. available.

__ I QUENCH TOWER

0 ~ -I.D. FAN

K - WET.SCRUBBER

L - STACK

I

r

A ~~ PRESSURE. FAN

B ~ PREHEAT TUBE

C - BED

D - COMBUSTION CHAMBER

E - ASH DROP-OUT

Q — REACTOR

H --CYCLONE

SYSTEM COMPONENTS

Union Chemical Co., Inc.

Model - RB - 81 Fuel Feeder

1) . Variable throat design to handle varying waste f u e l v i s c o s i t i e s

2) . Automatic a i r purge to minimize feed clogs.

3) . Water cooling jacket to minimize temperature induced d i s t o r t i o n

4) . Capacity f o r manual and/or automated feed c o n t r o l .

5) • Constructed of 316 stainless s t e e l .

- 5

operation are removed with pulses of 30 to 35 psi compressed a i r .

The ash drop out i s essentially a s e t t l i n g chamber f o r large

p a r t i c l e s . I t i s l i n e d with the same r e f r a c t o r y used i n the

combustion chamber. Solids are reoved through a ro t a r y valve

and f a l l i n t o a 55 gallon drum placed underneath.

The reactor was o r i g i n a l l y designed f o r dry n e u t r a l i z a t i o n

of acid gases. As a r e s u l t of the need f o r excess lime to achieve

complete n e u t r a l i z a t i o n a change was made to the more e f f i c i e n t

wet n e u t r a l i z a t i o n with a lime s l u r r y i n the quench tower.

The cyclone i s a Fisher Klosterman XQ un i t l i n e d with 2.5

inches of Kaiser acid resistant castable r e f r a c t o r y . The pressure

drop i s rated at 10 to 12 inches w.c. but the actual operating

pressure drop i s about 5 inches w.c. The unit i s equipped with a

continusously operating rotary valve, with solids dropping i n t o an

open head 55-gallon drum.

The quench tower i s approximately 30 feet high and 5 feet i n

diameter. The upper one t h i r d i s acid r e s i s t a n t refactory l i n e d .

The balance i s li n e d with an acid and base res i s t a n t asphaltic

epoxy coating. Quenching l i q u i d i s recycled from a p a r t i c u l a t e

s e t t l i n g chamber and lime s l u r r y and make up water are added as

needed.

The shells of the combustion chamber, ash dropout, reactor,

cyclone, quench tower and connecting ductwork are a l l of mild

s teel w ith thicknesses of to

The prime a i r mover i s a polyester epoxy l i n e d induced

d r a f t Twin City Fan blower with Inconel 625 baldes rated at 9220

scfm at 21 inches w.c. Transistions are also polyester epoxy

l i n e d .

The f i b e r glass l i q u i d cross flow scrubber manufactured by

Ceilcote i s packed with p l a s t i c T e l l e r e t t e s . The FRP unit i s

housed i n a cinder block building adjacent to the stack. The

nominal rated gas flow rate i s 12,000 cfm at 200°F and the l i q u i d

flow rate i s 110 gallons per minute, f o r a minimum L/G r a t i o of

approximately 9-2. The pH of the scrubber sump l i q u i d i s adjusted

using lime s l u r r y . Scrubber sump water i s provided at a rate of

4-5 gallons per minute from a well or a nearby brook, i n a counter

- 6

current manner. Over flow i s stored i n a 6000 gallon tank and

used f o r quench water makeup. The a i r p o l l u t i o n control system

i s designed so that there w i l l be no l i q u i d e f f l u e n t , other than

the water i n the fl u e gas leaving the stack and CACL2 solution.

Quench and scrubber l i q u i d s are either recycled or vaporized i n

the quench tower. A l l thermocouple wells are made of Inconel or

ceramic coated s t e e l (Fig. 33). D i g i t a l temperature readouts

are by Love Controls (Fig. 33A).

The FRP stack i s 60 feet high and 2 feet i n diameter. I t

i s free standing and supported by guy wires. A sampling platform

i s located 30 feet above the ground and 20 feet downstream form

the t r a n s i t i o n j o i n i n g the scrubber with the stack. The stack

i s equipped with two 4 inch sampling ports located 180° apart

a d d i tional ports plus an overhead t r o l l e y f o r method 5 and method

25 determinations are also i n place.

Incinerator Operation Conditions

The following operation temperatures are maintained during

operation of the inciner a t o r :

Combustion Chamber - i n f l u i d i z e d bed 1500°F - 1700°F

Combustion chamber above f l u i d i z e d bed 2000 2200°F

Ash Dropout

Reactor

2000°F

1900°F

Cyclone

Quench Tower Exit

Stack E x i t

1700°F

180° 220°F

1500 l6o°F

#2 f u e l o i l i s used as f u e l f o r the Ray Model RA100 preheat

&il~bUKjier, equiped with a 60° a i r atomized 10.5 gallon (1,4-70,000

BTU) per hour nozzle (Fig. 32A). Flammable wastes are not fed to

the incinerator u n t i l a temperature i n excess of 1129°F (auto

i g n t i o n point) i s attained i n the f l u i d i z e d bed. Halogenated wastes

are not added u n t i l a temperature of 2000°F i s achieved i n the free

board space.

I t should be noted that a f t e r i g n i t i o n of the waste (tem

perature i n freeboard CA 1350°F) the preheat burner i s turned o f f

and no fu r t h e r a u x i l l i a r y f u e l i s used or needed during the course

of the burn.

Excess a i r rates of up to 200 percent are used when only

1

J /v/ 7

Special Application Protecting Tubes & Assemblies fetal-Ceramic Protecting Tube

" t o SERV-RITE metal-ceramic protecting tube is composed Fmetallic chromium and aluminum oxide. The metal imparts lock rosistanceaDd-Wgh thermal conductivity for fa? ie roadinjjerme' stable ceramic rosists deformation co?i

/ » a b r 8 9 n a n d o x , d i z l n' oi w 0 5 t i 5 A , 9 atmosphehsa over t00 y \ 1204 C).

LLO.C' ,78" 10

10. 5/8"

h 5/r

Thermocouples can be installed directly, eliminating the expense of multi-tube assemblies. Metal-ceramics resist surface deformation below 2800° F (1538°C). and permit frequent intermittent immersion at up to 3000°F (1649°C) They are usoful in calcining kilns; for prohont tompornluro control of open honrth furnaces; for continuous immorslon In molten *>rass. bronze, copper, zinc and lead; and in sulphurous gases.

n use, oxcoss thermal or mechanical shock should be avoided Though suponor to ceramics, metal-ceramic tubos are not is shock resistant as metal alloys, and may require proheatlno

for certain applications. "

C M NO I D. ( 0.0 Ceratrucdon

1161 5/8" X 7/8" Sid. 3/4" 12" through 48* Conduit Connector in 6" increment*.

Mfer^rotoetooTUbot and Assemblies for Mplfen Aluminum,; rte and Galvanizing Applications

n , , , i i j . . . i iM jq l i i ^ i i .. i . .. ii

1100 Protecting Tube

J

1101 Protected Thermocouple

Tns 1100 Protecting Tubes with tough refractory laminated mling resist erosion from molten aluminum, zinc or galvani\a bnlhs. Thoy stay strong, ovon at higher temperatures, id roquire no "washing" or maintenance to prolong their rvice lite. A special protective "cap" at the tip provides fast sponse time, while permitting thermal expansion without mage to the refractory laminate. The .493" I.D easily ac>mmodates up to an 8-gauge beaded thermocouple. Stocked r Immediate shipment.

Tub* Cat No I D 0 0 r i t l in f Length 1100 .493" 11/2" Max. 3/4" NPI 12" through 48"

in 6" increments.

iries 1101 Protected Thermocouple Assemblies incorporate mlnoral- insulatod stainless steel shc-Uhcd XacTpack« irmocoupln hormolicnlly sonlod within a refractory lamiU)d Sorlos 1100 Protocting Tube. Standard calibration is po K (Cat. No. 402-2107), complete with 36" of high temperj re insulated thermocouple wire (Cat. No. K20-1-104). Like o 1100, tho 1101 assombly requires no "washing" or mainnnnco to prolong its service lifo, yot givos fasl, accurate ndlngs In molten aluminum, zinc and galvanizing baths.

ANSI Tub* No. dHbraOan 0.0. "RUnt U n f t h length

1101 11/r MM. 3/4" NPT 36" 12" through 48"

in 6" increments.

1102 Floating Protected Thermocouple

A thermocouple that floats! It contains a .125" O. D. XacTpack* ANSI Type K stainless steol sheathed Ihermocoupln for quick accurate temperaturo indication approximately 3" below tho surface of the melt or bath—where control is needed mostl This trouble-free unit gives you continuous temperature Indication at dip-out depth—regardless of metal level! Chances of breakage are minimized, thanks to a patented buoyant fiber collar that absorbs shock if struck by ladles or skimmora. The 1102 floats easily aside to permit unobstructed skimming. High temperature 36" insulated thermocouple wire is standard. A metal sleeve with strain relief spring at the top protects against molten metal splash and wire abrasion. The thick, rugged refractory laminated thermocouple protecting "cone" provides rapid heat transfer and full physical protection. Dimensions: sleeve, '/?" O.D.; laminated portion of sleeve! % O D . "buoy" at widest point, 4" ' O.D.; bottom of "coner% O.D.; standard stem length, 12."

ANSI Nominal i M d

CM. NO. Calibration OD U n t i l * Umgdi

1102 4" Max. 36" 12" A ntmly ol cuilomit*) Utlum lot poMtoninq tnd holding fno 1)0? tn a Ml* ot ml tmltblt. Contull liciory ^

e JJ7

atl iog Section 4* 10

y

Ceramic and Silicon-Carbide Protecting Tubes

Ceramic and s l l lcon-carb lde pro tec t ing tubes are used in ap

p l icat ions where con tamina t ion f rom host i le env i ronments or In select ing assemblies involv ing ceramic components max i

the cut t ing act ion of concent ra ted, direct f lame impinqement m u m expected temperatures mSst be cons idered are factors. Such cond i t ions usual ly also exceed the mel t inq Some ceramic materials go through a glass phase at atevateri points of c o m m o n metals and cal l for nob le metal thermo temperatures. As si l ica is one of the p ? i m c o n t S m t o S S *

U m i n acouples (p la t inum and its al loys) ° . r l K Protect ing tubes and element insu la foS n r , K C h o , c e 8 1m i f i ° r r e ° , e m P e r a t u r o s exceed ing MOO^F C h a s s e m* . . Z l - < 3 i U 2 r , a , , y - * U . , D l l e s inc lude two inner porcela in (1316 C ) . By the same r e a s o n i n g , g lazed tubes a r e n n t n e ° U , e r° h

8 " , c o n - c a r b i d e tube. The majorrty of ap recommended for any app l ica t ion involv ing n o b l V m S S . p l i c a t o r s however, can be sat isf ied w i th one inner and one See page 15 for some typ ica l assembly detai ls. outer tube to protect against al l but the most severe condi t ions

Ceramic and Slllcon-Carblde Protecting Tube Application Data * i * " J ' ? * " , f n « Thorn™) Shock M M A „ , L , b t .

T * m P * " ' O T Ch. r^ l 9 f W i c . U ^ K h S S * Typleol AoaUctUim* 9mtm%t Sags at 2900°F

Porcelain 320O*F Poor (1593*0; prone to (Mullite) Nonlerrous metals; gas tight pro(1760*0 Must be preheated 84

attack by halogen lection lor noble metal thermo gases; some penefo 900*7 |482°C) couples to 2400°F (1316°C) tration of dry

hydrogen. Contain* f Alumina silica. ( (99% or higher fair Iron, barium, crown glass; non3400'F Preheating to Sags al 2900*F ^ pumy) (1871'C) 900°f (4d2°C)

72 lerrous mtftals; gastight proteclion (I5').l-C); prevent* lor noble mrlal thermocouples in dry hydrogen penerecommended excess ol 2400°f (1316°C). tration. 3000*F Protection against llame cutting] Silicon-Carbide (1649*0 Porous; poor outer protecting tube lor noble thermal conducmetal thermocouples. tivity.

Porcelain or Alumina Protecting Tube, Plain End

Porcelain Protecting Tube with Collar

Slut gire

Porcelain or Alumina Protecting Tube with TH-43 Ferrule Porcelain or Alumina Protecting Tube with TH 190 or TH-I91 Fitting

Porcelain Protecting Tubes* C l No. Alumina (99% Minimum Purity) Protecting Tubes to « 0.0. Conrtrucllon U n g n

U v N — ° ' O • O O Coftttructlen ,L > n r >1152 Plain End

>II53 %" • % • Plain End 1146 Plain End 12" through 48"

in 6" increments. 1155 V i 1" Plain (nd 12" through 60" t l 147 Plain End '1154 Plain End in 6" increment*,. 1152C With Collar Approx. 1148 y." * i" Plain End 12"through 72" 5/16" X 3/r in 6" increments. USX With Collar Approx." r x iy4- 12" through 72" " ' / l l * » % " 1149 Plain End _5/16" X 1 1/16" in 6" increments.

With Collar Approx 12" through 1146N vr* v "TH-50 Ferrule 12" through 4 8 " " 5/16" X 1-3/8" 60" in 6" 7/8-27 Threads in 6" increments. With Collar Approx increments. TH 43 Ferrule 12" through 60 '1147N '/,r»%- " 5/16" X 1-5/8" 7/8-27 Threads in 6" increments. With TH 50 Ferrule" 1I52N

7/8—27 Threads 'Gittad ru£>«j tvniiabit on tpocitl order

With TH-43 Fertule " ,. "wn9"**I153N ' / „ " X % " 7;r'fn'' Z!,

hngT!2&?™2SaSZg '°°10c" No *" *""*TH "''

7/8-27 Threads

Close Sleel Nipple.

1-1/2" long. 1" NPT ovtr r n%or .OSOr whKhtnr tt ami*. '

U55N V« r Dirrnnvontt Toi»r»nct: up lo t»% or Oltr whtchtvr i, a , . „ „

Close Steel Nipple. 1154N 1-1/2" long, f-1/4" NPT

11 Catalog Sect ion 4a

,

BULLETIN 9472 MAY 1980

C O N T R O L S C O R P O R A T I O N ~w

1475 S. WHEELING ROAD • WHEELING, ILLINOIS 60090 312 - 541 -3232

Display Shown Actual Size

mm

One Men Hfgh, Back Lighted, Liquid Plug-In Transformer Crystal Display "AmThermostatic Cutout Protection for Very High Accuracy Power Transformer Switch Selectable °F. or °C. Spring Return Door for Inside Panel Thermocouple, Thermistor or RTD Adjustments Input Barrier Terminal Connections Heating and Cooling Lights 120/208/240 V.A.C., 50/60 Hz. •MM l>:*vAml®?-Selectable Set Point Ranges Voltage Input

r Press-To-Set Knob Fully Gasketed Upscale or Downscale Thermocouple Made in U.S.A. .';•>! i; i •J'i'jc'S'iiy. Break Protection is Field Selectable Only 4" H.x4%'W.x 7%' Deep Full Plug-In Construction behind Panel. Fits International 3%"x

•' '' !. 4 > • 3%" Panel Cutout.Plug-In Circuit Cards>!!•:'•

•\-%W'A

DISTRIBUTORS IN MOST PRINCIPAL CITIES OF THE WORLD

MY REMOTE AIR BURNER HIGH PERFORMANCE CAPACITY RATINGS

RATING BTU /HX »70" F «3r,o"F OH. CAPACITY GAS CAPACITY HEAT RELEASE COMBUSTION AW REQULHKMKNT MODEL GPH CFH VOLUME VOLUME 140 xlO3 BTU/GAL 1*103 BTU/FT3 CFM PRESSURE* CFM PRESSURE*

4200 30 4200 900 4.5"W.C 1380 6.9" RA150 6300 45 6300 1400 5.8"W.C 2140 8.9" RA200 8400 60 8400 noo 3.8" 2750 5.8" RA250 10500 75 10500 2200 5.5" 3360 8.5" RA300 12600 90 12600 2700 5.7" 4130 8.7" RA350 14700 105 14700 2900 3.2" 4430 5.0" RA400 16800 120 16800 3350 4.2" 5120 6.4" RA500 21000 150 21000 4200 6.5" 6420 9.9" RA600 125200 180 25200 5000 4.8" 7640 7.3" RA700 29400 210 29400 5800 65" 8860 9.9"

• PRESSURE DOSS THROUGH THE BURNER ONLY (IN W.C

CONTROLS All Ray Remote Air Burners are equipped with the latest automatic programming controls and with electronic safeguard protection against pilot for flame failure. A control cabinet containing electronic flame safeguard and all the necessary motor starters, contactors, relays, control switches, circuit breakers or fuses (if specified), can be provided. Special construction cabinets are available. The burners are wired to a terminal strip in a junction box mounted on the burner for easy held connection to the terminal strip in the control cabinet. Wiring errors are thus eliminated and labor cost are reduced to minimum. Optional features are available to meet practically any combustion requirement.

AIR CONTROLS IGNITION SYSTEM The Ray Remote Air Burners are designed Gas ignition or diesel ignition. External pilot with integral air control opposed blade damp is provided to keep this assembly out of the ers for accurate control of combustion air. high temperature zone.

GUARANTEE d f o r o n e y e a r f r o m d a t e o for w^rtems^rT ** shipment against defective material

RAY REMOTE AIR BURNERS - MODELS AND SEES # l o d e l # 2 0 i l^ 2 ~ J 2 4 ~ M ^ e l RAEO-144-*6 0i l

H ^ " n l ~ ? a 8 / # 2 0 i l RAEC-144-Gas/#6 0i l RAPG -104 - Gas RAEG -104 - Gas

Model RAO is an air atomizing burner designed to burn heavier than #2 oils. Model RAP Burners are pressure atomizing and are designed to burn * 2 oil.

1

12

"burning solvent wastes. When solvent wastes and contaminated

water are both injected i n t o the combustion chamber (the usual

case) excess a i r rates are 100% or less.

A residence time i n excess of 2 seconds i s achieved at \ ( j ^ t d L ^ temperatures i n excess of 1000°C. '

The t o t a l operation pressure drop across the incinerator

system i s less than 15 inches w.c. and i s itemized as follows:

Incinerator Component Pressure Drop

Fluidized bed 35 inches w.c. (provided by f l u i d i z i n g blower)

Combustion chamber freeboard 1 inch

Ash drop and reactor 1 inch

Cyclone 5 inches

Scrubber 4.0-5.0 inches

The combustion chamber i s maintained at -1 to -2 inches w.c.

which ensures that the entire system up to the I.D. fan i s maintained

at a negative pressur to eliminate f u g i t i v e emissions.

The incinerator operates 5 days per week, 24 hours per day,

f o r 45 weeks per year (5400 hours per year). Routine and preventive

maintenance are accomplished on weekends and during non-operating

weeks. Waste feed rates are 600 to 1200 pounds per hour, or about

60 to 120 gallons per hour. The unit i s capable of in c i n e r a t i o n of

up to 2 gallons per minute of comtaminated water i n the combustion

chamber plus the evaporation of 8 gallons of "clean" water per

minute i n the quench and scrubbing systems. No aqueous e f f l u e n t

i s discharged from the incinerator.

Fuel flow rates are measured by a F l o t e l l Model M Ultrasonic

Flow Meter and checked by manually reading changes i n depth of the

primary f u e l tanks. (Fig. 34) Total combustion a i r flow rates are

measured by an Airbar Model AIR-79 (Fig. 35) manufactured by Dieterich

Standard Corporation.

Flow, temperatures, l i q u i d and air-pressure sensors are. i n

sta l l e d - a t the points shown m figuresX|6\37, 38, 39, 39A B and C.

I f read outs are below or exceed set points at any of the indicated

sensors, a complete f u e l shutdown resu l t s (Fig. 40).

Power f a i l u r e and f u e l shutdown whether triggered by set

point controls or f u e l pump f a i l u r e have no adverse environmental

PARTICLES INTERRUPTING THE SOUND BEAM CAUSE FREQUENCY SHIFT (BY DOPPLER S PRINCIPLE! WHICH IS RECEIVED BY THE LISTENING CRYSTAL THE FREQUENCY MODULATION IS DIRECTLY PROPORTIONAL TO FLOW VELOCITY

DOPPLER SHIFT PRINCIPLE - SOI IN n MADE BY MOVING OBJECT CHANGES FREQUENCY IN PROPORTION TO VELOCITY AS IT APPOACHES OR DEPARTS FROM A FIXED POINT.

TRANSMISSION RECEPTION SOUND EMISSION IS CONTINUOUS, NOT PULSED. FREQUENCY SHIFT IS DETERMINED AND PROCESSED

FLOTELU^ INDICATES FLOW/NO FLOW SITUATIONS

FIG. 1 OPERATING PRINCIPLE OF FLOTELL

-7 -1 /8" (I60.9mm>OVERALL

«•— ALLOWABLE PANEL THICKNESS: 1/16" ( I J n n l THRU 1/4" l6J«ml

A HORIZONTALLY t VERTICALLY

1/2- THRU 2" PIPE (SPACER BLOCK REOUIRED FOR.1/2" THRU 1" PIPE)

-1-7/8" (47.6 mm)

-M)MOUNTMQCLFS W/SCREWS

3-1/16" r77.7m«n)

—(2) 1/8" 2-7/18" LO PRESS i FEMALE NPT 61.6mm)

(2) 1/4" SAE FITTINGS -1-1/8" (28.5mm) FLARE FITTINGS (CATALOG # C ) (CATALOG »F )

'WALL AND PIPE MOUNTING (CATALOG # w >>• 4-fl/18"— (115 8mm)

PRCygCT:"•' U H I ' Q I A C U ^ ^ V V . ' C C L I FLUSH PANEL MOUNT (CATALOGS I

LOCATION:

METER TYPE: £ FF-F1 MOUNTING: VfX^nA

HSTRUMENT FITTINGS:

CONNECTING HARDWARE PACKAGE :

MAMMUM SCALE READING: / , 9C/ '' H ^0

UNITS: MULTIPLIER:

CO 10*C3048mm) LO x 1/4" OD. NYLON TUBING. O i 10' (3046mm) LO x 1/4" Oi). NYLON TUBMG ASSEMBLED WITH 1/4" SAE FLARE NUTS. WTTHU) 1/8- MALE NPT TO 1/4" COMPRESSION \ STANDARD E A G L E E Y E METER (CATALOG # 11 FITTINGS - UNASSEMBLED.

L»ltSrRE»i5iOt« (CATALOG #2) Omm

CONNECTING HARDWARE PACKAGES

C-9800 Ary. ^ r .3 5"

73748 07/20/81 • PILGRIM INST. Cellout AIR-79 ID-16in Wall-O.73in •

/ssed bv SM

Annubar S e r i a l Number : 73748. A. tInformation

itomer PO No. 14341

Calc. Oat* : 07/20/81 Id Type & Nam*: Oat AIR

Calc. Number: 73748.A

Equation Number 3 Gas -- Volume Flow 8 Std Conditions 2 / ( Q )2

( S ) *NxKxDi\ / p Q « C

¥ h - < — )\/ f 8 \/ w ( C > W

'•Whose Value i s INDEPENDENT of Flow ConditionT

Tarm Value Unit*

i t Conver. Factor N 4692.9

jbar Flow C o e f t V ^ K 0. 6629

>rnal Plp>^Diameter D 16 inches

> Pressure 14. 73 PSIA

> Temperature 60 F

i f l c Gravity 1. 000* SO

Whose Value i s DEPEMOENT Upon Flow Conditions:

^ ^ p t i o n

T i ™ Normal Min Flow Units

RATE 300000 130000 8CFI

ULATION CONSTANT 212634

S

212654

ling Temperature, 70 70

ing Pressure 14 14 PSIA i

ing Density 0.0713 0.0713 l b / f t 3

ERENTIAL PRESSURE 1.99 0. 498 in H20 «68F w

Restrictions: Limiting Component: wable Temperature

wable Pressure ft 70F " 200 F Airbar Assembly

wable D. P. ft 70F - 19.7 PSIA Airbar Assembly

Flow ft Alowable D.P. 3 in H20 868F

nance Flow Range - 473500 SCFH

- 6.612 to 9.917 SCFH

T>, :COMMERCIAL DRILLSHEET - MODEL AIR-79 QTY. (1) : [ IAK '(> It "

log Celloutcessed.by

: 73748 : AIR-79

: SM ID«14.Sin

07/10/81 Wall«0.73in

Annubar S e r i a l

PILORIM INST*.

Number : 79748.A.t

Inside Diameter Wall Thickness

14.300 in 0,730 in

•79 C06

'0

t c i e l

rue tlons:

Name

re Extrusion

ithout t i p )

led Stud

Tip to far edge of

Tip to Center of

3robe Length

AIRBAR

AIRBAR Assembly

Submittal Drawing

P a r t No Dimension Name—Label

3 0 2 8 2 - 0 0 Impact Hole #1 A Impact Hole #2 B Impact Hole #3 C Impact Hole #4 D Imp. Hole Size S t a t i c Hole E

Sta. Hole Size

Overall Length 0

Overall Length A

QA Checkpoints Impact Hole #1 ( 23. 01 mm)

Impact Hole #2 < 101. 83 mm)

Impact Hole #3 ( 271. 23 mm)

Impact Hole #4 < 350. 06 mm)

S t a t i c Hole ( 184. 13 mm)

QA Dimension C 33 mm) < 387.

AIRBAR

.'.V

90038-01

Value(ln)

0.812

3.913

10.383

13.688

0.187

7. 230

0. 187

13.230

1. 188

0.906

4.009

10.679

13.782

7. 230

13. 230

mm

Flow Meter

Pressure Switch

A sJiMjL_down stops these pumps

TEMPERATURE SENSING SYSTEMS

Fuel

Nozzle

From Well

Liquid Pressure Sensors * - Cause shut down i f set points exceeded

UFO" Liquid Flowmeters

©W — Level. Indicators 3S COOLING AND QUENCH WATER SYSTEMS

\ . /

\

Shut dovm results i f differential between P£ P £ exceeds set point (ft .fcbfto (Mi vi cU^aii^ •

GAS STREAM PPE-SSTTPT? SPMQnoc * ^

'! v P O R T E R

Delta-P Ce//™ Pneumatic Differential Pressure Transmitter

Type50DP i t . ,

'The Fischer & Porter Pneumatic Delta-P Cell is a non-indicating, force-balance transmitter. The Delta-P Cell 'measures differential pressure in spans between 5 and 850 inches of water or 125 and 210 kPa for range limits

^between -1060 and *1060 inches of water or -260 and v+260 kPa at static pressures from full vacuum to 3000 ;.psio or 21 MPa ga. The transmitter output is 3 to 15 psi or 20 to 100 kPa linear with differential pressure measurement.

i. J

DESIGN FEATURES

• All welded body construction

• Continuously adjustable internal damping

• Process fluid isolation

• Hastelloy C1 diaphragms and trim standard

• Positive Overrange Protection — precisely machined convolutions in body support diaphragm during overrange and handling

ENGINEERING SPECIFICATIONS

Performance: See Table 1.

Output: 3 to 15 psig or 20 to 100 kPa ga.

Supply Pressure: 20 psig (140 kPa ga).

Air Consumption: 0.16scfm (0.27 mVh) @ maximum

output.

Air Connections: 1/4-inch NPTI.

Process Connections: 1 /2-inch NPTI on 2-1 /8-inch

centers.

Bolting: Cadmium plated steel cap screws and nuts

for body and process connectors standard (Stainless

Steel optional).

Cover: Fiberglass — reinforced polyester resin.

Body: 430 Stainless Steel (non-wetted).

Filling- Liquid: Silicone oil is standard; Fluorolube2

is optionally available.

Transmitter Base: Die Cast Aluminum.

Flange Gasket: Teflon3 seal

1. T.M.. Cabot Corporation 2. T.M.,. Hooker Chemical Company 3. T.M.. E.I. DuPonl do Nemours Co.. Inc

Mounting: Direct to process or with bracket for 2-inch horizontal or vertical pipe.

Diaphragm and Trim: Hastelloy C standard, other materials available — see list in model number-designation.

Flange and Adaptor: Cadmium plated carbon steel or 316 Stainless Steel standard — other materials optionally available, see list in model number designation.

ORDERING INFORMATION

Please Specify.

Model Number

Span

Range

Range Elevation or Suppression Fill Liquid

Output (3 to 15 psig or 20 to 100 kPa ga)

Optional Equipment

Integral Orifice

Specify: service (gas or liquid) flow, density, viscosity, pressure, temperature, and maximum allowable differential.

y

j Pneumatic Concept 45® \indicating Control Station

»• ii

Type 51 PC The F&P Concept 45 Indicating Control Station is a miniature (3" x 6" or 76 mm x 152 mm), panel-m'nted pneumatic controller operating on a 3-15 psig 20-100 kPa or a 0.2 to 1.0 kg/cm 2 input. The instrument can be provided with either a one, two, or three-mode controller, is available for either multiple or high density mounting; and includes continuous indication of process, set point and output. Balanceless, bumptess transfer from both automatic and manual position is a standard feature.

DESIGN FEATURES

• A pre-set manual permits the operator to preselect an output for each station and quickly switch to this value in an emergency.

• ' Short case depth — only 18 inches (457 mm).

• Batancetess, bumpless transfer.

• Modular construction permits interchange of all types and options of controllers with minimum number of parts.

Individual instrument cases.

ENGINEERING SPECIFICATIONS

Input: 3-15 psig, 0.2 to 1 kg/cm' or 20-100 kPa

Output: 3-15 psig nominal; minimum 0 psig; maximum

within 1 psig of supply pressure.

Temperature Limits: +40 to +125°F (4 to 52°C)

Temperature Effect: ±0.5% of span per 50°F (28°C)

Humidity: 10 to 95% relative humidity© 100°F(38°C)

Calibrated Accuracy: ±0.5% of scale span

Air Supply Requirements: 20 psig +2 psig (140 kPa

+14 kPa)

Steady State Air Consumption: 0.3 scfrn (0.5 mVh)

(complete station) @ 9 psig (60 kPa) output!

User Connections: 1 /4-inch NPTI - rear of case Terminal strip if alarms or lights are used.

Materials of Construction: All steel case with diecast bezel, Lexan window.

•1

Color: Standard bezel color is black; other colors are available.

Scales: Vertical - 4-inch (101.6 mm) length 1-3/4inch (44.5 mm) width Horizontal (output) scale 2-inch (50.8 mm) length, 0 to 100% markings

Identification: Front nameplate, typewritten on cardboard and protected by plastic. 2 lines, maximum of 24 characters per line. Engraved plastic nameplates available as an option. Rear of instrument includes an aluminum tag. screwed on.

Auto-Manual Transfer: Balanceless Bumpless. Manual tracks controller output when in automatic position In manual position, controller output tracks manual with set point remaining stationary. When switching to automatic, controller output corrects deviation' between process and set point at the reset rate.

Case Dimension: Depth 18-inches (457 mm). Bezel 6-11/16-inches (170 mm) high by 3-inches (76 mm) wide. Panel cutout 3 x 6 inches (76 x 150 mm).

Weight: 16 pounds (7.3 kilograms)

Upper Chassis — Control ler and

Indication Section

Chassis: Removable while manual section remains in the case. Slides to a locked service position for control mode adjustments or routine maintenance.

Accuracy: ±0.5% of input span

Repeatability: 0.1% of input span at 100% proportional band.

Supply Pressure Effect: 0.01 psig per 2 psig at 100% proportional band.

Capacity (at station output): 1.5 scfrn @ 9 psig output

Set Point: Local or remote; ±0.5% of span accuracy tracking ±0.5% of span. .

i

fry J9CPER

K ir" Concept 45® Pneumatic Indicators and Manual Loaders h,

Type 51 PG and 51PM

These Indicators and Manual Loaders are companion • Pieces to the Concept 45 Indicating Control System

Frontal appearance is harmonious with the controller

sinceithe same bezel, scale and pointers are used on

the entire line of instruments.

The Indicator is available in a single or dual pointer

version. Internal switches for high and low alarms

with lights, are optionally available for one variable'

In the dual pointer model, the alarms may be transferred

from one variable to the other by shifting a link.

Manual Loaders are available with or without remote/

local switching and single or dual pointers, one always

indicating regulator output. High and low alarm

switches, with lights, are available for only one variable

m a dual pointer unit

DESIGN FEATURES

• Short case depthj-onty 18 inches (45.7 cm)

' ' ''" I • Modular construction permits interchange of all

types and options of indicators and manual loaders

with minimum number of parts.

• Indicator can be changed to a Manual Loader or

vice versa, with component parts, in the field.

• Individual instrument cases regardless of type of

mounting—single, multiple or high density.

• Excellent readability from all parts of the control

room. Scale is 1-3/4 x 4 in (4 * 10 cm).

ENGINEERING SPECIFICATIONS

Input: 3-15 psig or 20 to 100 kPa ga

Accuracy: 10.5% of span

Repeatability: 0.1% of span

Temperature Limits: +40 to +125°F (+4 to +52°C)

Temperature Effects: ± 0.5% of input span per 50°F (28 °C)

User Connections: 1/4 inch NPTI-rear of case

Terminal strip and conduit box if alarms and liahts are

specified.

Chassis: Slideout

mm

51 PG Indicator

51PM Manual Loader

• Los s A.c f ] o t v /

CRI06-?

• S t o p

*s

f SPEED A

•a 3 CON0.TWISTED T2d is RUN JOG

V •a is START

STOP _ L _

SHUTDOWN

3bA CR103 TR103 32 B

• CR112-3 2£

ASPU3A

11 SF-2

X-1 X-2 NO'.S UNDERLINED IN RELIANCE CONTROLLER 0" -Q • FIELO TERMINAL BLOCK TR 103 ( ) TERMINAL NQ.ON DEVICE

TDAE 0-50S

6 i i £2 HCS 103

14 V • * I M « |

LIQUID FUEL FEED

.« w-«UNION CHEMICAL CO.

UNION CHEMICAL CO. WIRING SCHEMATIC

THE LEEN CO. NTS 9/2/B1 ...ORH r K i t ' l l .

irder for the l i q u i d fuel feed pump to run.switches,

CJU03, CR112-3. and TR103 or ASPI13A must be closed.

Switch CR103 opens when ever there is a safety shutdown/

Switch CRU2-3 closes when the bed temperature reaches a

preset minium safe ignition temperature. TR103 is a timed

switch which opens in 50 sec. i f the switch ASPI13A is not

closed by the combustion temperature reaching a preset

temperature, indicating that ignition has taken place.

- 2?

impact. At any point i n time the amount of residual f u e l i n the

bed and combustion zone i s i n s i g n i f i c a n t since the f u e l i s burned

as i t i s fed. Tests have shown a 0.5 - 2 seconds a f t e r burn on loss

of power or f u e l .

Stack gas is monitored and recorded continuously f o r THC, CO,

COgi using i n f r a red detectors manufactured by Infrared Industries

Model 7?23, (Fig. 4 l ) . Stack gas opacity is monitored by a Wager

Model VM-8A (Fig. 42) Unfortunately, the high vapor content of

the stack gas minimizes the effectiveness of the opacity monitoring

device. Continuous samples are conditioned and pumped from the

stack platform through a t e f l o n tube to the monitors i n the control

room.

PH c o n t r o l , monitoring and recording i n the quench tower and

scrubber i s performed by a - Fisher-Porter pH sensor c o n t r o l l i n g a

Wallace and Tiernan lime feeder (Figures 43,44,45). PH electrodes

are located i n sumps which are part of the quench tower and scrubbing

l i q u i d c i r c u l a t i n g systems.

WASTE ANALYSIS PLAN

Since Union Chemical Co., Inc. operates a solvent recycling

f a c i l i t y as well as a hazardous waste incinerator. The type of

wastes to be incinerated w i l l vary and w i l l include a number of

chlorinated and f l u o r i n a t e d compounds which are high on the l i s t

of POHC's prepared by EPA.

These: compounds include Tetrachlorethylene, 1,1,2 Trichloro

1,2,2 Trifluoroethane, 1,1,1, Trichloroethane, Trichloroethylene

and Methylene Chloride. I n addition flammable POHC's are included

such as Xylenes and Toluene.

During a test burn conducted by GCA Corporation f o r EPA i n

June of 1982 concentrations of these compounds were as follows.

Tetrachloroethylene 3.3%, 1,1,2 Trichloro, 1,2,2 Trifluoroethane

3.0$ 1,1,1 Trichloroethane 3-4% and Trichlorethylene 2.4$.

Viscosity of the waste fed to the incinerator varies from

2000 - 3000 centipoise. BTU content of the waste varies from 8_,.0.0.0

to 12.000 BTU per l b . Ash content can vary from 5$ to 20$. Total

non-volatile (150°C) ranges from 10-40$. Moisture content varies

from zero to 15$«

The waste to be used f o r the te s t burn w i l l be sim i l a r to a

blend being burned at t h i s time. The following is an analysis of

ZIR.7700 R A C K MOUMTED

GUS ANALYZER

This rack mounted gas analyzer offers

the greatest flexibility to the user who

requires multiple gas analysis. Up to

four gases can be monitored. Two

.difforent samples can be analyzed at the same time. Oxygen, CO, CO?, Hydrocarbons and many other gases can bo chockod.|A linearized digital display Is provided with recorder output. Built in 4-20mA outputs and setpoint alarm outputs are optional.

OPTIONS Oxygen pump Trace oxygen cell Sample cell heater (NDIR) 4-20 mA output 1-5 mA output Setpoint alarms i

RACK MOUNT ACCESSORIES (19 x 8%)

1-2 or 3 pen chart recorder with 10" chart width and multiple chart speed selector

Gas sample conditioner with dryer for water vapor extraction

Multipoint live sample selector.unit with electronic sequence timer

r - "7 J

• A N A L Y Z E S U P T O 4 G A S E S

• 19" R A C K M O U N T E D

• O X Y G E N A N A L Y S I S C A P A B I L I T Y

e D I G I T A L D I S P L A Y S

APPLICATIONS • Combustion Efficiency • Controlled Atmospheres • Respiration Studies • Hydrocarbon Monitoring • Oxyaon Analysis Applications • Complete Monitor & Control Systems

FEATURES/BENEFITS

13 combinations of sonsor units provide unexcelled .

flexibility and performance

Easy access for maintenance simplicity

Internal electronic options and linearizers on plug-in p.c.

board:;

Brushed aluminum and black front panel harmonizes

with other rack mounted units

Ball bec.ng slides

Linear digital direct reading displays .

Comp ict design provides greatest economy of

instal Hon

REAR PANEL TERMINAL STRIPS INCLUDE: Linear recorder outputs for each gas Logic outputs for remote indication of rango solectlon for each gas Logic outputs for romoto indication of "chock" function activation International power input selector for 100-120-220-240V50/60 Hz Dual sample gas input fittings for either series or parallel sample analysis Linear 4-20 mA transmitter outputs for each gas (optional) Dual sotpoint alarm with NO & NC dry contacts for each gas (optional J Low electrolyte indicator (oxygen)

ASSTEKOLUTEKOLUMM ASSOCIATFS INP LEXINGTONItXlNGlON. MA. 02173

617-862-7734617-862

I N F R A R E D INDUSTRIES, INC.1

/ /

I

/ MODEL IR-1100 SERIES

GAS SAMPLE CONDITIONING SYSTEMS FOR

STACK MONITORING

The IR-1100 Series Gas Sample Conditioning Systems are designed lo provide filtered, dry sample gas to the analyzer under the harshest of industrial environments.

The filtered sample is Introduced to a Perma Pure permeation dryer where water Is removed without condensation. The dryer provides sample gas at a dewpoint well below ambient temperatures which permits transporting sample to the analyzer without requiring heated lines. Ball valves are provided for the manual introduction of calibration gases and lor blowback of the probe filter.

The modular design of the IR-1100 Series permits the customer to soloct an IRI system which will best meet his specific sampling requirements. Probos are available in lengths up to 6 foot and special materials, such as Hastelloy C or Carpenter 20, are available as options.

Spocial probo mountings are availablo to permit traverse moa3uroment8 in stacks. Special Perma Pure drying systems can be offered to provide extremely dry sample gas lor those analyzers where water vapor acts as an interferent. Electrically-actuated and air-actuated ball valves are available as options to provide automatic calibration and automatic blowback features.

I P

Infrared Industries, Inc. Western Division, Instrumentation Group P.O. Box 989. Santa Barbara, CA 93102 (805) 684-4181 • Telex 658-480

NEVER AN INKING PROBLEM, thermal writing system that never drys. clots or runs out of ink- never

blots, smears, so.ls hands or clothing. Thermal stylus draws a finer line than felt tip pen. Watanabo Servocordcr Models SR6311 and SR6312, because the high resolution high contrast trace is produced by a tiny

thermal source on thermally sensitivity paper.

TRACE IDENTIFICATION IS EASY, even though the pens overlap on the 10 inch wide chart, because

pen one produces a red trace and pen two produces a black trace.

PUSH BUTTON SELECTABLE CHART SPEEDS, CHART REWIND CAPABILITY AND USE OF

ZFOLD CHARTS makes these strip chart recorders easy to use and convenient for data review.

ROLL CHART.PAPER USE 'is also optionally available and for data review, it is capable of rewinding the

entire length of the chart paper. *

ELEVEN PLUG-IN SIGNAL CONDITIONERS increase the applications flexibility and utility of these

compact machines for a wide range of performance for general or specialized use

RACK MOUNT. BENCH TOP OR PORTABLE, the Watanabe SR6311 . 6312 Servocorders are dependable, rugged and versatile.

UNIQUE PRINT HEAD OPTION is available to record time, lot number or other data more conveniently

displayed In digital form. .

*• ! MANUFACTURER'S NAME

Robert H. Wager Co., I n c . —

; Pa8sale Avenue

: Chatham, New Jersey 07928

2. APPLICATION

U S m k e I n d l c a t i n *I « e e s o r £ ° ****** *-8A complete with

3. CUSTOMLR

Union Chemical Co., Inc.

*• EQUIPMENT SUPPLIED PER SYSTEM

Name of Part Part No.

Receiving Unit 122-D0001

Lamp Unit 118-D0034

Amplifier Cabinet 122-D0077

Voltage Regulator 118-B0037

Purge Air Flange 150-C0001

Damper Unit 110A

Certified Correct

Certification Data Sheet

Wager Photoelectric Smoke Smoke Indicating System

M-8A

Robert H. Wager Co., Inc. Passaic Avenue Chatham, New Jersey 07928

Approval Date

Tel: 201-635-9200

Job Wo. 31-1072

7/13/81

/"/ j u v- £

REMOTE START/STOP

CONTROL CONFIGURATIONS

V ftiW'wA. Mats FOR powen a W*WO CONNECTION

MOONTi(0 BRACKET ' « * REMOTE CONTROL fttNEL)

«> W »A. UOVNTMQ MOUO

E M 0 U N T I N G/A.VUAVC D m . r ? ? i

0 T ARRANGEMENT

ALWAYS REQ'D FOR FM APPROVED CLASS H.DIVISIONI,

GROUPS E,F 8 G HAZARDOUS LOCATIONS •)

Y A R T , C L C 9 0 0° B ° ' N E C^ " ' * T « ' S "OLE IS PRESENT ONLY ON THE AUTC-mA CONTROL CONFIGURATION.

CONTROLLED VOLUMETRIC FEEDER-TYP| E (SUN?TALLATION ACBtTiBRNAN Control Panel Arrangements 3EWWUJ •

/ , j u ^ e L . / J 320055.110.021 ISSUE 0 i-ei

I" 'f>

177730 Rev. H Operator's and Service Manual

7075-3 pH RECEIVER

AND ELECTRODE PREAMPLIFIER

M r

LEEDS

SPECIFICATIONS

OPERATING PERFORMANCE

INPUT R A N G E S

0-14 pH. 2-12 pH. M cE(underRe,erenceo^',inPE^iRn sr «c^ V O L T A G E O U T P U T

SVlTT£°latZCl C U r r e m °U,DUHo' V2 « ™. 4-20. d e v e l 0 D i n Repeatability: 0.25% of span. maximum ' °' ^ 9 "P to 16 V

F E A T U R E S 2 R 5 E * F C ? 7 7 ^ E ^ ^ N O CONDIT IONS C a m b i e n tTransient protected power line an* i = , 10 i r ? 1 £ ? * , e m P ^ a t u r e . a 10 to 40% relative humidity

Optiona, l ightn ing-pJectod p'^ampfs 120 or 240 Vac line.

POWER R E Q U I R E M E N T S OPERATING INFLUENCES (Under Normal

" n ° m , n a ' ^Z i m u m 2 ^ 4 0 V Hz, Operat ing Condi t ions)

Effect on accuracy in porcont of span

0 1 % per °C temperature influence '

E L E C T R I C A L C L A S S I F I C A T I O N Less than 0.1% humidity influence '

Class I. Group B. Division 2 (when hermetic relays are 0.1% per volt line-voltage influence.

NORMAL OPERATING CONDIT IONS ALARMS 4 , 0 1 4 0 ) a m b i e n ti0°to°9w ° ? / 1 ° F temperature.

10 to 95% relative humidity . ^ o n , a c , s 3 Aac or 28 V dr- i «; A i - . . inductive 120 V m. ur « v ac. 1.5 A Inductive at 240 V ac.

100 to 132 or 200 to 264 V. 50/60 Hz.

P H Y S I C A L DATA ALARM CIRCUITS Case. 5-1/2" H x 8-5/8" W x 5-11/16" D (14 x 21 8 x 14 a High or low mode of operation, field selectable cm). Approximate weight 5 5 lb 1 2 a n d 3 R(corrosion resistant rainoroo i n n

n

, * d u s t Hysteresis. 2% of full scale. suitable for o u t d o o M ^ «0h«>.

Repeatability: 0.25% of full scale. panel. installation. Mounts on wall, pipe or

TABLE I - SUFFIX DESIGNATIONS A , B

ro75-3-[^jt3.6&t3& 2 o C Suffix B—Range 0 to 14 pH

147 2 lo 12 pH 107

Suffix C -L l ne Voltage 120 V, 60 Hz 240 V. 60 Hz ( l 2 o )

240 Suffix D - m A Oulput and Alarm Relay, No mA output; unsealed relays No mA output; sealed relays Go2)

032 mA output; unsealed relays 202 mA output; selaed relays 232

ifcfcfr 4 Northrup Company — 177730

4 v

277128 Rev. B

OPERATOR'S MANUAL

7081 pH MICROPROCESSOR RECEIVER/CONTROLLER

LEEDS & NORTHRUP

A U N I T O p G E N E R A L S I G N A L

SPECIFICATIONS

Range; 0 to 14 pH, -20 to 140°C. 0 to 999 flow u n j t s(optional).

K e T r f s ' g X r ^ ' ' ^ ° ' ^ « 1 « ~ unit. Non-Isolated pH Output-1

- 38

t h i s waste (St3-92783-l)

Methyl Alcohol approximately 2% Ethyl Alcohol 1% Acetone 2% Isopropyl Alcohol 3% Methylene Chloride 2% Freon 2% Methyl Ethyl Ketone 6% Ethyl Acetate 1% 1,1,1 Trichloroethane 9% Trichlorethylene 2% Methyl Isobutyl Ketone 1% Toluene Q% Butyl Acetate 1% Perchlorethylene 11% Xylene k% . Water 12% Ash j¥%_ Non V o l a t i l e @ 150°C 30?S(excluding Ash) BTU Content 10,000 BTU/lb^ Density 9-01 lbs./gal.

The water content of t h i s waste i s higher than normal and

as a r e s u l t the net BTU content i s a l i t t l e low. Ash i s also

lower than normal. I t i s anticipated that the actual test burn

material w i l l have a water content of less than 5% and as ash content of 7-9%. I t i s also planned to spike the waste with trichloromonofluro methane to obtain a concentration of 3-5% f o r the test burn.

INCINERATOR OPERATION.DATA AT STEADY STATE

Waste Feed Rate 1.0 - 1.5 gallon/min.

Contaminated Water Feed Rate 1 - 2 gallons/min.

Combustion Temperature 2000-2200°F

Bed Temperature 1300-1700°F

Stack Gas Volume CA 5500 ACFM

Stack Gas Velcoity CA 1750 FPM

Residence Time at 1000°C plus 2 seconds

Stack Gas Temperature 150°F

- 39

Scrubber C i r c u l a t i n g Rate 120 gpm

Quench Flow Rate 1 2 - 1 5 gpm

Scrubber pH 6.0 - 7.0

Quench pH 5.0 - 7.0

Total Combustion A i r i n 1500-1800 CFM

Total F l u i d i z i n g A i r 300 - 450 CFM

The above steady state conditions are the conditions that

w i l l be used f o r the test burn. I t should be noted that with

t h i s type of incinerator, the primary control e f f o r t i s to achieve

2000-2200°F i n the .combustion zone, i f a lower BTU waste i s used

than a higher feed rate i s necessary to maintain these temperatures

with the optimum amount of combustion a i r to ensure proper

turbulence. During the tests mentioned e a r l i e r by GCA Corporation

feed rates and combustion a i r flows varied by more than 25% with no s i g n i f i c a n t d i f f e r e n t i n DRE. During the l a s t year of operation

the only s i g n i f i c a n t difference noted when burning halogenated or

non-halogenated wastes has been bed temperature which i s a r e

f l e c t i o n of the amount of ash and non-volatile material i n the

waste. As an approximate r u l e , halogenated wastes have a higher

non-volatile portion ( f a t s , greases and o i l s ) and a lower ash

content. As a r e s u l t bed temperatures are higher and become a

l i m i t i n g factor on burning rate because the combustion a i r

(cooling) going through the bed i s l i m i t e d by the point of bed

slugging.

During: the test burn the following sampling, monitoring and

a n a l y t i c a l data w i l l be obtained. (Sampling points Figure 46)

1. Waste feed rat e .

2. Total combustion a i r flow rate.

3« Contaminated water feed rate>

4. Temperatures i n bed, combustion zone, cyclone, Quench

tower e x i t and stack.

5» Quench water flow r a t e .

6. Scrubber water flow r a t e .

7- Ash production per u n i t time.

8. Quench tower and scrubber pH.

9. Lime feed r a t e .

10. THC, Co, C02 i n stack gas.

Schematic of Union Chemical f luidized bed incineration system.

I

- 41

Sampling f o r analysis w i l l include the following.

1. Fuel f o r POHC's: Ash, BTU, Chlorine, Metals

2. Contaminated water: Chlorine

3. Ash: POKC's heavy metals (EP t o x i c i t y plus beryllium)

4. Scrubber water: l-OHC's and 1- IC • s 5- Scrubber water supply (blank sample).

6. Stack gas samples: Particulates, HCL, POKC's and

PIC's,Metals

GCA Corporation of Bedford, Massachusetts has been assigned

the contract to perform the test burn. They have submitted a

complete test burn plan including QA and QC to the Department of

Environmental Protection.

The plan submitted to Union Chemical Co., Inc. by GCA

Corporation has simutaneously been submitted to the EPA and

Maine DEP. I t i s E n t i t l e d Quality Assurance Project Plan

GCA Project #7-468-001.

I t i s essential that the above mentioned document be

studied along with the Union Chemical Co., Inc. test burn plan.

Emergency Shutdown System Test (\|)|\|

Tests of three of the emergency shutoff systems w i l l be

conducted immediately a f t e r the f i r s t sampling run ( t e n t a t i v e l y

scheduled f o r H/3/83).

The shut o f f systems tested w i l l be:

1. Proof of a i r flow.

2. Combustion chamber low temperature.

3- Scrubber water pump low pressure.

Proof of a i r flow i s obtained by measuring the pressure

d i f f e r e n t i a l across the cyclone. The set point i s at 0.5-1.0

inches w.c. I f a f t e r s t a r t , the pressure drop is down to that

point an automatic f u e l shutdown occurs. This w i l l be simulated

by disconnecting one of the pressure detectors on the cyclone.

This w i l l duplicate a drop i n d i f f e r e n t i a l pressure and test the

e ntire emergency shutdown switching sequences.

Tests number 2 and number 3 can be accomplished by either

placing jumpers across switches CR114-1 f o r number 2 and TR125A-1

f o r number 3 these switches are shown on page 24.

The closing of TR125A-1 causes a warning l i g h t to come on,

- 4 2 - iW an alarm to r i n g and activates a timing c i r c u i t which w i l l shut

down the burner i f the pressure i s not above the set point i n

100 seconds. I t has been determined the enough water remains

i n ths scrubber (the pump delivers i n excess of 100 gallons per

minute at the 10 l b . pressure set point) to maintain the scrubber

action of the equipment during that time period.

Tests number 2 and 3 can also be performed by changing the

set points to i n i t i a t e the shutdown however, operators have s t r i c t

i n s t r u c t i o n s , never to change set points.

INCINERATOR START UP PROCEDURE

NOTE: THIS PROCEDURE IS NOT TO BE CHANGED OR MODIFIED WITHOUT

PREVIOUS PERMISSION TO DO SO.

1. Power up instrument panel.

2. Make sure a l l a i r i s on.

3. Make sure f u e l nozzle i s clean.

4. Make sure a l l water f i l t e r s are clean and open valve to

well or brook water.

5. Open water tank feed valves.

6. Make sure a l l outlet (discharge) valves are closed before

pumps are started.

7. Start pumps and slowly open discharge valves and check_

output-pressure on scrubber pump & cooling pump. Cooling

pump should be c i r c u l a t i n g from quench tank only.

8. Check cooling water flow. (Should be 50-705$)

9. Check the cooling nozzles on quench tower and one on fan

entrance.

10. Start quench tower c i r c . pump and adjust approximate

flow rates.

A. S e t t l i n g Tank 2-5 gpm

B. pH electrode chamber 1 gpm

11. Clear and drain I.D. fan and catch pan next to scrubber.

12. Manually open and close ( a l l dampers) confirm by vi s u a l

inspection. Leave i n closed p o s i t i o n . I.D. fan_damper ,

should always be i n closed position before s t a r t i n g .

13. Start I.D. fan

14. Start cyclone & ash drop out rotary valves & make sure

they are clear.

15. Turn on lime s l u r r y tank water feed, adjust rate to match

lime feed rate (approx. 2 gpm)

16. Start lime s t i r r e r i f not running and check lime feeder

operation.

A. Check belts

B. Clean outlet

C. Check feed rate

- 2

1?. Turn on a i r to lime s l u r r y pump seal-cooling tank.

A. Check water l e v e l

B. Open valves on tank

18. Start Quench Tower f i l l pump (use c i r c . mode u n t i l burner

i s up to operation temp, ad.just flow 6-12 gpm, psi 30-60.

19. Start Slurry pump (discharge valve should be closed)

A. Slowly open discharge valve

B. Check pressure

C. Check flow (2 gpm minimum through back pressure valve)

20. Check tank levels of f u e l o i l , cooling water, d i r t y water.

21. Drain primary collector on stack sample t r a i n .

22. Start f l u i d i z i n g fan.

23. Start preheat burner.

A. Open a i r damper to 5 notches or u n t i l a i r flow i s

greater than 100 ft/m but less then 1500 f t / m i n .

B. Open a i r l i n e .

C. Turn on o i l (80-100 psi o f f ) (10-20 psi when burning)

D. Turn on gas. (4 psi normal running pressure)

E. Turn switch to "Run" leave on u n t i l under bed temp,

reads 50 .

F. Turn "Off" and wait u n t i l temp, drops 100° below the

peak temp, achieved.

G. Repeat E & F

H. Turn to "Run" leave on u n t i l underbed temperature reads

50 then turn o f f .

I . When temperature reaches i t s peak, tu r n burner to Run

u n t i l underbed temperature i s 50 above the reading at

the time of i g n i t i o n , then turn o f f .

f

J. .Repeat I u n t i l peak temp, reached i s above 600°F.

K. Turn preheat switch to "Auto" adjust cycle time, to

give 5 temp, r i s e m bed of not more than 200 /hr.

(approx. 2 i min. on/2j min. o f f ) .

L. When bed temp, reaches 500°F tur n preheat to "Run"

(maintain 200 /hr r i s e ) .

24. I n s t a l l clean pH electrodes i n scrubber and quench tower.

- 3

A. Turn on pH meters

B. Start chart recorder and mark date and time.

C. Standardize pH.

25> Check f u e l flow rate with stop-watch and record time to

f i l l 1 g a l . & flow meter reading.

26. I n s t a l l f u e l nozzle when bed reaches 800°F.

A. Clean & dry nozzle make sure nozzle i s closed.

B. Remove cover plate (need 2 wrenches 3/4" & adjustable

C. Put a i r hose on and tighten clamps.

D. Turn a i r on (cycle timer) immediately.

E. Put nozzle about way i n .

F. Shut o f f cooling water valve.

G. Disconnect hoses & connect to nozzle.

H. Turn cooling water on.

I . Put nozzle a l l the way i n and bo l t i n place.

J. Connect f u e l l i n e .

K. Turn smoke indicator on.

27. Open by-pass on f u e l l i n e and with pump at a s e t t i n g of 4

record the time to deliver 1 gallon of f u e l .

28. When bed temp, is above 1128°F open overfi r e dampers 1,2

5 notches and 3» 10 notches.

29. Put overfire a i r damper co n t r o l l e r on manual, open damper

40-50^.

30. Set combustion chamber temp, set-pt. (black) (1200°F).

31. Set l i q u i d f u e l pump to approx. 3i«

32. Push " s t a r t " button. (You now have 100 sec. to reach temp,

s e t - i n stemp 22).

33* I f you don't reach the set point temp, repeat step 24.

34. V i s i b l y check condition of flame i f necessary adjust

o v erfire a i r to f i v e a yellowish orange flame & keep

stack smoke free.

35« I f f i r e i s stable bed, temp, approx. 1200 and other temp,

climbing steadily preheat burner can be turned " o f f " .

- 4

36. Adjust preheat a i r damper to an a i r flow of 13-1500 ft./min

and turn o f f a i r l i n e .

37. For next 1 hr. slowly increase f u e l feed u n t i l you have a

steady 2000 - 2100 F operating temp, (flame condition should

be checked a f t e r each increase i n f u e l flow see step 27).

38. After f i r e has been stable f o r i hour s t a r t d i r t y water

m combustion space.

A. Turn on tank.

B. Start pump.

C. Check pressure.

D. Check nozzle.

E. Check flow gauge.

F. With nozzle flow jus t barely on, i n s t a l l nozzle.

G. Increase flow to desired l e v e l .

39- Check ash-dropout & cyclone c o l l e c t i o n drums.

40. Record data.

- 1

INCINERATOR SHUT-DOWN PROCEEDURE

1. Turn o f f f u e l switch.

(a) Close f u e l valve (manual wheel)

2. Close manual under bed a i r valve (next to preheater).

3« Remove d i r t y water nozzle.

(a) Shut-Off d i r t y water pump

4. Check to see that the over f i r e valve i s f u l l y closed, (automatic)

(ALTERNATE STEPS)

4a. Close a l l f i v e o v e r f i r e manual valves.

4b. Shut o f f f l u i d i z i n g fan.

( I f Shut-Down is longer than 30 minutes)

5« Shut o f f I.D. fan a f t e r not less than (15 minutes).

FOR MINIM-UK COOL DOWN TIME

1. Shut o f f f u e l switch.

( a ) . Close f u e l valve (manual wheel)

2. Remove d i r t y water nozzle,

(a) Shut-Off d i r t y water pump

3« Switch over f i r e control to manual

(a) Open a l l over-fire manual valves maxium.

4. Switch I.D. fan to manual and open damper.

NOTE: Keep careful eye on quench tower temperature.

LONG-TERM (more than 4 hours)

1. Shut o f f f u e l switch.

(a) Close f u e l valve (manual wheel)

2. Close manual under bed a i r valve (next to preheater)

3« Remove d i r y water nozzle.

(a) Shut-Off d i r t y water pump

4a. Close a l l f i v e overfire namual valves.

4b. Shut o f f f l u i d i z i n g fan.

5- Remove f u e l nozzle

6. Shut-Off lime feeder valves on Q.T. & Scrubber

7« Shut-Off I.D. fan when vapor space temperature reaches 1100°F.

8. Shut-Down quench tower cooling pump, (cooling pump #1)

- 2

9. Shut-Down cooling pump r/2 (aux heat exchangers quench make-up)

10. Shut-Down scrubber pump

( I f More Than 24 Hours)

11. Shut down lime s l u r r y pump.

(a) Slurry tank must be no more than ^ f u l l .

(b) Start f l u s h water and fl u s h f o r not less than 9 minutes.

(c) After 9 minutes of flus h open lime feed pinch-valve manium

f o r 30 seconds.

(d) Shut-Off pump

12. Put pH meters on stand by.

13« Put stack-gas analyser on blow-back c a l i b r a t e .

.14. Shut-Off cyclone rotary valve.

15. Shut-Off ash drop-out rotary valve.

16. Shut-Down flow meters ( f u e l * water).

17. Turn o f f instrument a i r ( a i r operators).

18. Remover pH electrodes and place i n bath.

lit

ft

Union Chemical P.O. Number 5412

GCA Project Number 7-468-001

QUALITY ASSURANCE PROJECT PLAN

UNION CHEMICAL TRIAL BURN

SAMPLING AND ANALYSIS

Robert Hall

Mary Kozik

Mark McCabe

Michael White

GCA CORPORATION

GCA/TECHNOLOGY DIVISION

BEDFORD, MASSACHUSETTS 01730

CONTENTS

P i 8 u r e » » Tables i v

1.0 Project Description i . 1 Overview * *

v

1

2.0

1.2 Facility Description. . ' . ' . ' . ' . ' . ' . ' . ' . I ' . ] ' . ]1.3 Sampling and Analysis ! 1.4 Schedule and Reporting

Project Organization # '

' ' \

, \ "

4.1 Liquid and Solid Sample Stream Identification .' ! ! ! ll 4.2 Flue Gas

5.0 Sample Custody ! ! ! ! ! ! 3^

5.1 Field Sampling Operations

31

5.2 Laboratory Operations

32

6.0 Calibration Procedures and Frequency

33

6.1 Source Sampling Equipment i i i ! ! ! ! ! ! 33

6.2 Analytical Instrumentation 34 7.0 Analytical Procedures

40

7.1 Field Measurements

7.2 Organic Laboratory Analysis Procedures . . . . ! ! ! 43

7.3 Chloride Laboratory Analysis Procedures ! 48

7.4 EP Toxicity—Trace Metals Laboratory Analysis

Procedures 5 0

8.0 Data Reduction, Validation and Reporting . . ! ! ! ! ! ! ! 51

8.1 Data Reduction. 51

8.2 Data Validation 51

8.3 Data Reporting. 53

8.4 Identification and Treatment of Outliers. . . ! ! ! ! 55

9.0 Internal Quality Control Checks ! ! 5 6

10.0 Performance and System Audits ! ! ! ! ! 58

10.1 Performance Audits ! ! ! * * * 58

10.2 System Audits 58

10.3 External Audits ! ! * * " " 59

11.0 Preventive Maintenance ! ! ! ! ! ! ! ! ! * 60

12.0 Assessment of Data Precision, Accuracy and Completeness! 63

12.1 Precision Estimates 63

12.2 Accuracy Estimates 65

12.3 Completeness 66

i i

CONTENTS (continued)

13.0 Corrective Action $7 14.0 Quality Assurance Reports to Management 71

14.1 Internal Reporting 71

14.2 Reports to the Client 71

References 73

Appendices

A. Data Sheets 74

B. Sample Calculations 95

i i i

Number

1-1

2-1

4-1

4-2

4-3

8-1

13-1

FIGURES

Pafce

Schematic of Union Chemical fluidized bed incineration

8 y 8 t e m

Project organization and responsibility. . 15

Schematic of RAC Staksamplr™ . . . . . 23

Schematic of volatile organic sampling train . . . . 25

Integrated gas sampling train . . . . 27

Data flow scheme • • . • 52

A closed-loop corrective acti :ion system

iv

TABLES

Number

Pa&e

1-1 Summary of Sample Streams and Required Measurements. . . . 6

1-2 Summary of Sampling and Analysis Plans for Liquid and

Solid Streams

7

1-3 Summary of Flue Gas Sampling and Analysis 11

1-4 Example POHC Concentrations i n the Stack Gas at Selected

Waste Feed Concentrations and Destruction Efficiencies . 12

1-5 Sampling Schedule 13

3-1 Goals for Precision, Accuracy and Completeness—Sampling . 17

3- 2 Goals for Precision, Accuracy and Completeneas-Analytical 18

4- 1 Solid and Liquid Sampling Scheme 20

4-2 Flue Gas Sampling Summary 29

6- 1 PFTBA Key Ion Abundance Criter ia 36

7-1 GC/TCD Operating Conditions for the Analysis of Fixed uases. . . . .

41

7-2

GC/ECD Operating Conditions, for Tedlar Bag Analysis. . . . 4 2

7-3

GC/MS Conditions for Volatile Organics Analyses 44

7-4 GC/MS Instrument Operating Conditions for VOST Analysis. . 47

7-5 Instrument Operating Parameters for IC Analyses 49

11-1

a n d F r e q u e n c y f o r F i e i d s a n *^ip n m e n ". P :°: e f u : e : : u

1.0 PROJECT DESCRIPTION

1.1 OVERVIEW

Union Chemical Company, Inc. operates a flu i d i z e d bed hazardous waste

incinerator i n South Hope, Maine. Permit applications have been submitted by

Union Chemical to the Maine Department of Environmental Protection. The

purpose of thi s document is to present an overview of the sampling and

analysis portions of the required t r i a l burn. The overall objective of this

project is to conduct a t r i a l burn to demonstrate compliance with the

hazardous waste incinerator performance standards. The results of the

sampling and analysis program w i l l include:

• A quantitative analysis of the t r i a l p r i n c i p a l organic hazardous

compounds (POHCs) i n the waste feed to the incinerator.

• A quantitative analysis of the exhaust gas for the concentration and

mass emissions of the t r i a l POHCs and hydrogen chloride (HC1) and

the concentration of oxygen (O2).

• I f the HC1 emission rate exceeds 1.8 kilograms of HC1 per hour

(4 lb per hour), a computation of HC1 removal efficiency w i l l also

be performed.

• A quantitative analysis of the scrubber water, scrubber sludge and

ash residues for the purpose of estimating the fate of the t r i a l

POHCs.

• A computation of destruction and removal efficiency (DRE).

• A computation of particulate emissions.

• A continuous measurement, by EPA Method 10, of carbon monoxide (CO)

i n the exhaust gas.

• A quantitative analysis of selected metals i n the combustible waste

feed and particulate emissions.

• A quantitative analysis of the exhaust gas for the concentration and

.mass emissions of possible v o l a t i l e Products of Incomplete

Combustion (PICs) which are defined for this program as v o l a t i l e

compounds whose concentrations exceed 100 pg/m3 that are

i d e n t i f i a b l e by the GC/MS procedures discussed l a t e r .

• EP t o x i c i t y results for scrubber sludge and ash residues.

1

/

Required process data w i l l be supplied by Union Chemical. In addition, Union

Chemical w i l l test the emergency shutoff systems immediately prior to or after

the sampling program.

Three replicate test runs over a 2-day period are planned. Two methods

w i l l be used to address the most important question; the concentration of

POHCs in the incinerator flue gas. A portable gas chromatograph equipped with

an electron capture detector w i l l be set up in a clean area near the site and

used to measure POHCs in flue gas samples collected in Tedlar bags. Flue gas

samples w i l l also be obtained with a volatile organic sampling train (VOST).

The Tenax and Tenax/charcoal cartridges from the VOST w i l l be returned to

GCA's laboratory in Bedford, MA for analysis of POHCs by thermal

desorption-gas chromatography/mass spectrometry.

The POHCs that have been selected for analysis are trichloromono

fluoromethane, tetrachloroethene, trichloroethene, and 1,1,1-trichloroethane.

In addition, although 1,1,2-trichloro-l,2,2-trifluorethane is not on EPA's

Appendix VI I I hazardous constituent l i s t , i t w i l l be measured as an additional

compound. These five compounds have been selected for analysis because they

w i l l be present in the waste feed at concentrations in the 2 to 12 percent

range and because they rank very high on EPA's hierarchy of waste

incinerability. EPA's hierarchy of waste incinerability, which is based on

heat of combustion, includes 271 organic compounds with the number one ranked

compound being the most difficult to incinerate. Trichloromonofluoromethane

is ranked f i r s t , tetrachloroethene is fifteenth, trichloroethene is

twenty-seventh and 1,1,1-trichloroethane is thirtieth. Demonstration of the

incinerator's ability to destroy these di f f i c u l t to incinerate compounds

should be adequate to conclude that i t can destroy compounds on EPA's

hierarchy.

Additional discussions of the incineration f a c i l i t y , sampling, and

analysis are presented in this section in order to completely describe the

project. Details of the project organization, sampling methods, analytical

methods and the associated quality control procedures can be found in

Sections 2.0 through 14.0 of the August 1983 Quality Assurance Project Plan

and a September addendum to the Quality Assurance Project Plan or standard EPA

methods in the Code of Federal Regulations. All sampling and analytical

methods and quality control results will be fully discussed in the final

report.

2

/

/

1.2 FACILITY DESCRIPTION

Union Chemical has submitted a detailed engineering description of the

incinerator as part of i t s Part B permit application. A brief description of

the f a c i l i t y is presented in this section as background to the sampling and

analysis strategy. A schematic of the Union Chemical fluidized bed

incineration system is presented in Figure 1-1.

Combustible wastes consist of residues from the solvent reprocessing

operations and other organic chemicals not suitable for reprocessing. These

wastes are mixed in either of two continuously stirred 1500 gal storage tanks

to achieve the proper viscosity, chlorine content, solid content, and heating

value. Typically, one tank contains nonchlorinated wastes and the other

contains chlorinated materials. For this test program, drums of selected

wastes w i l l be mixed in one of the tanks to meet the program specificatons.

One tank of waste is sufficient for 24 hours of operation and w i l l be

sufficient for a l l three replicate test runs.

Potentially contaminated water is collected and stored to prevent site

run-off. This water, containing trace organics, is also fed to the

incinerator.

The fluidized-bed incinerator is a refractory lined cylindrical vessel

with a height of 24 ft and an inside diameter that varies from 32 in. in the

bed area, to 42 in. in the freeboard area. Overfire air is injected into the

freeboard area at five different heights. Primary combustion a i r , for bed

fluidization, is supplied by a forced draft fan to the plenum below the air

distribution plate. The distribution plate supports the s i l i c a sand bed and

provides openings for injection of the fluidizing a i r .

The duct from the incinerator to the ash-drop-out chamber and the chamber

i t s e l f are refractory lined. The ash knockout chamber is essentially a

settling chamber that collects small quantities of sand elutriated from the

bed and coarse particulates from the waste feed. Typically, the temperature

at the inlet to the ash-dropout chamber is 2000-2200°F.

The reactor was originally designed for dry neutralization of acid gases

and cooling by air dilution, but is no longer used for this purpose.

3

» I500 # F

T 2 « 2000-2200*F

f 2000-2200*F

« I900°F

* I 300 W F

« I 8 0 - 2 0 0 ° F

» I 4 0 - I 5 0 ° F

OVERFIRE AIR

FREEBOARD •C0M8USTI0N

CHAMBER

SOL 10 FLUIDIZED WASTE

BEO

FORCED ^PJJMART DRAFT A I R

COMBUSTIBLE FAN WASTES;

PUMP

QUENCH TOWER

INDUCED

DRAFT

FAN

T » THERMOCOUPLE

CONTAMINATED WATER

PUMP

STACK

WET SCRUBBER

Figure 1-1. Schematic of Union Chemical fluidized bed incineration system.

A refractory lined Fisher Kostermann XQ cyclone removes most of the

particulate matter from the flue gas. Solids are removed by a continuously

operating rotary valve.

In the quench tower, flue gases are cooled from about 1300°F to 180-200°F.

Lime slurry is fed to the quench tower for removal of HC1 from the gas

stream. Quenching l i q u i d is recycled after the solids are removed i n a

s e t t l i n g vessel.

The f i n a l control device is horizontal cross flow packed tower

manufactured by Celicote. Lime slurry is used to adjust the pH of the

scrubber l i q u i d and to insure that HC1 emissions meet the regulatory

requirements.

The 2 foot diameter stack is 60 feet high. A sampling platform is

located 30 feet above the ground and 10 stack diameters downstream from the

t r a n s i t i o n j o i n i n g the scrubber with the stack. The sampling platform is

15 stack diameters upstream from the stack e x i t .

1.3 SAMPLING AND ANALYSIS

A l i s t of the seven-sample streams and the planned measurements i s

presented i n Table 1-1. Additional information on the plans for the six

l i q u i d and solid streams is presented in Table 1-2 and discussed below. The

plans for flue gas sampling are discussed l a t e r .

1.3.1 Combustible Waste Feed

Six sets of duplicate combustible waste feed samples w i l l be collected

during each of the three 2-hour test runs. The samples w i l l be collected from

s tap on the feed pipe to the incinerator. The samples w i l l be collected i n

Volatile Organic Analysis (VOA) vial s and stored at 4°C pending analysis. One

set of samples per run w i l l be composited for analysis of POHCs, chlorine, and

selected metals. The other set w i l l be stored i n GCA's sample bank.

The combustible waste feed samples w i l l be prepared for analysis of POHCs

following the general approach outlined i n Method AlOla. 1'^ The actual

method as developed and v e r i f i e d i n the GCA laboratory w i l l employ a

TABLE 1-1. SUMMARY OF SAMPLE STREAMS AND REQUIRED MEASUREMENTS

Stream type Measurements

Combustible waste feed POHCs,8 metalsb chlorine, ash,

Btu

Contaminated water feed POHCs, chlorine

Ash POHCs, EP toxicity

Scrubber water POHCs

Scrubber sludge POHCs, EP toxicity

Flue gas Moisture, C02, CO, O2, flow,

particulate,0 POHCs, PICs,d, HC1

'Trichloroethylene, tetrachloroethylene, 1,1,1-trichloroethane,

trichloromonofluoromethane and 1,1,2-trichloro-l,2,2-trifluoroethane.

'Arsenic, barium, beryllium, cadmium, chromium, lead, mercury,

selenium and silver. '

Particulates collected on the EPA Method 5 filter will be weighed

and then analyzed for arsenic, barium, beryllium, cadmium, chromium,

lead, selenium and silver.

Volatile organic compounds present at concentrations above

100 ug/m3 that are identifiable by the GC/MS procedures

discussed later.

6

TABLE 1-2. SUMMARY OF SAMPLING AND ANALYSIS PLANS FOR LIQUID AND SOLID STREAMS

No. of No. of

samples samples

Sample type collected analyzed*3

1. Combustible waste feed 36 VOA v i a l s 3 composites

9500 ml 3 composites

2. Contaminated water 6 VOA vi a l s 3 composites

3. Ash 3-1 gal 1 composite

4. Scrubber water 18 VOA v i a l s 3 composites

5. Scrubber sludge 3-1 gal 1 composite

6. Scrubber water supply 6 VOA v i a l s 3 samples

n t t r 0 e t h e n eJ lT J T t S e S J ™ i S ; ^ 5 ? 0 ' ^ . ^ " ^ h l o r o e t h a n e ,i » i » 2 - t r i c h l o r o - l , 2 , 2 - t r i f l u o r o e t h a n e .

Wfot including addi t iona l qual i ty control ana lyses .

c A r s e n i c , barium, beryl l ium, cadmium, chromium, l ead , mercury,

Analysis Method

P0HCsa Tetraglyme—GC/MS Chlorine Parr Bomb—Ion

chromatography Metals c ICAP and AA

POHCs Purge and trap—GC/MS Chloride Ion chromatography

POHCs GC/MS EP t o x i c i t y

EP t o x i c i t y POHCs

Purge and trap—GC/MS POHCs EP t o x i c i t y GC/MS

EP t o x i c i t y POHCs Purge and trap—GC/MS

trichloromonofluoromethane and

selenium and s i l v e r .

tetraglyme dispersion technique in lieu of polyethylene glycol. A small

portion of the tetraglyme dispersion w i l l be mixed with water and analyzed by

purge and trap GC/MS procedures similar to EPA Method 624. The analyses will

be conducted using a Hewlett-Packard 5985 computerized GC/MS system.

Total chlorine analysis of the combustible waste feed w i l l be performed

using Parr Bomb combustion (ASTM D808-63) with quantitation by ion

chromatography. The samples w i l l be oxidized by combustion in a Parr oxygen

bomb containing a sodium carbonate absorbing solution. The absorbing solution

and washings w i l l be combined, diluted to volume and analyzed for chloride

using a Dionex Model 14 ion chromatograph.

The combustible waste feed samples w i l l be analyzed for arsenic, barium,

beryllium, cadmium, chromium, lead, mercury, selenium and silver. All of

these metals with the exception of mercury w i l l be prepared for analysis by

means of temperature controlled dry ashing. Previous analyses of waste o i l

samples using this procedure indicate that the volatile elements, such as

arsenic, are not lost during the ashing procedure. The resultant ash is

dissplved by means of hot 1:1 nitric/hydrochloric acid. Metals concentrations

are subsequently determined by means of Inductively Coupled Argon Plasma

Emission Spectroscopy (ICAP).

The analysis of mercury in the waste feed samples presents a problem in

that the mercury may be present in volatile organometallic compounds.

Consequently, a digestion procedure designed to recover the total mercury is

required. We propose using ASTM Method D-3684-78 "Total Mercury in Coal by

the Oxygen Bomb Combustion/Atomic Absorption Method." This procedure combusts

the sample in an oxygen rich atmosphere with the mercury vapors collected in a

dilute ni t r i c acid solution. The acid solution and the solution used to rinse

the bowl are combined and subsequently analyzed by cold vapor atomic

absorption.

Ash content and heating value will be determined by ASTM Methods D-1888

and D-3286 respectively.

1.3.2 Contaminated Water Feed

The contaminated water feed contains POHCs and chlorine in trace

quantities. Past experience has shown that the contribution of the

8

contaminated water to the total POHC feed is not significant and that the

contribution to the total chlorine is minor.2 Therefore, one set of

duplicate samples, in VOA vials, w i l l be collected per run. The samples w i l l

be stored at 4°C and analyzed within 14 days after completion of the sampling

program. POHCs will be analyzed by an EPA Method 624 protocol with

modifications routinely used for priority pollutant analyses in the GCA

laboratory.

Contaminated water samples will be analyzed for chloride by means of ion

chromatography. Samples will be analyzed directly with no prior treatment

other than dilution where necessary.

1.3.3 Ash

Ash collected by the knockout chamber is periodically discharged to a

55-gullon drum while ash from the cyclone is continuously discharged to a

55-gallon drum. At the end of each run, a composite sample of both ashes w i l l

be collected.

Because the ashes are collected at temperatures above 1000°F, they should

not contain any of the POHCs that have been selected for this program.

However, one of the three composites will be selected for analysis of POHCs.

The analytical method will be similar to the procedure described for the

combustible waste field; dispersion in tetraglyme followed by purge and trap

GC/MS.

One ash sample wi l l be subjected to the Extraction Procedure Toxicity

test as outlined in §261.24 and Test Methods for Evaluating Solid Waste.3

Samples of the ash w i l l be extracted with deionized water which is kept at a

pH of 5 using acetic acid. The resulting extract will be analyzed for

arsenic, barium, beryllium, cadmium, hexavalent chromium, lead, mercury,

selenium, and silver Analyses for pesticides are not appropriate and are not

planned. The Extraction Procedure Toxicity test is not required by the

incinerator regulations but will be conducted to determine whether or not the

ash i8 hazardous.

9

1.3.4 Scrubber Water

The water that is recirculated through the packed bed scrubber and the

quench tower will be sampled to determine whether or not the POHCs are

accumulating in the water. I t should be noted that this water is not

discharged from the plant. During each run, three samples w i l l be collected

in duplicate VOA vial s . Samples will be stored at 4°C and analyzed within

14 days by purge and trap GC/MS procedures (GCA's modified version of EPA

Method 624). One composite sample will be analyzed for each run.

1.3.5 Scrubber Sludge

The sludge that is removed from the recirculated wat