Evaluation of the Limited Engineering Scale Testing of the

1,38

MB

PLASMOX Technology to Treat Chemical Warfare Materiel

157

stron

3401

ID

Department of Defense

2002

rok

Table of Contents

1.0 Introduction.1

1.1 Test Objectives. 1

1.1.1 Maximum Throughput 2

1.1.2 Continuous Stable Operation.. 2

1.1.3 Disposable Effluents 2

1.1.4 Fate of Phosphorus 2

1.1.5 Provide Engineering Data . 2

1.2 Evaluation Criteria . 3

1.2.1 Evaluation of Maximum Throughput.. 3

1.2.2 Evaluation of Continuous Stable Operation. 3

1.2.3 Evaluation of Disposability of Effluents 3

1.2.4 Evaluation of Fate of Phosphorus . 3

1.2.5 Evaluation of Engineering Data . 3

2.0 Background5

3.0 SYSTEM DESCRIPTION7

3.1 Plasma Reactor Vessel and Plasma Torch. 7

3.2 Rapid Oxidation Chamber .. 10

3.3 Off-Gas Treatment System. 11

3.4 Miscellaneous Systems . 11

3.5 Process Instrumentation 12

4.0 TEST DESCRIPTIONS .13

4.1 Simulants.. 13

4.2 Test Run Descriptions 14

4.2.1 Work-up Test Run.. 15

4.2.2 GB Neutralent Simulant Test Runs 16

4.2.3 H Neutralent Simulant Test Runs 22

4.3 Sampling and Analysis . 27

4.3.1 Solid and Liquid Grab Samples .. 28

4.3.2 Continuous On-Line Stack Analysis. 31

4.3.3 Stack Grab Samples .. 31

5.0 Operability ..35

5.1 Plasma Reactor.. 35

5.1.1 Deposition of Material.. 36

5.1.2 Vessel Geometry Issues .. 40

5.2 Plasma Arc Torch and Electrode . 40

5.2.1 PLASMOX® Plasma Torch Design .. 40

5.2.2 PLASMOX® Electrode Life.. 42

Torch Failures 43

5.3 Rapid Oxidation Chamber and Off-Gas Treatment 43

5.3.1 Rapid Oxidation Chamber.. 44

5.3.2 Off-Gas Treatment System. 44

5.4 Standard Operating Procedures, Training and Safety 45

5.4.1 Operational and Emergency Procedures Manual 45

5.4.2 Training Program 45

5.4.3 Emergency Power Supply.. 46

5.4.4 Engineered Safety Designs. 46

5.4.5 Worker Safety.. 46

5.4.6 Availability of Plasma Systems 47

6.0 Effluent Characterization..49

6.1 Solid Sample Analyses . 49

6.1.1 Slag Composition.Error! Bookmark not defined.

6.1.2 Trace Metals in the Slag.. 51

6.1.3 Leaching Properties of Slag.. 51

6.1.4 Analysis of Reactor Exit Piping Solid Material.. 52

6.2 Liquid Sample Analyses .. 53

6.2.1 Phosphorus Balance .. 57

6.2.2 Dioxins-Furans in Scrubber Water. 58

6.2.3 Total Organic Carbon, Chloride, Cyanide and Nitrates in Scrubber Water.. 58

6.2.4 Scrubber Performance.. 59

6.3 Gas Sample Analyses. 60

6.3.1 Destruction of MEA.. 60

6.3.2 NOX Emissions. 61

6.3.3 Dioxins and Furans. 63

6.3.4 Particulates and Metals in Stack Gas 64

6.3.5 Hydrocarbons and Hazardous Air Pollutants 65

7.0 CONCLUSIONS .67

8.0 RECOMMENDATIONS69

9.0 References71

Appendix A – Analytical Results

Appendix B – P&ID Figures for RIF-2 Unit

Appendix C – Scrubber Efficiency Calculation

Appendix D – MEA Destruction Calculation