MUSTARD AGENT TON CONTAINER TRIAL BURN PLAN FOR THE

0,41

MB

METAL PARTS FURNACE

106

stron

6556

ID

URS Corporation EG&G Division

2006

rok

TABLE OF CONTENTS

EXECUTIVE SUMMARY. ES-1

TABLE OF CONTENTS i

LIST OF APPENDICES.iv

LIST OF TABLES.v

LIST OF FIGURESvi

LIST OF ACRONYMS AND ABBREVIATIONS. vii

LIST OF UNITS OF MEASURE .x

LIST OF CHEMICAL SYMBOLS AND FORMULASxi

LIST OF IDENTIFICATION CODES FOR MPF INSTRUMENTS THAT MONITOR REGULATED

OPERATING PARAMETERS. xiii

1.0 INTRODUCTION .1

1.1 TRIAL BURN PLAN ORGANIZATION .2

1.2 FACILITY INFORMATION 3

1.3 WASTE TREATMENT SYSTEM PROCESS AND FEED DESCRIPTIONS3

1.3.1 Waste Handling and Storage 4

1.3.2 Combustion Process.4

1.3.3 Pollution Abatement System4

1.3.4 Wet Scrubber Recirculation Brine Description.5

1.4 WASTES TO BE TREATED 6

1.5 TRIAL BURN OBJECTIVES .9

1.6 TRIAL BURN APPROACH.10

1.7 PROPOSED MUSTARD TRIAL BURN PROGRAM10

1.8 TRIAL BURN SAMPLING AND ANALYTICAL PROTOCOLS.11

1.9 FINAL PERMIT LIMITS.12

1.10 JUSTIFICATION FOR EXEMPTION13

2.0 DETAILED ENGINEERING DESCRIPTIONS OF THE MPF14

2.1 PRIMARY COMBUSTION CHAMBER14

2.2 AFTERBURNER .18

2.3 BURNERS18

2.4 AUXILIARY FUEL SYSTEMS19

2.5 PRIME MOVER.19

2.6 WASTE FEED SYSTEM.20

2.7 RESIDUE HANDLING SYSTEM20

2.8 AUTOMATIC WASTE FEED CUTOFF SYSTEMS21

2.9 EXHAUST GAS MONITORING EQUIPMENT25

2.9.1 Continuous Emission Monitoring Systems 25

2.9.2 Agent Monitoring Systems.27

2.10 POLLUTION ABATEMENT SYSTEM.30

2.11 CONSTRUCTION MATERIALS.34

2.12 TEMPERATURE, PRESSURE, FLOW INDICATING AND CONTROL DEVICES34

2.12.1 PCC Feed Rate Control 35

2.12.2 PCC Zone Exhaust Gas Temperature and Burner Controls .37

2.12.3 Afterburner Temperature and Burner Control38

2.12.4 PCC Pressure Control 38

2.12.5 MPF Secondary Cooling Water Controls .39

2.12.6 Quench Outlet Gas Temperature 39

2.12.7 Quench Brine Flow .40

2.12.8 Quench Brine Delivery Pressure 40

2.12.9 Venturi Scrubber Brine Flow 40

2.12.10 Brine pH.40

2.12.11 Brine Density .40

2.12.12 Venturi Scrubber Differential Pressure .41

2.12.13 Scrubber Tower Sump Level Control 41

2.12.14 Clean Liquor Flow Control.41

2.12.15 Clean Liquor Delivery Pressure .41

2.12.16 Clean Liquor Level Control 41

2.12.17 Clean Liquor pH Control 42

2.12.18 Clean Liquor Density Control.42

2.12.19 Demister Level Control.42

2.12.20 Demister Candle Pressure Drop.43

2.12.21 MPF Bleed Air Valve Operation.43

2.12.22 MPF Exhaust Gas O2 Concentration 43

2.12.23 MPF Exhaust Gas CO Concentration.44

2.12.24 MPF Exhaust Gas Mustard Concentration.44

2.12.25 MPF Exhaust Gas Flow Rate44

2.13 INCINERATION SYSTEM STARTUP PROCEDURES .45

2.13.1 Startup Utilities.45

2.13.2 Startup the MPF PAS46

2.13.3 Startup the Afterburner 46

2.13.4 Startup of the MPF PCC.47

3.0 SAMPLING AND ANALYSIS PROCEDURES48

3.1 SAMPLING LOCATIONS .49

3.1.1 Exhaust Gas Sampling Locations49

3.1.2 Process Stream Sampling Locations .52

3.2 SAMPLING METHODS.52

3.2.1 Process Stream Sampling Methods .52

3.2.2 Mustard in Exhaust Gas Sampling Methods .53

3.2.3 Additional Exhaust Gas Sampling Methods53

3.3 ANALYSIS METHODS 54

3.3.1 Mustard Agent Analysis Methods54

3.3.2 Process Stream Sample Analysis Methods.54

3.3.3 Residue Sample Analysis Methods 54

3.3.4 Exhaust Gas Sample Analysis Methods.55

3.4 AUDIT SAMPLES.55

4.0 MUSTARD AGENT TRIAL BURN SCHEDULE 56

4.1 PERFORMANCE RUN SCHEDULE.56

4.2 DURATION .56

5.0 AGENT TRIAL BURN PROTOCOLS 58

5.1 WASTE CHARACTERIZATION 58

5.1.1 Mustard Waste Feed .58

5.1.2 Metals Spiking Materials 63

5.2 POHC SELECTION RATIONALE.65

5.3 TEST PROTOCOL AND OPERATING CONDITIONS 67

5.3.1 Development of Worst-Case Criteria67

5.3.2 Test Condition 1.67

5.3.3 Test Condition 2.68

5.3.4 Proposed Test Operating Conditions68

5.3.5 Metals Spiking Operations.69

5.4 COMBUSTION TEMPERATURE RANGES.70

5.5 WASTE FEED RATES AND QUANTITIES OF WASTES TO BE BURNED 71

5.6 EXHAUST GAS VELOCITY INDICATOR.72

5.7 AUXILIARY FUEL .72

5.8 WASTE FEED ASH CONTENT.73

5.9 ORGANIC CHLORINE CONTENT OF THE WASTE FEED73

5.10 METALS FEED RATES 73

5.11 POLLUTION CONTROL EQUIPMENT OPERATIONS 74

5.12 SHUTDOWN PROCEDURES.74

5.13 INCINERATOR PERFORMANCE76

6.0 MUSTARD AGENT SHAKEDOWN PROCEDURES.77

6.1 STARTUP PROCEDURES AFTER AGENT CHANGEOVER .77

6.2 MUSTARD AGENT SHAKEDOWN.78

6.3 POST-MUSTARD AGENT TRIAL BURN OPERATION.79

6.4 INCINERATOR PERFORMANCE79

7.0 TRIAL BURN SUBSTITUTE SUBMISSIONS .81

8.0 METAL PARTS FURNACE MUSTARD AGENT TRIAL BURN RESULTS 82

9.0 FINAL OPERATING LIMITS .84

9.1 GROUP A PARAMETERS85

9.2 GROUP B PARAMETERS86

9.3 GROUP C PARAMETERS87

10.0 REFERENCES 89

LIST OF APPENDICES

APPENDIX A. MPF QUALITY ASSURANCE PROJECT PLAN

APPENDIX B. MPF SHAKEDOWN PLAN

APPENDIX C. MASS AND ENERGY BALANCES FOR THE MPF MUSTARD TC ATB AND

EXHAUST GAS RESIDENCE TIME CALCULATIONS

APPENDIX D. AUTOMATIC WASTE FEED CUTOFF TABLES AND OPERATING CONDITION

TARGET VALUE TABLES FOR THE MPF

APPENDIX E. MUSTARD CHARACTERIZATION SUMMARY

APPENDIX F. ALTERNATE MONITORING REQUESTS

APPENDIX G. MPF MUSTARD TRIAL BURN FINAL REPORT OUTLINE

APPENDIX H. REFERENCED MPF DRAWINGS