MUSTARD AGENT TRIAL BURN PLAN FOR THE LIQUID

7,94

MB

INCINERATORS

333

stron

6557

ID

URS Corporation EG&G Division

2006

rok

TABLE OF CONTENTS

EXECUTIVE SUMMARY ES-1

TABLE OF CONTENTS i

LIST OF APPENDICES. V

LIST OF TABLES vi

LIST OF FIGURES vi

LIST OF ACRONYMS AND ABBREVIATIONS. vii

LIST OF UNITS AND MEASUREMENTS x

LIST OF CHEMICAL SYMBOLS AND FORMULAS .xi

LIST OF IDENTIFICATION CODES FOR LIQUID INCINERATOR 1 INSTRUMENTS MONITORING

REGULATED OPERATING PARAMETERS xiii

LIST OF IDENTIFICATION CODES FOR LIQUID INCINERATOR 2 INSTRUMENTS MONITORING

REGULATED OPERATING PARAMETERS.xiv

1.0 INTRODUCTION 1

1.1 MUSTARD AGENT TRIAL BURN PLAN ORGANIZATION.2

1.2 FACILITY INFORMATION3

1.3 WASTE TREATMENT SYSTEM PROCESS AND FEED DESCRIPTIONS.3

1.3.1 Waste Handling and Storage4

1.3.2 Combustion Process4

1.3.3 Pollution Abatement System.5

1.3.4 Wet Scrubber Recirculation Brine Description6

1.4 WASTES TO BE TREATED.6

1.5 MUSTARD AGENT TRIAL BURN OBJECTIVES.10

1.6 MUSTARD AGENT TRIAL BURN APPROACH.11

1.7 PROPOSED MUSTARD AGENT TRIAL BURN PROGRAM.11

1.8 MUSTARD AGENT TRIAL BURN SAMPLING AND ANALYTICAL PROTOCOLS12

1.9 FINAL PERMIT LIMITS.13

1.10 JUSTIFICATION FOR EXEMPTION13

2.0 DETAILED ENGINEERING DESCRIPTION OF THE LIQUID INCINERATORS 14

2.1 PRIMARY COMBUSTION CHAMBER .14

2.2 SECONDARY COMBUSTION CHAMBER .16

2.3 NOZZLE AND BURNER DESIGN17

2.4 DESCRIPTION OF THE AUXILIARY FUEL SYSTEMS 18

2.5 CAPACITY OF PRIME MOVER.20

2.6 DESCRIPTION OF WASTE FEED SYSTEMS .20

2.6.1 Agent Collection and Feed System .20

2.6.2 Spent Decontamination Solution Feed System .21

2.7 DESCRIPTION OF SLAG REMOVAL SYSTEM.21

2.8 DESCRIPTION OF THE AUTOMATIC WASTE FEED CUTOFF SYSTEMS21

2.9 EXHAUST GAS MONITORING EQUIPMENT26

2.9.1 Continuous Emissions Monitoring Systems27

2.9.2 Agent Monitoring Systems29

2.10 POLLUTION ABATEMENT SYSTEM.32

2.11 CONSTRUCTION MATERIALS .35

2.12 LOCATION AND DESCRIPTION OF TEMPERATURE, PRESSURE, AND FLOW INDICATING

AND CONTROL DEVICES.36

2.12.1 Primary Combustion Chamber Agent Feed Rate Control39

2.12.2 Primary Combustion Chamber Pressure Control 39

2.12.3 Primary Combustion Chamber Exhaust Gas Temperature and Burner Controls39

2.12.4 Secondary Combustion Chamber Exhaust Gas Temperature and Burner Control39

2.12.5 Secondary Combustion Chamber Decon Waste Feed Control.40

2.12.6 Slag Reservoir Shell Temperature40

2.12.7 Quench Outlet Gas Temperature .40

2.12.8 Quench Brine Flow .40

2.12.9 Venturi Scrubber Brine Flow .41

2.12.10 Brine pH41

2.12.11 Brine Density.41

2.12.12 Venturi Scrubber Differential Pressure.41

2.12.13 Scrubber Tower Sump Level Control .41

2.12.14 Clean Liquor Flow Control42

2.12.15 Clean Liquor Level Control 42

2.12.16 Clean Liquor pH Control 42

2.12.17 Clean Liquor Density Control.43

2.12.18 Demister Level Control .43

2.12.19 Demister Candle Pressure Drop .43

2.12.20 Liquid Incinerator Bleed Air Valve Operation44

2.12.21 Liquid Incinerator Exhaust Gas Oxygen Concentration 44

2.12.22 Liquid Incinerator Exhaust Gas Carbon Monoxide Concentration .44

2.12.23 Liquid Incinerator Exhaust Gas Mustard Concentration44

2.12.24 Liquid Incinerator Exhaust Gas Flow Rate45

2.13 INCINERATION SYSTEM STARTUP PROCEDURES .45

2.13.1 Startup of Utilities 45

2.13.2 Startup of the Liquid Incinerator Pollution Abatement System 46

2.13.3 Startup of the Secondary Combustion Chamber .47

2.13.4 Startup of the Liquid Incinerator Primary Combustion Chamber.47

3.0 SAMPLING AND ANALYSIS PROCEDURES. 48

3.1 SAMPLING LOCATIONS.49

3.1.1 Exhaust Gas Sampling Locations.49

3.1.2 Process Stream Sampling Locations 54

3.2 SAMPLING METHODS54

3.2.1 Process Stream Sampling Methods 54

3.2.2 Mustard Sampling Methods for Exhaust Gas.55

3.2.3 Additional Sampling Methods for Exhaust Gas55

3.3 ANALYSIS METHODS.56

3.3.1 Analysis Methods for Mustard .56

3.3.2 Analysis Methods for Process Stream Samples56

3.3.3 Analysis Method for Slag Samples .56

3.3.4 Analysis Methods for Exhaust Gas Samples.57

3.4 AUDIT SAMPLES .57

4.0 MUSTARD AGENT TRIAL BURN SCHEDULE . 58

4.1 PERFORMANCE RUN SCHEDULE.58

4.2 DURATION OF THE LIQUID INCINERATOR MUSTARD AGENT TRIAL BURN 58

5.0 MUSTARD AGENT TRIAL BURN PROTOCOLS 60

5.1 WASTE CHARACTERIZATION60

5.1.1 Mustard Agent Waste Feed 60

5.1.2 Metals Spiking Feed62

5.1.3 Spent Decontamination Solution Waste Feed.62

5.1.4 Surrogate Hazardous Air Pollutant Feed Stream 65

5.2 PRINCIPAL ORGANIC HAZARDOUS CONSTITUENT SELECTION RATIONALE 65

5.3 TEST PROTOCOL AND OPERATING CONDITIONS66

5.3.1 Development of Worst-Case Criteria .66

5.3.2 Liquid Incinerator Mustard Agent Trial Burn Operating Conditions 66

5.3.3 Metals Spiking Operations .67

5.3.4 Surrogate Hazardous Air Pollutant Feed Operations68

5.4 COMBUSTION TEMPERATURE RANGES.68

5.5 WASTE FEED RATES AND QUANTITIES OF WASTES TO BE BURNED.69

5.6 EXHAUST GAS VELOCITY INDICATOR 70

5.7 AUXILIARY FUEL .70

5.8 WASTE FEED ASH CONTENT 71

5.9 ORGANIC CHLORINE CONTENT OF THE WASTE FEED.71

5.10 METALS FEED RATES .71

5.11 POLLUTION CONTROL EQUIPMENT OPERATIONS73

5.12 SHUTDOWN PROCEDURES.73

5.13 INCINERATOR PERFORMANCE 74

6.0 MUSTARD SHAKEDOWN PROCEDURES. 75

6.1 STARTUP PROCEDURES AFTER AGENT CHANGE-OVER75

6.2 MUSTARD SHAKEDOWN .76

6.3 POST MUSTARD AGENT TRIAL BURN OPERATION.76

6.4 INCINERATOR PERFORMANCE77

7.0 MUSTARD AGENT TRIAL BURN SUBSTITUTE SUBMISSIONS 78

8.0 MUSTARD AGENT TRIAL BURN RESULTS. 79

9.0 FINAL OPERATING LIMITS 81

9.1 ESTABLISHING LIQUID INCINERATOR OPERATING PARAMETERS .81

9.2 GROUP A PARAMETERS82

9.3 GROUP B PARAMETERS83

9.4 GROUP C PARAMETERS84

10.0 REFERENCES. 87

LIST OF APPENDICES

APPENDIX A. LIQUID INCINERATOR QUALITY ASSURANCE PROJECT PLAN

APPENDIX B. LIQUID INCINERATOR SHAKEDOWN PLAN

APPENDIX C. MASS AND ENERGY BALANCE FOR THE LIQUID INCINERATOR MUSTARD

AGENT TRIAL BURN AND EXHAUST GAS RESIDENCE TIME CALCULATIONS

APPENDIX D. AUTOMATIC WASTE FEED CUTOFF TABLES AND OPERATING CONDITION

TARGET VALUE TABLES FOR LIQUID INCINERATORS 1 AND 2

APPENDIX E. MUSTARD AGENT CHARACTERIZATION SUMMARY

APPENDIX F. ALTERNATE MONITORING REQUESTS

APPENDIX G. LIQUID INCINERATOR MUSTARD AGENT TRIAL BURN FINAL REPORT OUTLINE

APPENDIX H. REFERENCED LIQUID INCINERATOR 1 DRAWINGS

APPENDIX I. REFERENCED LIQUID INCINERATOR 2 DRAWINGS