Complete Permit application Vol 1_Rev_1_6-8-18-2 PART 3.pdf

Appendix E

Human Health and Ecological Risk Assessment (HHERA)

This is currently a placeholder for the Main Base HHERA. It will be replaced upon completion of the HHERA and submittal of the document to NDEP.

Current schedule for completing of the Main Base HHERA:

- The Draft Protocol for the Main Base HHERA to has been submitted to NDEP for review. HWAD is awaiting comments and approval.

- Submittal of Draft HHERA to HWAD for review – 45 day after receipt of NDEP’s approval of the Protocol

- Submittal of HHERA to NDEP – 52 days after receipt of the final HHERA by HWAD

COMPREHENSIVE PERFORMANCE TEST PLAN

FOR

PLASMA ARC ORDNANCE DEMILITARIZATION SYSTEM

Prepared for:

HAWTHORNE ARMY DEPOT,

HAWTHORNE, NEVADA 89415

October 20, 2000

Prepared by:

TETRA TECH EM INC.

1325 Airmotive Way

Suite 200

Reno, Nevada 89502

(775) 322-0555 i:\projects\hwad\2017 rcra permit renewals\2018 permit application\main base renewal application\from jeff 021218\pods\cptp main document.doc\13-Mar-18\rkr i

CONTENTS

Section Page

ACRONYMS AND ABBREVIATIONS .................................................................................................... iv

1.0 INTRODUCTION ........................................................................................................................ 1-1

1.1 ORGANIZATION OF THE COMPREHENSIVE PERFORMANCE TEST PLAN ..... 1-3

2.0 DESCRIPTION OF PLASMA ARC ORDNANCE DEMILITARIZATION SYSTEM ............. 2-1

2.1 WASTE HANDLING AND BLENDING ....................................................................... 2-1

2.2 WASTE FEED SYSTEM ................................................................................................ 2-1

2.3 COMBUSTION PROCESS ............................................................................................. 2-2

2.3.1 Primary Processing Chamber .............................................................................. 2-2

2.3.2 Processing Operations ......................................................................................... 2-5

2.4 AIR POLLUTION CONTROL SYSTEM ....................................................................... 2-6

2.4.1 Plasma Furnace (Intrinsic Destruction) .............................................................. 2-6

2.4.2 Air Pollution Control Equipment Summary ....................................................... 2-6

2.4.3 Process Descriptions of System Unit .................................................................. 2-6

2.4.3.1 Secondary Combustion Chamber ....................................................... 2-8

2.4.3.2 Quencher............................................................................................. 2-8

2.4.3.3 Absorber (Scrubber # 1) ..................................................................... 2-8

2.4.3.4 High-Energy Scrubber (Scrubber # 2) ................................................ 2-8

2.4.3.5 Baghouse ............................................................................................ 2-9

2.4.3.6 Blower ................................................................................................ 2-9

2.4.3.7 NOx Removal .................................................................................... 2-10

2.5 ASH HANDLING ......................................................................................................... 2-10

2.5.1 Slag Collection Chamber .................................................................................. 2-10

2.5.2 Slag Handling Methods .................................................................................... 2-11

2.5.3 SCC and Baghouse Particulate ......................................................................... 2-12

2.5.4 Particulate Collection ........................................................................................ 2-12

2.6 PODS SCRUBBER LIQUID WASTEWATER TREATMENT SYSTEM .................. 2-13

2.6.1 Gross Solids and Metals Removal .................................................................... 2-13

2.6.2 Sludge Handling ............................................................................................... 2-14

2.7 CONTROL AND MONITORING SYSTEMS ............................................................. 2-14

2.7.1 Ordnance Feed Rate .......................................................................................... 2-17

2.7.2 Primary Processing Chamber (PPC) Pressure .................................................. 2-17

2.7.3 Primary Processing Chamber Temperature ...................................................... 2-17

2.7.4 Secondary Combustion Chamber Outlet Temperature ..................................... 2-18

2.7.5 Quench Water Flow .......................................................................................... 2-18

2.7.6 Quench Water Pressure ..................................................................................... 2-18 i:\projects\hwad\2017 rcra permit renewals\2018 permit application\main base renewal application\from jeff 021218\pods\cptp main document.doc\13-Mar-18\rkr i

CONTENTS (Continued)

2.7.7 Scrubber Liquor Absorber Sump pH ................................................................ 2-19

2.7.8 Absorber Solution Flow .................................................................................... 2-19

2.7.9 Absorber Solution Pressure .............................................................................. 2-19

2.7.10 Absorber Off Gas Exit Temperature ................................................................. 2-19

2.7.11 Absorber Sump Blowdown Rate ...................................................................... 2-19

2.7.12 High Energy Scrubber Atomizing Air Pressure ................................................ 2-20

2.7.13 High-Energy Scrubber Air Flow ....................................................................... 2-20

2.7.14 High-Energy Scrubber Water Flow .................................................................. 2-20

2.7.15 High-Energy Scrubber Solution Pressure ......................................................... 2-21

2.7.16 High-Energy Scrubber Pressure Drop ............................................................. 2-21

2.7.17 Baghouse Differential Pressure ........................................................................ 2-21

2.7.18 Baghouse Inlet Termperature ............................................................................ 2-21

2.7.19 Baghouse Leak Detection ................................................................................. 2-21

2.7.20 Stack Gas Mass Flow ........................................................................................ 2-21

2.7.21 CO in Stack Offgas ........................................................................................... 2-22

2.7.22 Instrument Span ................................................................................................ 2-22

2.8 CONTINUOUS EMISSION MONITORING SYSTEMS ............................................ 2-22

3.0 WASTE COMPOSITION AND FEED RATE ............................................................................ 3-1

3.1 WASTE TYPES .............................................................................................................. 3-1

3.2 WASTE COMPOSITION ............................................................................................... 3-1

3.3 CONTROL OF FEED RATE .......................................................................................... 3-2

3.4 PRACTICAL LIMITATIONS ON FEED RATE TO THE SYSTEM ............................ 3-4

3.5 FEED RATES FOR MINI BURNS AND FINAL REGULATORY LIMITS ................ 3-4

3.6 COMPOSITION OF AUXILIARY FUEL, IRON, AND SOIL ...................................... 3-4

4.0 SELECTION OF WASTE FEED FOR PERFORMANCE TESTING AND OPERATING

CONDITIONS .............................................................................................................................. 4-1

4.1 PROPOSED POLLUTANT FEED RATES .................................................................... 4-1

4.1.1 Metals ................................................................................................................. 4-2

4.1.2 Chlorine .............................................................................................................. 4-2

4.1.3 Principal Organic Hazardous Constituents ......................................................... 4-2

4.2 SELECTION CRITERIA FOR WASTE FEED .............................................................. 4-5

4.2.1 POHC Selection Criteria ..................................................................................... 4-5

4.2.2 Metal Spiking ...................................................................................................... 4-6

4.2.3 Chlorine Spiking ................................................................................................. 4-7

4.2.4 Ordnance Feed Items .......................................................................................... 4-8

4.2.5 Summary of Feed Items During Performance Testing ....................................... 4-8

4.3 OPERATING PARAMETER LIMITS ........................................................................... 4-8 i:\projects\hwad\2017 rcra permit renewals\2018 permit application\main base renewal application\from jeff 021218\pods\cptp main document.doc\13-Mar-18\rkr ii

5.0 SAMPLING AND MONITORING REQUIREMENTS .............................................................. 5-1

5.1 PERFORMANCE STANDARDS ................................................................................... 5-1

5.2 MACT RULE SAMPLING REQUIREMENTS ............................................................. 5-1

5.2.1 Particulate Matter ................................................................................................ 5-1

5.2.2 Organic Compounds ........................................................................................... 5-1

5.2.3 Metals ................................................................................................................. 5-1

5.2.4 Chlorides ............................................................................................................. 5-1

5.3 RCRA HRA STACK SAMPLING REQUIREMENTS .................................................. 5-1

5.3.1 Metals Emissions ................................................................................................ 5-2

5.3.2 PIC Emissions ..................................................................................................... 5-2

5.3.3 Particle Sizing ..................................................................................................... 5-2

5.4 PROCESS SAMPLES ..................................................................................................... 5-3

5.5 PROCESS MONITORING REQUIREMENTS .............................................................. 5-3

6.0 SAMPLING PROGRAM ............................................................................................................. 6-1

6.1 SUMMARY OF SAMPLING PROGRAM ..................................................................... 6-1

6.1.1 Sampling and Analysis of PODS Feed Streams ................................................. 6-2

6.1.2 Sampling and Analysis of Exhaust Stack Emissions .......................................... 6-3

6.2 SAMPLING POINTS AND TIMES ............................................................................... 6-7

6.3 SAMPLING SCHEDULE ............................................................................................. 6-14

6.4 PRE- AND POST-TEST ACTIVITIES ......................................................................... 6-14

7.0 ANALYTICAL METHODS ........................................................................................................ 7-1

7.1 LABORATORY QUALIFICATIONS AND CERTIFICATIONS ................................. 7-1

7.2 SPECIFIC ANALYTICAL METHODS ......................................................................... 7-1

8.0 THE QUALITY ASSURANCE PROJECT PLAN ...................................................................... 8-1

9.0 DATA ANALYSIS PLAN ........................................................................................................... 9-1

9.1 ANALYSIS OF FIELD DATA RESULTS ..................................................................... 9-1

9.2 ANALYSIS OF LABORATORY DATA RESULTS ..................................................... 9-2

9.3 CALCULATIONS ........................................................................................................... 9-3

9.4 DOCUMENTATION ...................................................................................................... 9-3

10.0 HEALTH AND SAFETY ........................................................................................................... 10-1

11.0 REFERENCES

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Appendix

A PODS OPERATION AND MAINTENANCE PRACTICES

B BAGHOUSE OPERATION AND MAINTENANCE

C INSPECTION AND MAINTENANCE CHECKLIST AND DATA QUALITY

ASSURANCE TEST PROCEDURE FOR PODS CONTINUOUS EMISSION

MONITORING SYSTEM (CEMS)

D MONITORING REQUIREMENTS FOR PODS

E SAMPLING METHODS

FIGURES

Figure Page

2-1 PODS PPC AND SLAG COLLECTION CHAMBER ............................................................... 2-4 2-2 AIR POLLUTION CONTROL SYSTEM .................................................................................... 2-7

4-1 EMISSION BASED REGULATORY FEED RATE LIMIT OF POHCS BY THERMAL

STABILITY

INDEX RANKING ....................................................................................................................... 4-7

4-2 PROPOSED DEMONSTRATION BASED REGULATORY FEED RATE LIMIT OF

OHCS BY THERMAL STABILITY INDEX RANKING ........................................................... 4-7 6-1 PODS SAMPLE PORT ELEVATIONS..................................................................................... 6-10 6-2 PODS LEVEL 1-4 PLATFORM ................................................................................................ 6-11 6-3 PODS ROOFTOP PLATFORM ................................................................................................. 6-12

TABLES

Table Page

2-1 AUTOMATIC WASTE FEED CUTOFF PARAMETERS ....................................................... 2-15 2-2 CEM SPECIFICATIONS ........................................................................................................... 2-21

3-1 40 CFR 261 APPENDIX VIII ORGANIC HAZARDOUS CONSTITUENTS CONTAINED

3-2 IN THE PODS WASTE FEED ..................................................................................................... 3-2 3-3 POLLUTANTS CONTAINED IN PODS WASTE ITEMS ........................................................ 3-2 3-4 REGULATORY POLLUTANT FEED RATES .......................................................................... 3-4 4-1 PROPOSED PERFORMANCE TESTS ....................................................................................... 4-2 4-2 MINI BURN TARGET POLLUTANT FEED RATES ............................................................... 4-3 4-3 POHC TEST FEED SELECTION ................................................................................................ 4-8 4-4 METALS SPIKING MATERIALS FOR SOLIDS .................................................................... 4-10 4-5 SUMMARY OF PODS FEED ITEMS ....................................................................................... 4-10 4-6 TARGET PODS OPERATING LIMITS .................................................................................... 4-11 5-1 MACT STANDARDS FOR NEW SOURCES ............................................................................ 5-1 5-2 OPERATING PARAMETERS FOR SPECIFIC EMISSIONS STANDARDS ........................... 5-5

6-1A SUMMARY OF STACK EMISSION TEST PROGRAM – TEST 1 (ORGANIC AND

METALS TEST) ........................................................................................................................... 6-4 6-1B SUMMARY OF STACK EMISSION TEST PROGRAM – TEST 2 (HRA RISK BURN) ........ 6-5

6-2 SUMMARY OF PODS WASTE STREAM TEST PROGRAM – TEST 1 (TEST BURN)

AND TEST 2 (RISK BURN) ....................................................................................................... 6-8 6-3A SAMPLING LOCATIONS, TIMES AND VOLUMES – TEST 1 (TEST BURN) ................... 6-10 6-3B SAMPLING LOCATIONS, TIMES AND VOLUMES – TEST 2 (RISK BURN) ................... 6-10 6-4 TENTATIVE PERFORMANCE TEST SCHEDULE ............................................................... 6-15 6-5 TENTATIVE DAILY PERFORMANCE TEST SCHEDULE .................................................. 6-16 7-1 ANALYTICAL PROCEDURES SUMMARY ............................................................................ 7-2 i:\projects\hwad\2017 rcra permit renewals\2018 permit application\main base renewal application\from jeff 021218\pods\cptp main document.doc\13-Mar-18\rkr iv

ACRONYMS AND ABBREVIATIONS

acfm Actual cubic feet per minute

APCE Air pollution control equipment

ASHRAE American Society of Heating, Refrigerating, and Air-Conditioning Engineers, Inc.

AWFCO Automatic waste feed cutoff

BIF Boiler and Industrial Furnace

BTU/hr British Thermal Units per Hour

C Celsius

CAA Clean Air Act

CARB California Air Resources Board

CEM Continuous emission monitor

CEMS Continuous emission monitoring system

CFR Code of Federal Regulations

CFM Cubic feet per minute

Cl2 Chlorine

CLP Contract Laboratory Program

CO Carbon monoxide

COPC Chemical of potential concern

CPT Comprehensive performance test

CPTP Comprehensive performance test plan

CVAA Cold vapor atomic absorption

DAS Data acquisition system

DRE Destruction and removal efficiency

DZHC Day and Zimmerman Hawthorne Corporation

EDD Electronic data deliverable

EPA U.S. Environmental Protection Agency

ESS Emergency shutdown sequence

F Fahrenheit

FID Flame ionization detector

FR Federal Register ft3 Cubic feet g/s Grams per second

GC/MS Gas Chromatography/Mass Spectroscopy

GC/FID Gas Chromatography/Flame Ionization Detection

GC/NPD Gas Chromatography/Nitrogen-Phosphorous Detector gpm Gallons per minute

GRAV Gravimetric

H20 Water

HAP Hazardous Air Pollutant

HCl Hydrogen chloride

HEPA High-efficiency particulate air (filter)

HPLC High performance liquid chromatography HRGC/HRMS High Resolution Gas Chromatography/High Resolution Mass Spectroscopy

HRA Health risk assessment i:\projects\hwad\2017 rcra permit renewals\2018 permit application\main base renewal application\from jeff 021218\pods\cptp main document.doc\13-Mar-18\rkr v

ACRONYMS AND ABBREVIATIONS (Continued)

HVM Highly volatile metal

HWAD Hawthorne Army Depot

HWI Hazardous waste incinerator

HWC MACT Hazardous Waste Combustor Maximum Achievable Control Technology

ICP/MS Inductively coupled plasma/mass spectroscopy

ID Inner diameter item/hr Items per hour lb/hr Pounds per hour

LVM Low volatility metal mg/dscm Milligrams per dry standard cubic meters g/dscm Micrograms per dry standard cubic meters

MACT Maximum achievable control technology mg/m3 Milligrams per cubic meter

MIDAS Munition Item Disposition Action System

MSE MSE Technology Applications, Inc.

ng/dscm Nanograms per dry standard cubic meters

NDEP Nevada Department of Environmental Protection

NO Nitrogen oxide

NOx Oxides of nitrogen

NO2 Nitrogen dioxide

NSN National Stock Number

NESHAPs National Emission Standards for Hazardous Air Pollutants

NPD Nitrogen phosphorus detector

O One oxygen atom

O2 Oxygen

OH Hydroxyl

PAH Polynuclear aromatic hydrocarbon

PCDD/PCDF Polychlorodibenzodioxin/Polychlorodibenzofuran pH Standard unit for measurement of acidity/alkalinity

PIC Product of incomplete combustion

PM Particulate matter

PNA PolynNuclear aromatic

PODS Plasma-Arc Ordnance Demilitarization System

POHC Principal organic hazardous constituents

PPC Primary processing chamber

PPE Personal protective equipment psig Pounds per square inch gauge ppb Parts per billion ppm Parts per million ppmv Parts per million by volume psid Pounds per square inch differential i:\projects\hwad\2017 rcra permit renewals\2018 permit application\main base renewal application\from jeff 021218\pods\cptp main document.doc\13-Mar-18\rkr vi

ACRONYMS AND ABBREVIATIONS (Continued)

QA Quality assurance

QAPP Quality assurance project plan

QC Quality control

RCRA Resource Conservation and Recovery Act

RO Reverse osmosis

SCC Secondary combustion chamber scfm Standard cubic feet per minute

SOP Standard Operating Procedure

SSRA Site-specific risk assessment

SVM Semivolatile metal

STEM Sampling Train for Energetic Materials

SVO Semivolatile organic

TCLP Toxicity Characteristic Leaching Procedure

TCO Total chromatographable organics

TDS Total dissolved solids

TEQ Toxicity equivalence

TSS Total suspended solids

THC Total hydrocarbon

TSDF Treatment, storage, and disposal facility

TSI Thermal Stability Index

VOA Void of air

VO Volatile organic

VOC Volatile organic compound

VOST Volatile organic sampling train

WADF Western Area Demilitarization Facility i:\projects\hwad\2017 rcra permit renewals\2018 permit application\main base renewal application\from jeff 021218\pods\cptp main document.doc\13-Mar-18\rkr 1-1

1.0 INTRODUCTION

The U.S. Army is proposing to install a Plasma-Arc Ordnance Demilitarization System (PODS) in

Building 117-2 at the Hawthorne Army Depot (HWAD) Western Area Demilitarization Facility (WADF).

PODS is designed to destroy a wide variety of obsolete or unserviceable munitions using plasma technology.

Design and operation of the facility must satisfy both federal and state environmental regulations. This

Comprehensive Performance Test Plan (CPTP) document describes a testing program which will demonstrate that the proposed PODS meets or exceeds all the requirements of the Resource Conservation and Recovery Act (RCRA), the Clean Air Act (CAA) and the Nevada Division of Environmental

Protection (NDEP). This CPTP is designed to meet the operating and emission limitations set forth in the

National Emission Standards for Hazardous Waste Combustors (Title 40 Code of Federal Regulations

[CFR] Part 63, Subpart EEE), also known as the hazardous waste combustor maximum achievable control technology (HWC MACT) regulations.

By promulgating the HWC MACT, the U.S. Environmental Protection Agency (EPA) has transferred implementation of both emission standards and operating requirements from the RCRA program to the

CAA Title V air permitting program (FR Vol. 64, No. 189, Sept 30, 1999, p. 52979). Furthermore, the function of the RCRA trial burn has been redefined. The following quote, from EPA’s Hazardous Waste

Combustor website, explains the changes:

“Traditionally, a RCRA trial burn serves three primary functions: (1) demonstration of compliance with performance standards such as destruction and removal efficiency;

(2) determination of operating conditions that assure the hazardous waste combustor can meet applicable performance standards on a continuing basis; and (3) collection of emissions data for incorporation into a SSRA [site-specific risk assessment] that, subsequently, is used to establish risk-based permit conditions where necessary. The hazardous waste combustion MACT rule transfers the first two functions of a RCRA trial burn from the RCRA program to the CAA program (as part of the comprehensive performance test requirements), so the traditional RCRA trial burn will no longer be applicable. The responsibility for collecting emissions data needed to perform an SSRA is not transferred to the CAA program, however, because SSRAs are exclusively a RCRA matter…”

The performance tests are conducted with specific wastes selected to produce maximum emission rates of regulated pollutants. Important operating parameters will be monitored and recorded during operation of

PODS so that it will be possible at the conclusion of the tests to develop operating parameter limits which will ensure that emission rates will not exceed regulatory limits during continued operations. Waste feed i:\projects\hwad\2017 rcra permit renewals\2018 permit application\main base renewal application\from jeff 021218\pods\cptp main document.doc\13-Mar-18\rkr 1-2 limits have been proposed on a pollutant basis, and not on a munitions-type basis, and these feed rates will be validated by the testing program.

Limits set on a feed rate basis for both inorganic and organic pollutants provide more stringent control of organic emissions and more flexibility in munitions destruction than limits on total waste feed rate or total organic content of the waste feed. In developing the MACT standards, EPA has instituted feed rate control for metals and total chlorine. HWAD proposes to extend this concept by regulating organic constituents in the same way. In return, HWAD asks that the PODS unit not be limited on total waste feed amount since specific emissions limits will be set for all pollutants in the hazardous waste feed . The wide variety in physical form of the approximately 400 munitions to be destroyed makes it difficult to set an overall waste feed limit for the PODS system.

At the same time, HWAD is seeking a waiver from the ash feed rate limit requirement. This waiver is based on documentation of fabric filter pressure drop and use of a continuous opacity monitor and is presented in the Federal Register preamble to the HWC MACT (64 Federal Register [FR] Vol. 64, No.

189, Sept. 30, 1999, p. 52955, September 30, 1999).

These tests are also intended to satisfy the data gathering requirements of a risk burn. The emission data collected will be used to validate the health risk assessment.

The testing will be carried out in two phases. The first phase will be a Mini Burn period. The Mini Burn will be used to refine sampling and analytical methods proposed in this CPTP and to ensure representative operation of PODS during the performance test. The Mini Burn will provide NDEP and

Day and Zimmerman Hawthorne Corporation (DZHC) with a preliminary assessment of the proposed methods and the ability to measure extremely low concentration of the regulated pollutants, and will help to ensure that emissions resulting from PODS are representative of its proposed operation.

The Mini Burn will also be conducted to verify the assumptions for control of the feed rate for the various regulated pollutants contained in specific ordnance as well as assumptions that involve the efficiency of the pollutant control system.

The Mini Burn is intended to be a “shakedown” period and is not intended to demonstrate compliance with emission limitations or control efficiencies. Thus, DZHC will not submit the results of the Mini

Burn as part of the permit process. However, all operational parameters such as automatic waste feed i:\projects\hwad\2017 rcra permit renewals\2018 permit application\main base renewal application\from jeff 021218\pods\cptp main document.doc\13-Mar-18\rkr 1-3 cutoff (AWFCO) limits will be implemented during the testing program for protection of human health and the environment.

After the Mini Burn, MSE Technology Applications, Inc. (MSE), the PODS manufacturer, will adjust the pollutant feed rate levels, the PODS, the feed rate control, or monitoring systems as required.

The second phase is the formal performance testing, which is described in detail in Sections 6 through 8 of this document.

1.1 ORGANIZATION OF THE COMPREHENSIVE PERFORMANCE TEST PLAN

Section 2.0 of this CPTP describes the operation of PODS, including waste handling, air pollution controls, emission monitoring, and operating parameters. Section 3.0 describes in detail the wastes destroyed by PODS, their composition, feed rates, and proposed feed rate limits. The waste feed selection process for the performance test is presented in Section 4.0. Sampling and monitoring requirements are summarized in Section 5.0. Sections 6 thru 8 describe in detail the sampling, analytical, and quality assurance (QA) portions of the testing program. Section 9.0 explains how the sampling and monitoring data are analyzed, and Section 10.0 outlines the health and safety program. References used in preparing this document appear in Section 11.0 Figures and tables appear throughout the text. Finally, five appendices supplement this text:

• A: PODS Operation and Maintenance Practices

• B: Baghouse Operation and Maintenance

• C: Inspection and Maintenance Checklist and Data Quality Assurance Test Procedure for PODS

Continuous Emission Monitoring System (CEMS)

• D: Monitoring Requirements for PODS

• E: Sampling Methods i:\projects\hwad\2017 rcra permit renewals\2018 permit application\main base renewal application\from jeff 021218\pods\cptp main document.doc\13-Mar-18\rkr 2-1

2.0 DESCRIPTION OF PLASMA ARC ORDNANCE DEMILITARIZATION SYSTEM

PODS will be installed in Building 117-2 in the WADF. The PODS unit will be used to demilitarize obsolete and unserviceable small arms munitions, detonators, fuses, primers, pyrotechnic, smoke, incendiary, and other selected munitions. PODS has been designed to safely destroy a wide variety of obsolete and unserviceable munitions that are not otherwise currently treatable. Most of the materials to be treated in the PODS are considered RCRA hazardous waste because of their explosive (reactive) components. Some materials may also be hazardous because of their metal or organic content. The residence time for hazardous waste in the primary processing chamber is a minimum of 2 seconds for combustion gas and a minimum of 5 minutes for ash or slag.

PODS will consist of a plasma furnace with air pollution control equipment and a water treatment system.

The plasma furnace consists of computerized controls, a primary processing chamber, a slag collection chamber, two plasma arc torches, and a feed system. The air pollution control equipment consists of destruction or removal process steps for organic, volatile metal, acid gas, particulate, and oxides of nitrogen (NOx) contaminants. The water treatment system removes total metals, total dissolved solids, and total suspended solids.

System components, design, and operation are described in this section. Unless specified as a

Regulatory Control Parameter, design and operating conditions described in the text are based on design specifications or best engineering judgment and are for information only.

2.1 WASTE HANDLING AND BLENDING

Before they are treated in PODS, waste munitions will be controlled by the same handling and record keeping protocols that control these materials throughout their service life. These procedures provide comprehensive waste tracking (including inventory and custody) before materiel is placed on the PODS feed conveyer. No waste materials are blended prior to primary furnace treatment.

2.2 WASTE FEED SYSTEM

The waste feed systems consists of separate conveyor belts and isolation valves for ordnance and soil/iron

(see Figure 2-2). The soil/iron feed is not a waste but is a feedstock that facilitates formation of nonhazardous slag for subsequent ease of disposal. The soil and ordnance feeders are belt conveyors with individual pockets to hold ordnance, metal pieces, or loose material. Each belt has a cell that measures i:\projects\hwad\2017 rcra permit renewals\2018 permit application\main base renewal application\from jeff 021218\pods\cptp main document.doc\13-Mar-18\rkr 2-2 and records the weight of the contents of each conveyor pocket (cell). If the cell records a pocket weight that exceeds the specifications in the operator standard operating procedure, the weight cell halts the conveyor and alerts the operator. Each belt conveyor empties into a wye chute connected to the top of the primary reactor. The wye chute has two sets of valves that provide isolation from the primary reactor.

The ordnance conveyor uses two slide valves. The two slide valves operate in sequence so that individual items drop on top of the first valve. The first valve then opens, and the item falls into the space between the two valves. The first valve closes, the second valve opens, and the item falls into the primary reactor.

The soil feeder uses two flap-gate isolation valves with the same control scheme as the slide valves. The flap-gate isolation valves are commonly used in soil handling applications.

2.3 COMBUSTION PROCESS

The principal munitions treatment and destruction operation occurs in the primary processing chamber

(PPC). Design and operation of this unit are summarized in this section.

2.3.1 Primary Processing Chamber

The PPC shown in Figure 2-1 consists of a crucible section, a refractory-lined spool piece, and a refractory-lined dome. The PPC is designed and manufactured by MSE. A model number has not been assigned. The internal diameter of the chamber is approximately 6.5 feet after the refractory has been installed. The external diameter is almost 8 feet. The spool piece section is 4 feet high. The dome adds another 41/2 feet of internal height, and the crucible adds another foot in depth for slag. The internal volume of the chamber is approximately 284 cubic feet (ft3) and 19 ft3 in the crucible. A refractory packed “transition piece” is located at the bottom of the spool piece and over the crucible to provide a smooth transition between the cylindrical spool piece and the six sided top of the crucible. The types of refractory in the PPC for the Plasma Ordnance Demilitarization System are as follows:

• Upper section – Harbison Walker 14-85 castable refractory

• Lower section – Ruby SR firebrick

• Transition piece – Harbison Walker Ruby plastic

The crucible is fabricated with water-cooled, carbon-steel plates capable of maintaining structural integrity when full of slag and processing ordnance. The crucible is electrically grounded to allow transferred torch operation. A water-cooled port in the crucible acts as the tap hole when pouring slag.

The crucible will not have a refractory lining; instead, the cooling passages through the crucible panels i:\projects\hwad\2017 rcra permit renewals\2018 permit application\main base renewal application\from jeff 021218\pods\cptp main document.doc\13-Mar-18\rkr 2-3 will be designed to adequately cool the crucible, assuming molten material is in contact with the hot face of the panel. The slag will solidify next to the crucible, forming an insulating barrier next to a majority of the crucible surface during operation.

A water-cooled, carbon steel, refractory-lined spool piece provides volume to the furnace, allowing burnout of the ordnance reaction products as well as surge volume for the sudden expansion of gases as the ordnance burns or detonates. The spool piece also removes excess heat resulting from ordnance that has generated high heat during combustion. The internal volume of the PPC has been sized for a minimum gas residence time of more than 2 seconds at maximum processing rates. The unit has additional ports for mounting oxygen lances, cameras, and miscellaneous instrumentation.

G0771-02\i:\projects\hwad\2017 rcra permit renewals\2018 permit application\main base renewal application\from jeff 021218\pods\cptp main document.doc\13-Mar-18\rkr 2-4

FIGURE 2-1

PODS PPC AND SLAG COLLECTION CHAMBER

G0771-02\i:\projects\hwad\2017 rcra permit renewals\2018 permit application\main base renewal application\from jeff 021218\pods\cptp main document.doc\13-Mar-18\rkr 2-5

Gaseous oxygen is delivered to the chamber from a single lance. Pinhole cameras are mounted to allow viewing the arc, the molten slag (melt), and the processing feed material inside the chamber.

An emergency rupture disk is installed on the primary chamber to relieve pressure should it exceed the design limit of 15 pounds per square inch gauge (psig). Gases are vented from the primary chamber to the atmosphere outside of the building via a large duct. The rupture disc is a last-resort, protective measure. Numerous alarms and automated protective interlocks are in place to prevent overpressurization in the PPC.

2.3.2 Processing Operations

To initiate operation, PODS will be heated using the plasma arc torches until residual slag material is melted and a molten pool has been established. The system conditioning time is approximately 2 hours based on the warm-up time for the secondary combustion chamber. Next, the operator will verify that all

AWFCO parameters have been met. The ordnance feed will then be initiated and gradually increased to production rates. At this point, temperatures in the PPC will be maintained by control of ordnance feed rates, injection of water into the PPC, and use of lower torch power. Because of the design of the PPC, the operator has limited control over the lower end of the operating temperature in the PPC. The plasma torches are not designed to maintain maximum PPC temperatures without ordnance processing.

Ordnance will be processed at rates established for specific waste items. Oxygen levels and all offgas parameters will be maintained within the parameters specified by the RCRA and air quality permits.

When the hearth is full, feeding of ordnance will be stopped. The slag pool will continue to be treated to ensure oxidation, mixing, and processing of ordnance.

Periodically, the slag will be poured into a 55-gallon drum in the slag collection chamber, as described in

Section 2.5.1. After the pour has been completed, ordnance processing will resume. The filled slag drum and safety mold will be moved into the cooling position and replaced with an empty drum and safety mold.

When all scheduled ordnance processing has been completed, PODS will be shut down by first stopping all feed into the furnace. The molten slag is handled in the same manner as described in Section 2.5.1 and in Section 2.5.2. Some or all of the processed slag may be left in the hearth and then cooled, providing a slag layer for a cold startup later. Next, the torches will be secured, followed by the Secondary

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Combustion Chamber (SCC). Lastly, when the furnace has cooled to below 300° F, the air pollution control equipment may be secured.

2.4 AIR POLLUTION CONTROL SYSTEM

This section provides a comprehensive description of the hardware components (unit process hardware) for air pollution control in PODS. The air pollution control system (Figure 2-2) is presented in this summary and is available in Section 5.0 of the air permit application. Operation and maintenance practices are presented in Appendix A.

2.4.1 Plasma Furnace (Intrinsic Destruction)

Destruction is ensured by passing exhaust gas from the plasma arc furnace to a secondary combustion chamber (discussed separately). All exhaust gas generated in the plasma furnace and the secondary combustion chamber will pass through a series of air pollution control systems under sustained negative pressure.

2.4.2 Air Pollution Control Equipment Summary

The air pollution control equipment (APCE) consists of the following:

Secondary combustion chamber

Offgas quencher

Packed bed absorber

High-energy scrubber

Baghouse

Induced draft blower

Selective catalytic reduction for NOX removal.

A blower system is used to maintain negative pressure and prevent leakage. Superheaters, reheaters, and demisters are included to properly recondition the exhaust gases to optimize the efficiencies of the various control devices.

2.4.3 System Unit Process Descriptions

This section describes the specific unit process equipment included in PODS.

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FIGURE 2-2

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2.4.3.1 Secondary Combustion Chamber

The SCC is situated between the PODS furnace and the other components of the air pollution control equipment. Exhaust gas from the PODS furnace enters the SCC through an insulated pipe. The SCC is constructed of carbon steel, and is refractory lined with Harbison Walker 26 Castable and will be fired on #2 distillate fuel. The SCC is sized to maintain exhaust gas at a minimum of 1,800 °F and provide a minimum 2-second residence time at the design maximum combustion gas flow rate.

2.4.3.2 Quencher

The quencher uses fresh water to cool the hot combustion gases exiting the SCC before they enter the scrubber. The quencher is constructed of stainless steel. Recirculated scrubber liquor washes the lower walls of the quenchers to prevent the plating of solids and provides additional cooling of the offgas.

2.4.3.3 Absorber (Scrubber # 1)

The primary function of the absorber is to remove metals and acid gases. The absorber also removes heat from the offgas. The absorber is constructed of stainless steel and is filled with stainless steel packing material. The upflow packed bed scrubber recirculates scrubber liquor, which consists of a caustic solution of sodium hydroxide that is mixed into the liquor stream before it is sprayed into the absorber.

The quencher, absorber, and high-energy scrubber share a common sump, which is monitored to automatically maintain the pH in the sump. Because fresh water is injected in the quencher and high-energy scrubber, liquid must be blown down to maintain sump level. The addition of fresh water is used to maintain the liquids/solids ratios in the sump liquid. This scrubbing liquor is cooled to approximately

50 °F with a chiller before it is introduced to the absorber. Process gases will be cooled to less than 90°F before it exists the quencher or absorber.

2.4.3.4 High-Energy Scrubber (Scrubber # 2)

Fine water droplets moving at a high rate of speed capture particulate. The mechanism of capture is principally impaction. The fine water droplets are formed by the action of the high-speed free air jet upon a water spray laid onto the periphery of the free-jet stream. When the water spray strikes the high-speed jet stream, it is shattered into many small droplets of an optimum size so that it can be a target for fine particulate. Dust particles tend to bypass water drops of a large size, but will impact and be captured by smaller drops.

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For the creation of the small water droplets, a water spray is formed with a ring of fan type water spray nozzles surrounding the free-jet stream. At the boundary of the free-jet stream, there is essentially zero velocity external to the stream, and gas jet velocity internal to the stream, forming a region of very high shear wherein the water spray is applied.

The mixing process immediately follows as the gas is driven down an elongated mixing tube. It insures the complete wetting of any particles not already wetted by collision, and provides a coalescing of water drops into increasingly larger sizes so that final removal in a liquid/gas separator completes the process.

The liquid coalesces in a mixing tube (agglomerator) into larger droplets, which are removed downstream in a cyclone separator.

The water from the high-energy scrubber and moisture separator is drained back to the quencher and absorber sump and then is treated to reduce concentrations of dissolved and suspended metals.

2.4.3.5 Baghouse

A superheater reheats the offgas leaving the moisture separator before it enters the baghouse. The reheater has been designed to provide a maximum reheat of 190 °F. This process raises the moisture level in the gas above the dew point and optimizes the efficiency of the baghouse. The baghouse provides additional capture of the remaining particulate as it exits the scrubbing systems. The amount of particulate collected in the baghouse is expected to be small, as approximately 95 percent of the particulate should be removed by the hydrosonic scrubber. The baghouse has been equipped with an air pulsejet cleaning system. Particulate collected on the surfaces of the bags will drop into a hopper. The baghouse will use polyester bags. Appendix B contains a detailed plan for operation and maintenance of the baghouse. A baghouse leak detector will also be installed downstream of the baghouse. Details of the bag leak detection system are also in Appendix B.

2.4.3.6 Blower

A blower located downstream of the air pollution control equipment provides a vacuum of up to 30 inches of water in the PODS furnace and air pollution control system. Because the system upstream of the blower is under partial vacuum, any gas leaks will cause air to be drawn into the system rather than leak to the atmosphere. The blower is controlled to maintain negative pressure in the PPC.

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2.4.3.7 NOx Removal

NOx is removed from the offgas by a selective catalytic reduction removal system for nitrogen oxides. A reheater heats the gas as it exits the baghouse to a catalytic temperature of approximately 500 °F before it enters the NOx removal unit. The heated gas flows to the catalytic reactor, where anhydrous ammonia is injected. The ammonia reacts on the catalyst with nitrogen oxide (NO) and nitrogen dioxide (NO2) to form elemental nitrogen and water.

2.5 ASH HANDLING

A large portion of the waste feed will melt into the slag and never become ash. Some particulate matter will be created, however, and will escape from the furnace into the air pollution control equipment. This ash will be handled in two ways. First, the wet scrubbers are the primary air pollution control for particles. They will collect the majority of the ash that escapes the furnace chamber. The ash trapped by the scrubber becomes wastewater sludge. Second, a small amount of ash will escape the wet scrubber.

This material will collect in the baghouse dust collector downstream of the scrubbers. Ash from the baghouse will be analyzed using the Toxicity Characteristic Leaching Procedure (TCLP) extraction procedures and will be disposed of at a landfill or treatment, storage, and disposal facility (TSDF), as appropriate. The next sections cover handling of slag from the PODS combustion chamber and the dust from the SCC and baghouse. The ash that is collected in the scrubbers becomes wastewater sludge and is covered in Section 2.6.

2.5.1 Slag Collection Chamber

The slag collection chamber is located directly below the primary PODS furnace chamber. The slag chamber is an enclosed carbon-steel vessel to ensure that personnel are not exposed to hot materials. This chamber contains the automated mechanisms needed to tap a pour hole into the crucible with a tapping lance and guide the molten slag into a standard 55-gallon drum that is contained in a safety mold. The slag safety mold contains the slag drum during hot slag handling operations, before the slag is solidified.

The slag collection chamber contains three slag drums with safety molds on a conveyor system that moves the slag drum and safety mold for positioning. The empty slag drum and safety mold will be loaded onto the conveyor through the loading door in the back of the chamber. The slag drum with safety mold will then be conveyed to the pour position. After the pour, the hot (full) drum and safety mold will be removed to the cooling position, where the molten slag will be cooled and solidified into a stable, G0771-02\i:\projects\hwad\2017 rcra permit renewals\2018 permit application\main base renewal application\from jeff 021218\pods\cptp main document.doc\13-Mar-18\rkr 2-11 solid, glassy waste product that will be stored and disposed of in its steel, 55-gallon container. Once the slag has solidified (after about 60 minutes), the barrel is removed via a door opposite the loading door.

The three-drum design ensures that an empty drum is in the pour position at all times.

A “burning bar” tapping mechanism for clearing the tap hole of solidified slag is mounted on the side of the slag collection chamber. The “burning bar” consists of a lance torch mounted to a positioning mechanism. The tapping lance is a steel casing packed with special aluminum or magnesium wire.

Pressure-regulated, gaseous oxygen is introduced into the cold end of the bar. Oxygen flows through the wire packing to the hot end of the bar. The wire-filled bar is then ignited. In the presence of oxygen, the wire packing burns at high temperature. The flow rate of the oxygen is varied to control burn rate and temperature. The tapping lance bar is a commercial product used in foundries and steel mills to open tap holes, and is also used by the construction industry for specialty demolition of steel and concrete structures. The tapping lance is a consumable item with additional segments added to the cold end. The tap hole is normally plugged with solidified slag, and the burning bar is needed to open this port.

Two maintenance doors are mounted on the slag collection chamber wall opposite the tapping mechanism for maintenance of the crucible, conveyors, and other equipment contained within the chamber.

A shroud encloses the crucible and seals the collection chamber to the primary processing chamber for

PODS. The slag chamber is also fitted with purge air capability, which allows the chamber to be completely purged before the slag access doors are opened. All gases from the cooling slag, the tapping lance, and all slag chamber purges will be routed to the PODS afterburner and controlled with other process emissions.

2.5.2 Slag Handling Methods

The safety mold contains the pour drum and acts as a backup if a drum were to rupture, overflow, or lose structural integrity. A conveyor system moves the pour mold into position for pouring and out for drum removal through the slag access doors. The slag in the drum is cooled until it is solidified into a stable, solid, glassy waste product.