High Temperature Calcination - MACT Upgrade Equipment Pilot Plant Test
About one million gallons of acidic, hazardous, and radioactive sodium-bearing waste are stored in stainless steel tanks at the Idaho Nuclear Technology and Engineering Center (INTEC), which is a major operating facility of the Idaho National Engineering and Environmental Laboratory. Calcination at high-temperature conditions (600 C, with alumina nitrate and calcium nitrate chemical addition to the feed) is one of four options currently being considered by the Department of Energy for treatment of the remaining tank wastes. If calcination is selected for future processing of the sodium-bearing waste, it will be necessary to install new off-gas control equipment in the New Waste Calcining Facility (NWCF) to comply with the Maximum Achievable Control Technology (MACT) standards for hazardous waste combustors and incinerators. This will require, as a minimum, installing a carbon bed to reduce mercury emissions from their current level of up to 7,500 to <45 {micro}g/dscm, and a staged combustor to reduce unburned kerosene fuel in the off-gas discharge to <100 ppm CO and <10 ppm hydrocarbons. The staged combustor will also reduce NOx concentrations of about 35,000 ppm by 90-95%. A pilot-plant calcination test was completed in a newly constructed 15-cm diameter calciner vessel. The pilot-plant facility was equipped with a prototype MACT off-gas control system, including a highly efficient cyclone separator and off-gas quench/venturi scrubber for particulate removal, a staged combustor for unburned hydrocarbon and NOx destruction, and a packed activated carbon bed for mercury removal and residual chloride capture. Pilot-plant testing was performed during a 50-hour system operability test January 14-16, followed by a 100-hour high-temperature calcination pilot-plant calcination run January 19-23. Two flowsheet blends were tested: a 50-hour test with an aluminum-to-alkali metal molar ratio (AAR) of 2.25, and a 50-hour test with an AAR of 1.75. Results of the testing indicate that sodium-bearing waste can be successfully calcined at 600 C with an AAR of 1.75. Unburned hydrocarbons are reduced to less than 10 ppm (7% O2, dry basis), with >90% reduction of NOx emissions. Mercury removal by the carbon bed reached 99.99%, surpassing the control efficiency needed to meet MACT emissions standards. No deleterious impacts on the carbon bed were observed during the tests. The test results imply that upgrading the NWCF calciner with a more efficient cyclone separator and the proposed MACT equipment can process the remaining tanks wastes in 3 years or less, and comply with the MACT standards.
- Research Organization:
- Idaho National Lab. (INL), Idaho Falls, ID (United States)
- Sponsoring Organization:
- DOE - EM
- DOE Contract Number:
- DE-AC07-99ID-13727
- OSTI ID:
- 910616
- Report Number(s):
- INEEL/EXT-04-01625; TRN: US200724%%289
- Country of Publication:
- United States
- Language:
- English
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