8ShircoInfrared

'- Systems( n c o r p o r a t e d

April 7, 1987

Mr. Steven M. LuzkowRemedial Action SectionGroundwater Quality DivisionMichigan DNRP. O. Box 300028Lansing, MI 48909

Dear Steve:

Regarding our telephone conversation, I am enclosing thefollowing:

1) Technical Specifications of the Shirco PilotDemonstration Unit as requested by the DNR AirDivision.

2) List of on-site requirements for the utilizationof the unit at the Rose Township site (assuming 10operating days).

3) Economic model detailing the estimated costs as-sociated with thermally treating the soils at RoseTownship utilizing a full-scale Shirco InfraredSystem.

The following assumptions were used to determine the unitcosts and total costs in the economic model:

1) A mass to volume (tons/cubic yard) ratio of 1.3:1.e.g. 45,000 cubic yards is equivalent to 58,500tons.

2) Total cost/ton in the model is pre-tax, pre-profitand pre-interest. Therefore, additional contingencyshould be added. An assumption of an additional 30%over model prediction can be made to estimate bidswith our equipment ($99.29 x 129.08 say $130/ton).

We hope these estimates will be of help to you in completingthe Rose Township Feasibility Study.

As for a site safety plan, I have received your copy of themaster plan and am incorporating appropriate portions intothe established Shirco plan. I hope to forward a draft copyfor your comments within the next few days.

EPA Region 5 Records Ctr.

1195 Empire CentralDallas. Texas 75247-4301 231424

(214)630-7511

Please feel free to call me anytime if you need additionalinformation.

Mark L. deLorimierManagerTechnical ProductsiEnclosures

cc: Kevin Adler, U.S. EPA w/enclosuresLinda Galer, U.S. EPA w/enclosuresHoward Wall, U.S. EPABill Frietsch, U.S. EPASeymour Rosenthal, EnvirsponseAndrew Hogarth/Ronald Willson, MDNRJim Linton, MDNRDave Ferrier, MDNR

ON-SITE REQUIREMENTS FOR SHIRCO DEMO UNITROSE TOWNSHIP SUPERFUND SITE

Power Generator (1) - 480 volts, 60 amps, 3 phase

Scaffolding - 14 feet high minimum for sampling crew

Platform balance (1) - capable of 200 Ibs. /£/<"/4/̂ /̂̂ /»̂ *ui.

LP gas (100 Ib. bottles) - assuming 10 operating days at12/hours/day, it is estimated that no more than a totalof 30 bottles will be required.

Tables (4)

Chairs (12)

Water Storage Tanks - It is estimated that no more than atotal of 200 gallons/day will be required. (Unit oper-ations plus potable supply.)

Steam Cleaner (1) - Diesel

Toilet facilities

Support Trailer (1) - large enough for miscellaneous supplystorage and crew breaks.

Telephone (1)

Planking for trailer roof - (6) 2" x 12" x 14'

Exterior lighting (2)

Drums - equivalent number of 55-gallon drums for ash asthere are feed drums.

- (10) 30-gallon drums (I/day) for blowdown water

Drum hauler (1)

Site security

Site Preparation - grading, fill, etc., for 45' trailer

ROSE TOWNSHIP SUPERFJND SITE

-Apr-87 ON-SITE MOBILE INCINERATION SERVICEESTIMATED ECONOMIC MODEL

APRIL 1987

Equipment =* 1 Shirco Mobile Furnace System 9 x 61 with related ancillaries

Effective Thruput 36.855 tons in 50 wks/yr a 123 tons/day =

At 82.42X Utilization

Operating Expense:

PersonnelWage RateOverhead Rate

12 Men - 3 Shifts - 6 days/wk$ per hr =

Total Labor

$500 per day$1.25 per ton$16.67 per ton (max)

$0.80 per 1000 gal

$2.50 per ton

Site Expenses:Pit & TransferChemical CostEnergy CostAsh DisposalScrubber EffluentCooling Waterapai e km is

MaintenanceMonthly Oper Costs

Compliance,Etc $3.00 per tonFuel $1.68 per tonOper Ovhd $30,713 per mo

Permit/Process Assistance - OSISRelocation, Transport

Insurance

Misc Contingency 10.00%

TOTAL OPERATING COSTS

Equipment Cost Estimate:Shirco Mobile System 9 x 61

+ Instrumentation, Control VanGenerators, Feed Prep EquipField Facilities

TOTAL EQUIPMENT COST

EQUIPMENT COST PER TON

3,110,000

For Payback in - 36 months

10,238 Ib/hr

per yr average rateage Rate

$ Per Year

150,00046,069

x) 614,400> 0> 0

I 12.442ou.uuu92,138

110,56561,916368,550

120,00060,000

248,800

238,421

$2,622,628 DIRECT COST/TON

2,860,000

(Est) 150,000(Est) 100,000

$/TON

4.071.2516.670.000.000.34£.. I/

2.50

3.001.68

10.00

3.26

1.63

6.75

6.47

$71.16 /

$28.13

yr.

TOTAL COST PER TON Before PROFIT,INTEREST and TAXES $99.29 /«,=========== '

RUSE 'JtJWNSHIP SITE

ON-SITE INCINERATION SERVICE

HCOEL ASSUMPTIONS (9 x 61)

Furnace Residence TimeMaterial DensityBed Thickness

Operating Utility

Payout Period

Price per Ton

16.00 min90.00 Ib/ft31.00 in

\ Daily Tons> 123

/ r====

6 days/wk50 wks/yr ( 300 days/yr)

82.42% out of 7 days for 52 weeks

36 months1 Units

$200.00 36,855 tons/yr

Operating CrewAverage Hourly WageMaintenance Cost per tonFuel Cost per tonEnergy cost per tonChemical Cost per tonTesting Cost per tonWater Usage per tonOper Cost Contingency %Monthly Oper OverheadEquip Insurance

12 men$12.00$2.50$1.68$16.67 3$1.25$3.00422 gal

10.00%$30.713 per mo$248,800 per yr

$92,138 /yr

$0.80 /gal

$368.55 /day

5.00% of Monthly Revenue8.00% of Equip Cost

Material PropertiesOrganic ContentWater ContentHeating Value

0%7%0 BTU/lb

TECHNICAL SPECIFICATIONSSHIRCO THERMAL DEMONSTRATION UNIT

ROSE TOWNSHIP SUPERFUND SITE

1) Primary Chamber (Furnace)

A. Internal Dimensions* - 22.5"(H) x 16"(W) x 100"(L)

B. Refractory Thickness and Typeo 85% silica/15% alumina ceramic fiber blanket man-

ufactured by Carborundum Companyo 7" thick sides & top; 5" thick bottom

C. Temperature - maximum operating temperature of1900°F

D. Method of Heating - Infrared energy provided by 12transversely-mounted .75" O.D. silicon carbideheating elements (Carborundum Company)

E. Fuel Used & Rate - Electricity, 40 KW

F. Burner Used - None

G. Combustion Controls -1) Temperature via PI controllers receiving T/C

signal from primary chamber and sending adjust-ment signal to power source.

2) Combustion air rate and distribution3) Residence time via belt speed

H. Internal Pressure - .01" WC (slightly below atmo-spheric)

I. Soil Feed Rate - 150 Ib/hour maximum, actual feedrate to be determined based on 1) moisture content,2) particle size, 3) % volatiles, and 4) density

*Refractory face to refractory face

2) Secondary Chamber

A. Internal Dimensions - 15" square x 18.5 ft. long

B. Refractory Thickness & Type - 12" thicksilica/alumina

C. Exhaust Gas Flow Rate - 830 ACFM (maximum)

D. Temperature - 1800 - 2200° F (as required)

E. Fuel - Propane may be used for all cases between1800-2200° F; 1.5" electric heating elements may beused for some cases up to 2000° F.

F. Burner Description

o Primary Burner - Forced air nozzle mix burner by"Maxon." Model #36600, 1 1/2" Kinemax burnerwith blower and double block and bleed gas train.Rated 375,000 Btu/hr at 70 SI air diff. (propanegas)

o Auxiliary Burner - Forced air, premix gas burnerby "North American." Model #4651-01-B with #4031pilot mixer and double block and bleed valve.Burner rated 36,700 Btu/hr at 8" w.c. air pres-sure. Burner gas and air supplied by primaryburner system.

G. Combustion Controls - 1) Temperature vis PI con-troller to adjust firing rate 2) O2 and gas analyzerused by operator to adjust input combustion air forparticular waste 3) G>2 for burners linked with gasinput valve and adjusted upon calibration of burner.

3) Heat and Mass Balance

See attached furnace analysis for previous PCB contami-nated soil test (Twin Cities).

4) Material Handling

Material excavated by the customer or subcontractorshall be screened and delumped by Shirco or a subcon-tractor prior to start of test program. Samples ofmaterial prepared shall be taken and analyzed at leastsix weeks prior to the start of the test program. Feedin 55 gallon drums will be transferred to five gallonpails and hand fed to the hopper by an operator. Ash isdischarged through a screw conveyor into a sealed 55gallon drum for each test case. Disposal would be byothers after analysis.

5) Analysis of Soil

To be done by others.

6) Monitoring Equipment - Description

A. Opacity - noneB. Oxygen - SCC exhaust by electrochemical cellC. Carbon Monoxide - SCC exhaust by NDIRD. Carbon Dioxide - SCC exhaust by NDIRE. Temperature - Process temperatures are monitored by

Type K metal-sheathed mineral-insulated thermocoupleassemblies manufactured by CGS ThermodynamicsCompany. The following process temperatures aremonitored:

Primary Chamber

Waste Feed ZoneZone AlZone A2Mid-zoneZone BlZone B2Exhaust GasAsh Collection Hopper

Secondary Chamber

Mid ChamberExhaust Gas

Stack

Exhaust Gas

7) Preventive Maintenance

Preventive maintenance is a part of the establishedinspection procedure used to verify that the Demonstra-tion Unit, waste containers, and safety and emergencyequipment are operating normally, or in a state ofstandby readiness. Copies of the Inspection Scheduleand associated checklists are attached.

8) Venturi & Scrubber

A. Scrubbing liquor/exhaust gas flow rate ratio12 gpm/500 CFM minimum15 gpm/500 CFM nominal

B. Pressure Drop Across System13-15 w.c.

C. Liquor Cleaning & NeutralizingScrubbing liquor is water with NaOH used for neu-tralizing. The NaOH is injected by an operator ashe measures pH. Scrubbing for particulates is doneby a single venturi, and a spray tower is used forgas scrubbing. No packing is used.

D. Liquor pH at Inlet - 7 to 8

E. Demisting Equipment - Chevron or wiremesh mist elim-inators

P. Exhaust Gas Flow Rate & Temperature -160 CFM at 180° F nominal200 CFM at 200° F maximum

G. Stack Height & Exit Point24 feet above ground3.875 inches I.D.

H. Monitoring EquipmentpH - currently accomplished with litmus paper on 30-

minute intervals. A pH meter has been proposedfor installation.

Liquid Flow Rate - NonePressure Drop - Magnehelic gauge in inches W.C.Suspended Solids - Settling in graduated cylinder

9) Fugitive Emissions Control

A. During Excavation - To be done by othersB. Feeding - Maintenance of negative draftC. Exiting Chamber - Conveyor screw discharge into

sealed drumD. Final Disposal - To be done by others

10) Plot Plan

To be done.

11) Failures

11.1 General

System alarms are very important to any processcontrol system since they aid the operatorinsupervising the overall operation of the processvariables and equipment. An alarm is initiallyindicated by the sound of a horn or bell as wellas a flashing light on the annunciator panel whichindicates the particular area of the furnace that

is having trouble. The audible alarm can besilenced and the flashing of the light stopped bypressing the alarm acknowledge push button. Thelight on the annunciator will stay on, however,until the trouble is resolved.

Presented in the following paragraphs is adescription of each system alarm. Section 11.2covers the alarms which incorporate "interlocking"with other equipment resulting in automaticallycontrolled component shutdowns. These shutdownsare designed into the control system for componentprotection. Section 11.3 covers the alarms whichannunciate only.

11.2 Alarms - Interlocking

11.2.1 High Primary Chamber Temperature

Function: Thermocouples located in thechamber send signals to the control cabi-net. A temperature above 1850° F turns onan alarm light and sounds a horn.

Response: Operator should compare thetemperature on recorder with temperatureon temperature switch display. IF theyare significantly different, suspect afalse alarm (bad thermocouple). Checkthermocouple connections at patch panelinside control cabinet. Verify controllersetpoints. Check combustion air supply.If it starved air process, you may need todecrease combustion air. If it is a com-plete combustion process, you may need toincrease combustion air. If temperaturecannot be reduced in 15 minutes, operatorshould cease waste feed.

Interlock: Shuts off primary HEPCs untillimit value is no longer exceeded.

11.2.2 High Secondary Chamber Temperature

Function; Thermocouple mounted in sec-ondary chamber sends a signal to thecontrol cabinet. If the signal exceeds2500°F (adjustable) a light flashes on theannunciator panel and a horn or bellsounds.

Response: The operator should check thetemperature control loops to make sure itis a legitimate alarm. If it is, heshould increase secondary air flow to tryto cool the chamber down. Check to seethat the gas valve actually closed. Itmay be a monetary highly volatile spot inthe feed, and the problem should clearshortly. If this is not the case and thetemperature does not decrease in 15 min-utes, the operator must reduce the feedrate.

Interlock: Deactivated secondary chambergas and/or HEPC until temperature fallsbelow the limit value.

11.2.3 Low Secondary Chamber Temperature

Function: A thermocouple mounted in thesecondary chamber provides a signal to thecontrol panel. A temperature below 1800°F(adjustable) turns on a flashing light atthe annunciator panel and sounds a horn orbell.

Response: The operator should immediatelycheck the fuel supply for low level orpressure. If the HEPC is in use, checkfor proper operation.

Interlock: Deactivates the feed conveyorclutch which stops feed to the primarychamber. The feed will resume when thetemperature rises above the limit value.

11.2.4 Secondary Chamber Fuel (Gas) Pressure Low

Function: A pressure switch mounted onthe fuel supply line sends a signal to thecontrol cabinet. If the pressure fallsbelow five inches water column, an alarmlight is actuated and a horn or bellsounds.

Response; Operator should first check thegas source. If a truck or tank is used, atank change may be in order. If itappears that pressure cannot be quicklyrestored, the HEPC should be turned on.If the process cannot be sustained withoutgas, then a normal shutdown should be ini-tiated.

Interlock: The fuel gas main servicevalve closes until the pressure risesabove limit value.

11.2.5 Secondary Chamber Burner Off

Function: A flame sensor in the burnergas control system signals the controlcabinet if the burner flame is extin-guished. A flashing alarm light is turnedon at the annunciator panel and sounds ahorn or bell.

Response; If restart cycle does notrelight the burner, the operator mustdetermine whether the shutoff is due to aninterlock or whether it can be repairedquickly. If necessary, the heating ele-ment power center should be turned on.

Interlock: Initiates restart cycle.

11.3 Alarms - Annunciate Only

11.3.1 Heating Element Power Center Off

Function: HEPC contact turns off statuslight at control panel and activatesflashing alarm light for appropriate HEPCat annunciator panel and sounds a horn orbell.

Response; Operator must quickly determineif the HEPC has failed or is shut down byan interlock. If not an interlock, hemust then determine whether processing cancontinue at the present or at a reducedrate. Appropriate shutdown or reductionin feed rate is then made.

11.3.2 Scrubber Recycle Pump Off

Function: A contact on the pump motorstarter provides a signal to the controlcabinet which turns off the status lightand turns on a flashing alarm light at theannunciator panel. An audible alarm isalso sounded.

Response: The operator should immediatelyshut off feed to the primary chamber. Heshould then open the valve supplying waterto the venturi from the make up water tosupply enough water to maintain the stacktemperature below 200° F. If temperaturecan be maintained, processing of materialthat is already in the primary chamber maycontinue. If it cannot be maintained, heshould shut off all HEPCs and the burner.

11.3.3 Scrubber Recycle Liquid Pressure Low

Function: A pressure switch in the scrub-ber water recycle supply line signals thecontrol cabinet and turns on a flashingalarm light at the annunciator panel andsounds an audible alarm if the pressurefalls below 5 psig.

Response; Operator should stop feed andshut off the HEPCs and burner if stacktemperature cannot be maintained at lessthan 200° F.

11.3.4 High Exhaust Stack Temperature

Function; A thermocouple in the stacksends a signal to the control cabinet. Atemperature above 200° F turns on a flash-ing light at the annunciator panel andsounds an audible alarm.

Response; Operator should discontinuefeed and shut off HEPCs and burner.

This failure condition may be a result oflow or no scrubber liquid flow due toscrubber recycle pump off or scrubber liq-uid pressure low. See these occurrences.

•'-'(,;'. ; •: ' ' • • . '

£>.*•;:>•'•'.''•

SHIRCO INFRPRED FURPCE PNPLYSIS

THIN CITIES BPRREL «2 PORTPBLE

12/17/88

FURNPCE PPRpnETERS

TOTPL FEEDTOTflL OKI SOLIDS

j l DRT SOLIDS1 I UOLPTILE SOLIDS1 » UDLPTILE LIQUIDj I UPTER

UOLPTILE SOLIDS P/FUOLPTILE LIQUID P/FUOL. SOL. HEPTINO UPLUEUOL. LIQUID NEPTINO UPLUEFURNPCE PREP FT2« EXCESS PIR« LI8. UOL. COnpUSTED IN FURN

1 Jt UOL. SOL. CDHBUSTED IN FURN• l UOL. SDL. IN EXHPUST1 CPC03

1 SLUDGE TEnrERflTLKEI FURNPCE EXHPUST TErFERPTUREj SOLID PRODUCT TEHPERPTURE1 SOLID PRODUCT SrFfi-r COOLED?] COMBUSTION PIR TEflPERPTURE

UNIT ESTlrPTE

IBB88.8891.B795.8433.B677149B0B18B8Bisaa.71eB301480

5BBNO50

PFTERBURNER PPRPflEIERS

P/B GPS P/F 14ft/B EXHAUST ItriP 7IBBft/-B fifiif FT2 155H/B OflS HEP I INS UflLUE I8BBBR/B FRPCI EXCESS OXT .Bfl0/B CDHBUSTIDK «IR SBP/B EXH. DILUTION PIR BDILUTE TO 7 DEQREES F 8

FR^criONS of cxineusiioN PRODUCTS co2- .2883 «o- .BSSBIS in- .7325 502- i.g

INPUT rtpSS t*>0 ENERGfL8/HR BTU/HP

IHEO PIP 81. 381313 738.38298EXCS PIR B BSLQ H20 6.7 333SDL UOL ?.S22B<I5 32. 78558̂ 5SOL PSH 88.287155 1B78. 58344LIO UOL 4.33 137.53ASH GLG H20 B B

OUTLET PPSS PhD ENEFGTLB/HF BTU/HR

EXST OPS 75.83476 -42829.8826DRf COIIB 83,1327157 -22832.1332COnB HJD 3.39884B67 -633B. 37337SLG K20 8.7 -11712.27EXCS PIR B 0GPS UOL 1.317 -2B34. 87395SOL flSH 8B.2B7J33 -18783.8344SOL UOL B BPSH CLQ H20 B B

HEPT OF COrtBUSTION 78913.883SLIRFPCE HEPT LOSS -37500INPUT ENEKST REOUIFED -381 5. "'1 391ELECTRIC POUER REQUIRED -J.S73M318 KU

PFTERBURNER INLET IVIES I EHEPGTLB/HR BTU/HR

FURN EXST 73.B3478 42829.8628THEO PIR 18.438 721.256EXCS PIR 38.8357287 37B. 288721PSH CLG H20 B 8

AFTERBURNER OUTLET npSS I ENEROTLxB/HR BTu/HP

TOT EXH 124.4B433 -313B1.3643CRT COrB 81.7258643 -47631.4437IOTPL H2B 11.876535 -26314.8386EXCS PIR 3B. 8557267 -17438.2828EXH CLG H20 8 <

HEPT OF census u ON ?3>eoSLIRFPCE HEPT LOSS -3875BINPUT ENERGY REQUIRED B3I77.3776ELECTRIC POUER 18.4381352 KU

PFTtRBURNER EXHPUST ENTHPLPT•-812. 784431 BTU/LB DRT GPS

PFTERBURNER INLET CONDITIONS UITH PROPPNELB/lf BTU/HR

FURN EXH 73.83478 42823.6628THEO PIR 18.438 221.258EXCS PIR 38.8557267 378.288721PSH CLQ H28 0 8pROFPNf s. enrr47?2 283.33ee88COr«B Klft 131.385433 3433.27424EXCESS PI» 36.3474334 678,363343

AFTERBURNER OUTLET CONDITIONS UITH PROPPNELB/HR BTU/HR

TOT EXH 343.B3S82 -243874.831DRT COMB 223.836818 -134113.833TOT H20 27. 8537755 -81714.7241EXCS PIR B7.4B3222I -17438.2828

PCFtl

13.e388O>l8

B

pern82.173B31?46.88283745.B23B9928.41813B44B1.83778322

8

PCFP62.173B5124.1B2803748.8833828B

PCFH143.B7715388.732133121.333163634.3438523a

FUELpern

82.17383124.187883740. 8633828014. 34388 J 733.688133312.3MB873

FUELPCFtl

334.473838243.433261S0.B38184133.88*41 34

TEWCDEG F)7B7B

OBB

TEI1PCDEO F)14KB14M14BBMPBM0e1488

148B

TEtlPCOEO F314BB

7B7B1488

TEnPCDEG FJ22BB228B728022BB770B

TEW IDE 0 F3148878781498787«;n

TEPPtDEG FJ7288?7BB72B822 BB

AFTERBURNER EXMWJST ENTHPLPT—774.934841 BTU/LB DRT OPS

SCRUBBER EXWUST fLOUTEMPCDEB FJ FLOU CCU. FT/nlN312B 87.3258281130 32.6082BS8148 33.432748815B 1B8.733B4310B 171.3434721'B 141.73883518B 174.33S537

JNLET MUHIDITT .1BS835378 LB M70/LB DR