WERF MACT Feasibility Study Report

This study was undertaken to determine the technical feasibility of upgrading the Waste Experimental Reduction Facility (WERF) at the Idaho National Engineering and Environmental Laboratory to meet the offgas emission limits proposed in the Maximum Achievable Control Technologies (MACT)rule. Four practicable offgas treatment processes were identified, which, if installed, would enable the WERF to meet the anticipated MACT emission limits for dioxins and furans (D/F), hydrochloric acid (HCI), and mercury (Hg). Due to the three-year time restraint for MACT compliance, any technology chosen for the upgrade must be performed within the general plant project funding limit of $5 M. The option selected consists of a partial-quench evaporative cooler with dry sorbent injection for HCI removal followed by a sulfur-impregnated activated carbon bed for Hg control. The planning cost estimate for implementing the option is $4.17 M (with 24% contingency). The total estimated cost includes capital costs, design and construction costs, and project management costs. Capital costs include the purchase of a new offgas evaporative cooler, a dry sorbent injection system with reagent storage, a new fabric filter baghouse, a fixed carbon bed absorber, and two offgas induced draft exhaust fans. It is estimated that 21 months will be required tomore » complete the recommended modification to the WERF. The partial-quench cooler is designed to rapidly cool the offgas exiting the secondary combustion chamber to minimize D/F formation. Dry sorbent injection of an alkali reagent into the offgas is recommended. The alkali reacts with the HCI to form a salt, which is captured with the fly ash in the baghouse. A design HCI removal efficiency of 97.2% allows for the feeding 20 lbs/hr of chlorine to the WERF incinerator. The sorbent feed rate can be adjusted to achieve the desired HCI removal efficiency. A fixed bed of sulfur-impregnated carbon was conservatively sized for a total Hg removal capacity when feeding 10 g/hr Hg to the WERF incinerator. An added benefit for using carbon adsorption is that the activated carbon will also capture a large fraction of any residual D/F present in the offgas.« less