&EPA Hospital Incinerator operator Training Course: Volume I1 Presentation Slides
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&EPA Hospital Incinerator operator Training Course: Volume I1 Presentation Slides
P
E PA - 45 0 / 3 - 8 9 -0 0 4
HOSPITAL INCINERATOR OPERATOR
TRAINING COURSE:
VOLUME I I P R ES EN TAT1 0 N S L I DES
CONTROL TECHNOLOGY CENTER
SPONSORED BY:
Emission Standards Div is ion O f f i ce of A i r Qua l i t y Planning and Standards
U.S. Environmental Pro tec t ion Agency Research Triangle Park, NC 27711
A i r and Energy Engineer ing Research Labora tory O f f i ce o f Research and Development U.S. Environmental Pro tec t ion Agency '
Research Triangle Park, NC 27711
Center for Environmental Research In format ion O f f i ce o f Research and Development U.S. Environmental Pro tec t ion Agency
Cincinnati , OH 46268
March 1989
EPA-450/3-89-004 March 1989
HOSPITAL INCINERATOR OPERATOR TRAINING COURSE: VOLUME I 1
PRESENTATION SLIDES
EPA Contract No. 68-02-4395 Work Assignment 16
Prepared by:
Midwest Research Institute Suite 350
401 Harrison Oaks Boulevard Cary, North Carolina 27513
Prepared for:
James A. Eddinger Office o f Air Quality Planning and Standards
U. S. Environmental Protection Agency Research Triangle Park, North Carolina 27711
Control Technology Center U. S. Environmental Protection Agency
Research Triangle Park, North Carolina 27711
0 ISCLAIMER
This document generally describes the proper operation of a hospital waste incinerator. It is based on EPA's review and assessment of various scientific and technical sources. The EPA does not represent that this document comprehensively sets forth procedures f o r incinerator operation, or that it describes applicable legal requirements, which vary according to an incinerator's location. Proper operation o f an incinerator is the responsibility o f the owner and operator.
endorsement or recommendation for use. Mention o f trade names or commercial products does not constitute
i i i
ACKNOWLEDGEMENT
This document was prepared by Midwest Research Institute located in Cary, North Carolina. Principal authors were Roy Neulicht and Linda Chaput; Dennis Wallace, Mark Turner, and Stacy Smith were contributing authors. Participating on the project team for the EPA were Ken Durkee and James Eddinger of the Office of Air Quality Planning and Standards, Charles Masser of Air and Energy Engineering Research Laboratory, James Topsale of Region 111, Charles Pratt of the Air Pollution Training Institute, and Justice Manning of the Center for Environmental Research Information. Also participating on the project team were Carl York and William Paul of the Maryland Air Management Administration.
Numerous persons were very helpful throughout this project and provided information and comments for these course materials. below are some who deserve special acknowledgement for their assistance.
Listed
Mr. Larry Doucet, Doucet and Mainka, who provided a thorough review of the student handbook.
The following persons and facilities who provided our staff access to their facilities:
Messrs. Steve Shuler and Greg Swan, Joy Energy Systems; William Tice, Rex Hospital; Dean Clark, Bio-Medical Services, Inc.; Gary Kamp, Presbyterian--University Medical Center; Don Rust, Duke University Medical Center; Chip Priester, Southland Exchange Joint Venture; and Gregory Price, The Johns Hopkins Hospital.
The following manufacturers who provided us with detailed operating and maintenance information:
Joy Energy Systems, John Zink Company, Cleaver Brooks, and Industronics.
Mr. Charles Bollack and his staff, Mercy Medical Center, who hosted the first trial run of this course and Mr. Robert J. Winterbottom, R. J. Winterbottom, Inc., who assisted during the course at Mercy Medical Center.
iv
PREFACE
The program for development of a training course for operators of hospital medical waste incinerators was funded as a project of EPA's Control Technology Center (CTC)
(ORD) and Office of Air Quality Planning and Standards (OAQPS) to provide technical assistance to State and local air pollution control cgencies. Three levels of assistance can be accessed through the CTC. First, a CTC HOTLINE has been established to provide telephone assistance on matters relating to air pollution control technology. Second, more in-depth engineering assistance can be provided when appropriate. Third, the CTC can provide technical guidance through publication of technical guidance documents, development of personal computer software, and presentation of workshops on control technology matters. The technical guidance projects, such as this one to develop training materials for hospital waste incinerator operators, focus on topics of national or regional interest that are identified through contact with State and local agencies.
The CTC became interested in developing a basic training course for operators of hospital waste incinerators with the idea that properly trained operators can improve operating and maintenance procedures and, consequently, minimize air emissions. This training course was prepared to provide the operator with a basic understanding of the principles of incineration and air pollution control and to identify, in a general sense, good operating practices. substitute for site-specific hands-on training o f h e operator with the specific equipment to be operated.
The CTC was established by EPA's Office of Research and Development
The course is not intended as a
The course consists of three volumes: Volume I--Student Handbook Volume 11--Course Presentation Slides Volume 111--Instructor Handbook This volume contains the classroom materials including a copy of the
presentation slides and student worksheets. A copy of the presentation slides is provided in Part I so that you can easily follow along during the class. You may want to make notes on the slides to remind yourself later of important points brought up by the instructor or other students. Several worksheets also are included in Part 11. Your instructor will allow time for you to complete these worksheets during class
V
CONTENTS
PART I: COURSE SL IDES
COURSE INTRODUCTION
SESSION 1. PROTECTING THE ENVIRONMENT - YOUR RESPONSIB IL ITY
SESSION 2. BASIC COMBUSTION P R I N C I P L E S
SESSION 3. BASIC INCINERATOR DESIGN
SESSION 4.
SESSION 5. MONITORING AND AUTOMATIC CONTROL SYSTEMS
A I R POLLUTION CONTROL EQUIPMENT DESIGN AND FUNCTIONS
SESSION 6. INCINERATOR OPERATION
SESSION 7. A I R POLLUTION CONTROL SYSTEMS OPERATION
SESSION 8. MAINTENANCE INSPECTION--A NECESSARY PART OF YOUR JOB
SESSION 9. TYPICAL PROBLEMS
SESSION 10. STATE REGULATIONS
SESSION 11. SAFETY: AN IMPORTANT PART OF YOUR JOB
L I S T OF SOURCES FOR DRAWINGS
PART 11: CLASSROOM WORKSHEETS
1. INCINERATOR SYSTEM INFORMATION
2. INCINERATOR SYSTEM INFORMATION
3. INCINERATOR SYSTEM INFORMATION
4. OPERATING REVIEW
5. OPERATING PROBLEMS REVIEW
6. INCINERATOR SYSTEM INFORMATION
7. SAFETY REVIEW
v i
I
PART C.
REFERENCES FOR SLIDES
References for Slides
Session 2
1. McRee, R. Operation and Maintenance of Controlled Air Incinerators. Ecolaire Environmental Control Products. Undated.
Session 3
1.
2.
3.
4.
5.
6.
7.
Air Pollution Control District of Los Angeles County. Air Pollution Engineering Manual, 2nd Edition AP-40. (NTIS PB 225132). U. S. Environmental Protection Agency. May 1973.
Ecolaire Combustion Products, Inc. Technical Article: Principles of Controlled Air Incineration. Undated.
McRee, R. Operation and Maintenance of Controlled Air Incinerators. Ecolaire Environmental Control Products. Undated.
Consertherm Systems@. Industronics, Inc. Undated.
Technical Data Form for Rotary Kiln.
Doucet, L. Waste Handling Systems and Equipment. Fire Protection Handbook, 16th edition. National Fire Protection Association.
Consertherm Systems". Industronics, Inc. Undated.
Technical Data Form for Rotary Ki In.
U. S. Environmental Protection Agency. Source Category Survey: Industri a1 Inci nerators. EPA 450/3-80-013. (NTIS PB 80-193303) May 1980.
Session 4
1. Joseph, J. and D. Beachler. APTI Course SI:412C, Wet Scrubber Plan Review Self-Instructional Guidebook. EPA 450/2-82-020, U. S, Environmental Protection Agency. March 1984.
2. U. 5. Environmental Protection Agency. Control Techniques f o r Particulate Emissions from Stationary Sources, Volume 1. €PA 450/3-81-005a. (NTIS PB 83-127498) September 1982.
3. Beachler, 0. and M. Peterson. APTI Course SI:412A, Baghouse Plan Review Student Guidebook. EPA 450/2-82-005. U. S. Environmental Protection Agency . April 1982.
Session 5
1. Cleaver Brooks". Operation, Maintenance, and Parts Manual for the Pyrolytic Incinerator. Publication No. CEK 6826. September 1988.
2. Jahnke, J. APT1 Course SI:476A, Transmissometer Systems Operation and Maintenance, an Advanced Course. EPA 450/2-84-004. U. S. Environmental Protection Agency, Research Triangle Park, N.C. September 1984.
Session 6
1. McRee,, R. Operation and Maintenance of Controlled Incinerators. Ecolaire Environmental Control Products. Undated.
Session 9
1. U. S. Environmental Protection Agency. Workbook for Operators of Small Boilers and Incinerators. EPA 450/9-76-001. March 1976.
PART I. SLIDE PRESENTATION
This section presents the s l ides and worksheets which w i l l be used during the classroom por t ion o f the course. session. The sl ides presented here w i l l be supplemented w i th actual photographs (which are not presented i n t h i s hand-out) during the presentation. Some drawings have been taken from other documents; the sources for these drawings are l i s t e d a t the end o f t h i s part.
The s l ides are organized by
v i i
COURSE GOALS
T O PROVIDE YOU W I T H AN UNDERSTANDING OF:
-- BASIC PRINCIPLES OF INCINERATION -- PROPER OPERATION AND MAINTENANCE PRACTICES -- REGULATORY REQUIREMENTS AND SAFETY CONCERNS
UPON COMPLETING THIS COURSE YOU SHOULD:
UNDERSTAND A I R P O L L U T I O N PROBLEMS AND HOW TO M I N I M I Z E THEM
UNDERSTAND THE CAUSE OF COMMON OPERATING PROBLEMS AND S A F E T Y HAZARDS AND HOW TO M I N I M I Z E THEM
KNOW HOW TO MONITOR OPERATION TO AID IN COMPLYING W I T H REGULATORY REQUIREMENTS
SESSION 1.
PROTECTING THE ENVIRONMENT - YOUR RESPONSIBILITY
SLIDE 1-1
WHY INCINERATE?
REDUCES WEIGHT AND VOLUME OF WASTE
STERILIZES THE WASTE
DESTROYS ORGANIC M A T E R I A L S THAT MAY DEGRADE AND PRODUCE HARMFUL BY-PRODUCTS I N L A N D F I L L S
AESTHETIC REASONS--DESTROYS WASTES SUCH AS BODY PARTS THAT P U B L I C F I N D S OBJECTIONABLE
.-
SLIDE 1-2
ENVIRONMENTAL CONCERNS
PATHOGEN DESTRUCTION
A I R EMISSIONS
ASH QUALITY
SLIDE 1-3
Particulate Carbon Organic Monoxide
ComPuMS;\ I[- Metals Toxic
Fugitive Particulate *\: 1-1 7 /(windblown ash)
Waste Feed (May contain pathogens)
(May contain pathogens) ( /
ENVIRONMENTAL CONCERNS
SLIDE 1-4 %
. THE OPERATOR--YOUR ROLE
I T I S YOUR ROLE AND R E S P O N S I B I L I T Y TO PROTECT THE ENVIRONMENT B Y :
MINIMIZING POLLUTANT EMISSIONS THROUGH PROPER OPERAT I ON
MAINTAINING ACCEPTABLE ASH QUALITY THROUGH PROPER OPERATION
PREVENT I NG PART I CULATE EM I SS I O N S FROM ASH HANDLING AND STORAGE
IDENTIFYING MAINTENANCE PROBLEMS B Y PERFORMING REGULAR I N S P E C T I O N S
SESSION 2.
BASIC COMBUSTION PRINCIPLES
SLIDE 2-1
Organics in Auxilary
Fuel
Combustion Gases
T .T
Energy f - 0 2 Air
Organics in Hospital Waste
I I I Heat
Ash
THE COMBUSTION PROCESS
SLIDE 2-2
Combustion Air
I
f /
/ N2 (79%) /
React 0 -
- I 02(21%) 0 \ \ \
Carbon and
Hydrogen 4
I Organic Feed and Fuel
FATE OF COMBUSTION AIR
SLIDE 2-2
Organic Feed and Fuel
FATE OF COMBUSTION AIR
SLIDE 2-3
- 0 2
OXYGEN REACTION
SLIDE 2-4
OPERATING FACTORS RELATED TO COHBUSTI ON
COMBUSTION A I R FLOW RATE D I S T R I B U T I O N
-- --
OPERATING TEMPERATURES
W A S T E FEED CHARACTERISTICS
SLIDE 2-5
-a Organics
t 1
Combustion 0 2 Air b
Waste I Fuel Organics
1’
Ash
STOICHIOMETRIC AIR LEVEL
SLIDE 2-6
Combustio Air
Waste/ Fuel
AIR LEVEL BELOW STOICHIOMETRIC "STA RV E D- A I R "
SLIDE 2-7
W m a T D Organics
Combustion Air 4
1 Ash
AIR LEVEL ABOVE STOICHIOMETRIC "EXCESS AIR"
SLIDE 2-8
TEMPERATURE
MAXIMUM TEMPERATURE
I
DEFICIENT AIR i EXCESS AIR
PERCENT EXCESS AIR - CONTROL OF TEMPERATURE A S A FUNCTION OF E X C E S S A I R ’
SLIDE 2-9
W A S T E TYPE
HOSP I TAL WASTE CHARACTER I STI CS
HIGH HEAT HEAT VALUE
BTU/LB x BTU/LB VALUE Mo I STURE , AS-F I RED ,
G A U Z E , PADS, SWABS, 8,000-12,000 0-30 5,600- 12,000 GARMENTS , PAPER
PLAST I cs
HUMAN ANATOMICAL
9,700-20 I 000 0-1 9,600-20,000
8,000-12,000 70-90 800-3,600
SLIDE 2-10
KEY OPERATING PARAMETERS
COMBUSTION AIR
, M I X I N G
TEMPERATURE
RESIDENCE TIME/RETENTION TIME
W A S T E CHARACTERISTICS -- HEATING VALUE -- MOISTURE CONTENT -- CHLORINE CONTENT
. .
SLIDE 2-11
a- Waste1
n
Ash-lnoqanrs No Pathogens -. Sterile -+- .. Not Combustible
COMPLETE COMBUSTION
SLIDE 2-12
INCOMPLETE COMBUSTION
SLIDE 2-13
OPACITY
Poor Mixing
Starved-Air Conditions
Low Temperatures
AcidGases
SLIDE 2-14
Low 0, -- INSUFFICIENT AIR
HIGH 0, -- TOO MUCH EXCESS AIR COOLS G A S
HIGH CO M E A N S POOR COMBUSTION
SLIDE 2-15
ASH QUALITY
VISUAL APPEARANCE
NO RECOGNIZABLE M E D I C A L WASTES
BURNOUT--CARBON REMA I N I NG -- WHITISH GRAY VS BLACK
SESSION 3 .
BASIC INCINERATOR DESIGN
SLIDE 3-1
loool To Atmosphere
t Control and
I I I I I I
I I
I I I
Stack 1 I I
Monitoring L - - - - - - -
To Atmosphere
t I
Stack I
I I
I I ' r------ 1 1
I I Air I I I
Waste (.Waste 1 i I System I
System Removal
Ash
M A J ~ R COMPONENTS OF AN INCINERATION SYSTEM
*-
SLIDE 3-2
I NC I NERATOR TYPES
MULTIPLE CHAMBER--EXCESS AIR
CONTROLLED ( S T A R V E D ) A I R
ROTARY KILN
SLIDE 3-3
MULTI PLE-CHAMBER INCINERATORS
COMBUSTION OCCURS I N TWO OR M O R E CHAMBERS
P R I M A R Y A N D SECONDARY CHAMBER OPERATE W I T H A I R LEVELS ABOVE STOICHIOMETRIC
P R I M A R I L Y USE O V E R F I R E COMBUSTION A I R
IN-LINE AND RETORT DESIGNS
UOlWkJ3NI3NI tJIV-SS33X3 'tJ3ffWVH3-3ldIllflW 3NIl-NI 1
SLIDE 3-5
Charging
RETORT MULTI PLE-CHAMBER, EXCESS-A I R I NC I NERATOR 1
SLIDE 3-6
CONTROLLED-A I R I NCI NERATI ON
COMBUSTION OCCURS IN TWO OR MORE CHAMBERS
AMOUNTS AND DISTRIBUTION OF COMBUSTION A I R TO EACH CHAMBER ARE CONTROLLED -- PRIMARY CHAMBER BELOW S T O I C H I O M E T R I C -- SECONDARY CHAMBER ABOVE S T O I C H I O M E T R I C
SLIDE 3-8
i TEMPERATURE
PRIMARY SECONDARY CHAMBER OPERATING I CHAMBER OPERATING RANGE RANGE I
I
EXCESS AIR 1 DEFICIENT AIR I
PERCENT EXCESS AIR
CONTROL OF TEMPERATURE AS A FUNCTION OF E X C E S S AIR
SLIDE 3-7
7 COMBUSTION GASES
MAIN BURNER FOR MAINTAINING
SECONDARY CHAMBER MINIMUM COMBUSTION Volatlle Content IS Bumed TEMPERATURE
4/ - Under Excess Air Conditions
(Starved Air Condltion) - WASTE FEED
NON-COMBUSTIBLES
AUXllAR IGNITION BURNER
CONTROLLED UNDERFIRE AIR FOR BURNING "FIXED CARBON
PRINCIPLE OF CONTROLLED-AIR INCINERATION
SLIDE 3-9
Control Panel
Secondary Bumer
Primary Combustion Air Bumer Blower
MAJOR COMPONENTS OF A CONTROLLED-AIR INCINERATOR
SLIDE 3-10
ROTARY K I LNS
COMBUSTION OCCURS IN MULTIPLE CHAMBERS
PRIMARY CHAMBER IS ROTATING CYLINDER --PRODUCES TURBULENCE I N WASTE BED
SLIDE 3-11
/
.
& v i ' Scrubber
- 4
- 1 - 1 ._
Fan
ROTARY KILN WITH AUGER FEED4
SLIDE 3-12
OPERATING MODE
SINGLE BATCH
INTERMITTENT DUTY
CONTINUOUS DUTY
SLIDE 3-13
WASTE FEED LOAD I NG/CHARGI NG SYSTEMS
CONSISTENT W I T H INCINERATOR C A P A C I T Y
CONSISTENT W I T H OPERATING MODE
MANUAL vs MECHANICAL vs AUTOMATED
S L I D E 3-14
Hydraulic Fire e,
Hydraulic Ram Actuator
HOPPER RAM ASSEMBLY’
SLIDE 3-15
SRCl FIRE W O R OPENS
S R C 4 FIRE OOOR CLOSES
S W S RAM WTIJRNS TO START
HOPPER RAM CHARGING SEQUENCE
SLIDE 3-16
ASH DISCHARGE AND REMOVAL SYSTEMS
CONSISTENT W I T H OPERATING MODE
CONSISTENT W I T H CAPACITY
M A N U A L vs M E C H A N I C A L
SLIDE 3-17
HECHAN I CAL ASH REMOVAL
TRANSFER OF ASH TO END OF HEARTH
COLLECT I ON CONTA I NER
TRANSFER FROM COLLECTION POINT
SLIDE 3-18
To Boiler
Secondary Burner
Primary Bumer
Ash Transfer Rams
Ash Chute ’ ’P Ash Discharge Ram
Ash Quench
INCINERATOR WITH STAGED HEARTH AND AUTOMATIC ASH REMOVAL ’
SLIDE 3-19
COHBUSTI ON GAS HANDL I NG SYSTEMS
NATURAL DRAFT
INDUCED DRAFT
BALANCED DRAFT
..*
SLIDE 3-20
HAJOR COMPONENTS OF BURNER SYSTEM
FORCED AIR BLOWER(S)
FUEL TRAIN
PILOT AND M A I N BURNER
FLAME SAFE GUARD SYSTEM
SLIDE 3-21
4 Bypass Stack
1
Stack
ID Fan
I N C I N E R A T O R W I T H WASTE HEAT B O I L E R A N D BYPASS STACK*
SESSION 4 ,
A I R POLLUTION CONTROL EQU I PMENT
DESIGN AND FUNCTIONS
SLIDE 4-1
CONTROL STRATEG I ES FOR A I R POLLUTANTS
POLLUTANT CONTROL Particulate Hydrochloric Tox i c Toxic Carbon strategy matter acid organics metals monoxide
Contro 1 1 i ng X feed material
Combustion control
Add-on pollution control equipment:
X
Spray tower a
Venturi X
Packed- bed a
Fabric filter X
Dry inject ionb X
Dry scrubberb X
ESP X
X X
X
X
X
a
X
a
X
a X
a X
X
‘Achieves 1 imited control ; not designed for high efficiency. bFol lowed by high-efficiency particulate control.
SLIDE 4-2
A I R POLLUTION CONTROL SYSTEMS FOR HOSPITAL WASTE I NCINEMTORS
W E T SCRUBBERS -- SPRAY TOWERS -- VENTURI SCRUBBERS -- PACKED-BED SCRUBBERS
FABRIC FILTERS
DRY SCRUBBERS -- DRY I NJ ECTI ON -- SPRAY DRYERS
ELECTROSTAT I c PREC I P I TATORS
. -.
- .
SLIDE 4-3
SPRAY TOWER
LOW ENERGY
LIMITED PARTICULATE CONTROL
LIMITED HCL ACID G A S CONTROL
SLIDE 4-4
Dirty Flue
A Clean Exhaust Gas
COUNTERCURRENT-FLOW SPRAY TOWER'
SLIDE 4-5
Water inlet
Tower Combustion Gases from Secondary
Stack
Chamber
* Waste Water
to Drain
ID Fan
Spray Tower System
SLIDE 4-6
VWTURI SCRUBBER
HIGH ENERGY
HIGH EFFICIENCY PARTICULATE CONTROL
LIMITED HCL A C I D G A S CONTROL
SLIDE 4-7
SPRAY VENTURI w ITH RECTANGULAR THROAT 1
SLIDE 4-8
CYCLONIC MIST ELIMINATOR^
SLIDE 4-9 Stack
I I :-q Cyclonic -7 Mitt I Eliminator v ?:;p 1 , ~ +F--,------J Caustc Feed Scrubber
Liquor Recycle
I Tank I Discharge * (Blowdown) I
VENTURI SCRUBBER SYSTEM WITH RECIRCULATED SCRUBBER LIQUOR
SLIDE 4-10
PACKED TOWER
LOW ENERGY
HIGH EFFICIENCY ACID GAS CONTROL
SLIDE 4-11
DIRTY EXHAUST
CLEAN EXHAUST
PACK I NG
MIST ELIMINATOR
LIQUID SPRAYS
COUNTERCURRENT-FLOW PACKED-BED SCRUBBER’
. .
SLIDE 4-12 Stack
comeusaon Gases from Secondary ChMlber
----- M* UP W a M Causbc Feed
scrubber Liquor
RecyW Tank
I I
I I I I I I I I Dlscharg8 L,,,,,,+
(Blowdown) I I I t g - 7 I
I Pump I I I
VENTURI SCRUBBER WITH PACKED BED
SLIDE 4-13
FABRIC FILTER
OFTEN CALLED "BAGHOUSE"
PARTICULATE CONTROL -- E S P E C I A L L Y E F F E C T I V E FOR F I N E P A R T I C U L A T E
ACID GAS CONTROL _- I F USED I N CONJUNCTION WITH DRY SCRUBBER
SLIDE 4-14
ToClean Air Outlet and Exhauster
D
Housing - -Tubular Filter Bags
- -0irty Air Plenum
PULSE JET BAGHOUSE'
SLIDE 4-15
DRY SCRUBBERS
ACID GAS CONTROL
I N CONJUNCTION WITH PARTICULATE CONTROL FABRIC FILTER --
-- ELECTROSTATIC PRECIPITATOR
SLIDE 4-16~
!ncanemtor Boiler
Storage
Pneumatic
F W k r , Expanson/ Partuxlate
Control Device
Reaction Chamber
Stack I tino
t
DRY INJECT I O N ABSORPTION SYSTEM
SLIDE 4-168
t
+ Combustion War0 Contactor
P ~ l ~ Conwed - D w l a
DRY INJECTION ABSORPTION SYSTEM
Gases f” Heat b Inanetator Boiler
Reactor - 1 Solid
SLIDE 4-17
Sorbent Slurry
Flue Gas
SPRAY DRYER ABSORBER VESSEL
SLIDE 4-18
r
hme Slaker -
Lime Storage
Slurry Slurry Mixing 4 Tank
Slurry Feed a
Tank Stack
I) Spray Particulate Combustion Gases Dlyer Control
C*..-*
Absorber
* Solid
Residue
Device
I IO
COMPONENTS OF A S P R A Y DRYER ABSORBER SYSTEM
SLIDE 4-19
ELECTROSTAT I C PREC I P I TATORS
PARTICULATE CONTROL
LARGER REGIONAL FACILITY MOST LIKELY APPLICATION
SOMETIMES USED WITH DRY SCRUBBERS
a
SLIDE 4-20
H O P F
COMPONENTS OF AN E S P 3
3
SLIDE 4-21
Coilmion electrode
GAS FLOW THROUGH A PLATE PRECIPITATOR^
SESSION 5. MONITORING AND AUTOMATIC CONTROL SYSTEMS
SLIDE 5-2
CONTROL ROOM
t
TEMPERATURE MONITORING SYSTEM
SLIDE 5-3
Temperature
60
Ace Heating and Cooling
Point
THERMOSTAT WITH TEMPERATURE "SET POINT"
SLIDE 5-4 CONTROL ROOM
Warning Limit
I
r--- Signal Processor r-- ----i- I
I I
Recorder El I . I I I
Combustion Chamber
Ld Burner
I
Combustion Air
Blower
SCHEMATIC OF TEMPERATURE CONTROL LOOP
SLIDE 5-5
ROTATE OUTER DIAL TO SLLLCTTEMPERANRE SLTWINT OR PROPORTIONAL S L T W I M \ r
ROTATE INNER OIAL TO I SELECT TEMPERATURE SRPOIWT
TEMPERATURE INDICATOR
-TEMPERATURE CONTROLLER/METER WITH LOW/HIGH SETPOINTS '
SLIDE 5-6
HIGH SETWINT LOWsmFoINT I ADJUSTMENT ADJUSTMENT
TEMPERATURE CONTROLLER WITH DIGITAL DISPLAY
SLIDE 5-7
. BASIC TYPES OF INCINERATOR PROCESS CONTROL SYSTEMS
MANUAL
AUTOMATIC TIMER SEQUENCE
AUTOMATIC MODULATED CONTROL
SLIDE 5-8
AUTOMATIC TIMER SEQUENCE
PRESET T I M E R SEQUENCE -- ACTIVATES ON/OFF OR HIGH/LOW SETTINGS
- BURNERS - COMBUSTION A I R - CHARGE FEEDER
S E T P O I N T L I M I T S OVERRIDE T IMER SEQUENCE
SLIDE 5-9
AUTOHATI C MODULATED CONTROL
SETPOINT FOR CONTROLLED PARAMETER IS CHOSEN
OPERATING PARAMETERS A R E CONTINUOUSLY ADJUSTED TO M A I N T A I N S E T P O I N T -- COMBUSTION A I R
SLIDE 5-10
MONITORED AND CONTROLLED PROCESS PARAMETERS FOR I NCI NERATORS
MON I TORED~ONTROLLED INCINERATOR FUNCTIONS
PARAMETER CONTROLLED
TEMPERATURE COMBUST I ON A I R Aux I L I ARY BURNERS (PRIMARY AND
SECONDARY CHAMBERS)
DRAFT
OXYGEN
CARBON HONOX I DE
OPAC I TY
CHARGE RATE
BAROHETR I c DAMPER ID FAN DAMPER
COUBUST I ON A I R
--
--
AUTOMATIC FEED INTERLOCK
SLIDE 5-11
MONITORED AND CONTROLLED PROCESS PARAMETERS FOR SCRUBBERS
MONITORED PARAMETER SCRUBBER FUNCTIONS CONTROLLED
PRESSURE AND PRESSURE DROP VENTURI THROAT
I D FAN
.SCRUBBER LIQUID FLOW RATE OR PRESSURE
SCRUBBER u a u m PH
INLET TEMPERATURE
LIQUID FLOW CONTROL VALVE
CAUSTIC FLOW CONTROL VALVE
PREQUENCH EMERGENCY QUENCH BYPASS STACK DILUTION AIR
.
SLIDE 5-12
MONITORED AND CONTROLLED PROCESS PARAMETERS FOR FABRIC FILTERS
HONITORED PARAMETER FABR I c FILTER OPERAT I NG FUNCTIONS CONTROLLED
PRESSURE DROP
INLET GAS TEMPERATURE
CLEAN I NG CYCLE
EMERGENCY BYPASS STACK
EMERGENCY QUENCH DILUTION A I R
SLIDE 5-13
HON I TORED AND CONTROLLED PROCESS PARAMETERS FOR ESP's
MON I TORED PARAMETER ESP OPERAT I NG FUNCTIONS CONTROLLED
POWER INPUT -- PRIMARY VOLTAGE
PRIMARY CURRENT SECONDARY VOLTAGE SECONDARY CURRENT
-- -- --
SPARK R A T E
INLET GAS TEMPERATURE
POWER SUPPLY T/R S E T T I N G S
GAS TEMPERATURE RAPPER OPERATION CONDITIONING AGENTS
( R E S I S T I V I T Y 1
I N C R E A S E ~ D E C R E A S E INCINERATOR OR B O I L E R OUTLET TEMPERATURE
CONDITION G A S
SLIDE 5-14
TEHPEMTURE
THERMOCOUPLE(S)
DEGREES FAHRENHEIT
EXIT OF SECONDARY COMBUSTION CHAMBER
MIDDLE OF PRIMARY CHAMBER
BEFORE/AFTER APC
SLIDE 5-15
7 \ CHAMBER
THERMOCOUPLE LINING PENORATlON
THERMOCOUPLE AND DRAFT GAUGE CONNECTIONS
SLIDE 5-16
INCINEMTOR DRAFT AND APCS PRESSURE DROP
DIFFERENTIAL PRESSURE GAUGE, AP
INCHES OF WATER COLUMN, IN. WL.
DIFFERENCE OF PRESSURE A T TWO POINTS
DRAFT :
AP OF I N C I N E R A T O R CHAMBER AND ATMOSPHERIC PRESSURE
APCS PRESSURE DROP:
AP BEFORE AND AFTER APC
*-
SLIDE 5-17
HIGH BRACT SeTPolNT INOICATO R
LOW ORAPT / 1 . . 7 INDICATOR s-lm+' '
HIGH ORACT SeTPoINT ADJUSTMENT KNOB
LOW ORACT S m l N T ADJUSTMENT KNOB
METER FOR DIFFERENTIAL PRESSURE GAUGE'
SLIDE 5-18
Air -
To Atmosphere
'Draft" J
Stacl /
BAROMETR I d A U T O M A T I C DAMPER
SLIDE 5-19
Damper Fully Open
/ L J / Stack
Fan
Damper Partially
/ Closed
I r
Fan
fJ
/ Stack
ID FAN DAMPER CONTROL
SLIDE 5-20
. ...
11 / W S I T I O N MOTOR
CONTROL LINKAGE
COMBUSTION BLOWER WITH AUTOMATIC CONTROLLER
SLIDE 5-21
OXYGEN AND CO MONITORS
CONTINUOUS E M I S S I O N MONITORING SYSTEMS, CEMS
PERCENT OXYGEN, 2 0,
PARTS PER MILLION CARBON MONOXIDE, PPM CO
MONITOR LOCATION -- COMBUSTION CHAMBER OUTLET
-- STACK -- SOMEWHERE I N BETWEEN
SLIDE 5-22
In-Situ Extractive
Stack
- b -Detector
1 1 Stack
Probe
IN SITU VS EXTRACTIVE CEMS
SLIDE 5-23
-
VENT
- LEVEL LEVEL CAL. CAL.
EXTRACTIVE MONITORING SYSTEM
SLIDE 5-24
Blower
OPACITY MONITORING SYSTEM (Transmissometer)
SLIDE 5-25
CHARGE RATE
LB/LOAD
LB/H
WEIGH SCALE/LOG BOOK
AUTOMATIC WEIGH SCALE OR WEIGH HOPPER
SLIDE 5-26
APC MONITORS
SCRUBBER LIQUID FLOW GALLONS PER M I N U T E , GPM -- FLOW METER PUMP PRESSURE
-- --
PH OF SCRUBBER L I Q U I D PH METER --
TEMPERATURE THERMOCOUPLE --
PRESSURE DROP, AP -- D I F F E R E N T I A L PRESSURE GAUGE
SESSION 6.
INCINERATOR OPERATION
SLIDE 6-1
TOP I CS
WASTE H A N D L I N G
OPERATION OF CONTROLLED-AIR I N C I N E R A T O R S
OPERATION OF EXCESS-AIR I N C I N E R A T O R S
SLIDE 6-2
WASTE HANDL I NG
STURDY CONTAINERS
MINIMIZE HANDLING
PROPERLY OPERATEI’MA I NTA IN WASTE CHARGING DEVICES
SAFE STORAGE--EVEN FOR SHORT TIMES
SLIDE 6-3
INCINERATOR OPERATION
K E Y OPERATING PARAMETERS
OPERATING RANGES
MON I TOR I NG OPERAT I ON
CONTROLLING OPERATION
W A S T E CHARGING PROCEDURES
ASH HANDLING PROCEDURES
STARTUP/SHUTDOWN PROCEDURES
SLIDE 6-4
KEY OPERATING PARAMETERS FOR CONTROLLED-A I R I NCI NERATORS
CHARGING R A T E
PRIMARY CHAMBER TEMPERATURE
SECONDARY CHAMBER TEMPERATURE
COMBUSTION CHAMBER DRAFT
PRIMARY CHAMBER COMBUSTION A I R LEVEL
TOTAL COMBUSTION AIR LEVEL
COMBUSTION G A S O X Y G E N CONCENTRATION
SLIDE 6-5
- KEY PERATING P RAMETER--WASTE CHARG I NG RATE
OPERATING R A N G E :
HEAT INPUT CONSISTENT W I T H DESIGN SINGLE BATCH OPERATION
FILL CHAMBER: DO NOT OVERFILL I NTERM I TTENT AND CONT I NUOUS DUTY
SMALL BATCHES A T FREQUENT INTERVALS
--
-- 10 TO 25 PERCENT RATED CAPACITY AT 5 TO 15 M I N U T E S --
FACTORS :
W A S T E PROPERTIES OPERATING MODE OF INCINERATOR
SLIDE 6-6
KEY OPERATI NG PARAMETER--WASTE CHARGING RATE
OPERATOR MONITORS :
CHARGE R A T E , LB/H
a ASH BED AMOUNT AND FREQUENCY OF CHARGE
Bu I LDUP
"GOOD" B u R N ou T a TEMPERATURE TRENDS
Low TEMPERATURE--CHARGE NEEDED?
--
-- a ASH Q U A L I T Y
--
-- -- HIGH SECONDARY TEMPERATURE--WAIT?
CONTROL B Y :
SMALLER OR LARGER BATCHES LESS OR MORE FREQUENT CHARGES
SLIDE 6-7
Secondary Chamber
Charges I
L Primary I Chamber I
I I Temperature I I I I I I !-
Burndown
TEMPERATURE TREND'
SLIDE 6-8
PRIMARY CHAMBER TEHPERATURE
LOWER LIMIT: MINIMUM OPERATING TEMPERATURE
ACHIEVE ADEQUATE BURNOUT STERILIZE ASH
UPPER L I M I T : MAXIMUM OPERATING TEMPERATURE
LIMIT SLAGGING OF ASH
THERE MAY BE A REGULATORY REQUIREMENT ON LOWER L IMIT
SLIDE 6-9
KEY OPERATING PARAMETER-+ R I MARY CHAMBER TEMPERATURE
RECOMMENDED OPERATING R A N G E :
BATCH - 1000" TO 1800°F INTERMITTENT - 1000" TO F CONTINUOUS - 1400" TO 1800°F
OPERATOR MONITORS
TEMPERATURE READ I NG TEMPERATURE TREND
CONTROL B Y :
ADJUSTING CHARGING R A T E ADJUSTING PRIMARY COMBUSTION Aux I LI A R Y BURNER OPERAT I ON
A I R LEVEL
SLIDE 6-10
SECONDARY CHAMBER TEMPERATURE
LOWER LIMIT: MINIMUM OPERATING TEMPERATURE
HIGH ENOUGH TEMPERATURE TO COMBUST ALL ORGANIC COMPOUNDS
UPPER LIMIT: MAXIMUM TEMPERATURE
PREVENT DAMAGE TO REFRACTORY
THERE MAY BE A REGULATORY REQU I REMENT ON LOWER L I MI T
SLIDE 6-11
KEY OPERATI NG PARAMETER--SECONDARY CHAMBER TEMPERATURE
RECOMMENDED OPERATING R A N G E :
1800" TO 2200"
OPERATOR MON I TORS :
TEMPERATURE READING TEMPERATURE TREND
CONTROL B Y :
ADJUSTING SECONDARY COMBUSTION A I R LEVEL SECONDARY BURNER OPERATION ADJUSTING PRIMARY CHAMBER PARAMETERS ADJUSTING CHARGING R A T E
SLIDE 6-12
PRIHARY CHAMBER COMBUSTION A I R LEVEL
CONTROLS COMBUSTION R A T E AND TEMPERATURE IN PR I MARY CHAMBER
CONTROLS RELEASE R A T E OF COMBUSTIBLE GASES TO SECONDARY CHAMBER
MA I NTA I NED BELOW STO I CH I OMETR I c
SLIDE 6-13
KEY OPERATING PARAMETER--PRIHARY CHAMBER COMBUST1 ON A I R
RECOMMENDED OPERATING R A N G E :
30 TO 80 PERCENT OF STOICHIOMETRIC
MONITOR :
VISUAL OBSERVATION
PRIMARY CHAMBER TEMPERATURE
DARK RED SMOKEY COMBUSTION Z O N E --
CONTROL B Y :
INCREASE/DECREASE COMBUSTION AIRFLOW
i
SLIDE 6-14
SECONDARY CHAMBER AND TOTAL COMBUSTI ON A I R LEVEL
CONTROLS TEMPERATURE OF SECONDARY CHAMBER
EXCESS A I R ASSURES SUFFICIENT O X Y G E N FOR COMPLETE
COMBUSTION
SLIDE 6-15
KEY OPERATING PARAMETER--TOTAL COMBUSTION A I R LEVEL
RECOMMENDED OPERATING R A N G E :
140 TO 200 PERCENT E X C E S S AIR
MONITORING :
SECONDARY COMBUSTION CHAMBER TEMPERATURE STACK GAS O P A C I T Y
COMBUSTION G A S O X Y G E N LEVEL BLACK SMOKE * D E F I C I E N T A I R --
CONTROL B Y :
ADJUSTING SECONDARY A I RFLOW
SLIDE 6-16
COMBUST1 ON CHAMBUi DRAFT
PREVENT EXCESSIVE PARTICULATE MATTER ENTRAINMENT
PREVENT A I R OUT-LEAKAGE
I
SLIDE 6-17
KEY OPERATING PARAMETER--COMBUSTION CHAMBER DRAFT
RECOMMENDED R A N G E :
NEGATIVE 0,05 TO 0,1 INCHES WATER
MON I TOR :
DRAFT GAUGE
CONTROL B Y :
NATURAL DRAFT DAMPER SETTING -- BAROMETRIC, AUTOMAT I c , MANUAL
e FAN DAMPER SETTING
I
SLIDE 6-18
OTHER PARAMETERS TO MONITOR
STACK G A S OPACITY
EASY TO DO
I ND I CATOR OF PART I CULATE EM I ss I ON/POOR COMBUST I ON
ADJUST SECONDARY A I R OR CHARGE R A T E
CHECK SECONDARY BURNER
3
SLIDE 6-19
OTHER PARAMETERS TO MONITOR
ASH QUALITY
EASY TO DO
PIECES OF UNBURNED W A S T E NOT GOOD
GRAY COLOR BETTER THAN BLACK
INCREASE PRIMARY TEMPERATURE
DECREASE CHARGE R A T E
INCREASE BURNOUT TIME
SLIDE 6-20
OTHER PARAMETERS TO MONITOR
STACK G A S CARBON MONOXIDE
~
I ND I CATOR OF COMBUST I ON EFF I C I ENCY
NEED INSTRUMENT
SHOULD B E 4 0 0 PPM
¶
SLIDE 6-21
OTHER PARAMETERS TO MONITOR
SECONDARY BURNER FLAME PATTERN
BR GHT YELLOW/ORANGE
NO SMOKE
NO IMPINGEMENT
I
SLIDE 6-22
CONTROL AND MON I TORI NG SUMMARY
W A S T E COMPOSITION, CHARGE R A T E , TEMPERATURES, A I R LEVELS ARE ALL INTERRELATED
WITHIN LIMITS OF DESIGN--AUTOMATIC CONTROL SYSTEM ADJUSTS
A I R L E V E L TO CONTROL HEAT RELEASE AND TEMPERATURE
OPERATOR CAN CONTROL CHARGE R A T E
SLIDE 6-23
CONTROL AND MON I TORI NG SUMMARY ( CONT I NU ED 1
T O OPERATE INCINERATOR W I T H I N D E S I G N L I M I T S , THE OPERATOR
-- MONITORS : - TEMPERATURES - CHARGE R A T E - W A S T E BED APPEARANCE
- ASH QUALITY - OPACITY
-- ADJUSTS : - CHARGE R A T E - COMBUSTION A I R LEVELS - BURNERS
I
SLIDE 6-24
1000
600
CAPAClTY 5oo
400
Imr
,u naw 3 ~ . o w . u w D I u i i i r
HEAT CONTENT OF WASTE BTUtlb
INCINERATOR CAPACITY VERSUS HEAT CONTENT OF W A S T E
I
SLIDE 6-25
PROPER WASTE CHARG I NG PROCEDURES
SINGLE BATCH OPERATION
CHARGE INCINERATOR COLD
Do NOT "STUFF" INCINERATOR
DECREASE SIZE OF L O A D , A S N E C E S S A R Y , TO P R E V E N T E M I S S I O N S A T STARTUP
SLIDE 6-26
PROPER WASTE CHARG I NG PROCEDURES
I NTERM I TTENT DUTY AND CONTI NUOUS DUTY
MORE FREQUENT SMALLER CHARGES A R E BETTER THAN ONE L A R G E CHARGE
ADJUST CHARGE VOLUME AND FREQUENCY TO ACCOUNT FOR W A S T E
V A R I A T I O N S
SLIDE 6-27
PATHOLOG I CAL WASTES
LIMIT AMOUNT OF PATHOLOGICAL WASTE IF INCINERATOR IS NOT A PATHOLOGICAL D E S I G N
OPERATE PRIMARY BURNERS DURING INCINERATION
C H A R G E W A S T E T O H E A R T H IN SHALLOW L A Y E R
DO NOT P I L E -- EXPOSE TO FLAME --
SLIDE 6-28
0
0
0
0
0
0
0
0
PROPER ASH HANDLING PROCEDURES
s I NGLE BATCH/ I NTERM I T T E N T OPERAT I ON
ALLOW INCINERATOR TO COOL
USE FLAT/BLUNT TOOL FOR ASH REMOVAL
PLACE A S H IN M E T A L CONTAINER
DO NOT SPRAY WATER I N T O COMBUSTION CHAMBER
A V O I D P U S H I N G ASH I N T O U N D E R F I R E PORTS
DAMPEN ASH TO PREVENT F U G I T I V E DUST
PROPERLY D I S P O S E OF ASH M A K E SURE ASH DOOR I S PROPERLY SEALED I NSPECT ASH QUAL I T Y ; MAKE CORRECTIONS TO O P E R A T I O N , I F NECESSARY
SLIDE 6-29
PROPER ASH HANDLING PROCEDURES
CONTINUOUS DUTY
WATCH FOR JAMS I N CONVEYOR SYSTEMS
ASSURE QUENCH WATER FLOW IS ADEQUATE
R E P L A C E F U L L A S H CONTAINER WITH EMPTY CONTAINER
K E E P A S H WET OR COVER T O PREVENT FUGITIVE DUST
INSPECT A S H QUALITY ADJUST INCINERATOR O P E R A T I O N , I F NECESSARY
3
SLIDE 6-30
STARTUP AND SHUTDOWN
SINGLE BATCH UNIT
STARTUP :
CHARGE INCINERATOR COLD
PREHEAT THE S E C O N D A R Y CHAMBER BEFORE IGNITING W A S T E
SHUTDOWN :
INCREASE PRIMARY COMBUSTION CHAMBER AIR TO PROMOTE
AFTER PRIMARY TEMPERATURE DECREASES T O PRESET LEVEL,
KEEP COMBUSTION BLOWERS OPERATING T O COOL INCINERATOR REMOVE ASH AFTER INCINERATOR COOLS
COMBUSTION OF F I X E D CARBON
SHUT DOWN SECONDARY BURNER
SLIDE 6-31
STARTUP AND SHUTDOWN
I NTERM I TTENT AND CONT I NUOUS DUTY
STARTUP :
PREHEAT SECONDARY CHAMBER BEFORE I N I T I A T I N G CHARGING CHARGE W A S T E
IGNITE WASTE
SHUTDOWN :
INTERMITTENT DUTY- -SAME A S B A T C H CONTINUOUS DUTY
-- STOP CHARGING SYSTEM MAINTAIN OPERATION OF INCINERATOR AND A S H S Y S T E M
SHUTDOWN INCINERATOR
-- U N T I L ALL WASTE I S DISCHARGED FROM I N C I N E R A T O R
--
I
SLIDE 6-32
OPERATOR'S LOG
WRITTEN LOG BOOK
RECORD SIGNIFICANT EVENTS
-- STARTUP/SHUTDOWN -- ADJUSTMENTS -- CHANGES I N C H A R G E R A T E
e RECORD UNUSUAL PROBLEMS A N D CORRECTIVE ACTIONS
SLIDE 6-33
P A Y CAREFUL ATTENTION TO CHARGING RATE -- ADJUST CHARGING R A T E , IF N E C E S S A R Y
MONITOR COMBUSTION TEMPERATURES
-- LEARN TO RECOGNIZE TRENDS
MONITOR STACK OPACITY
INSPECT T H E C H A M B E R S THROUGH V IEWPORTS
INSPECT ASH Q U A L I T Y -- ADJUST OPERATION, I F N E C E S S A R Y
PROPERLY HANDLE AND DISPOSE OF A S H
PREHEAT THE SECONDARY CHAMBER BEFORE STARTUP
KEEP AN OPERATING LOG
SLIDE 6-34
DON ' T
IGNORE PROBLEMS INDICATED B Y MONITORS
OVERCHARGE THE INCINERATOR
SLIDE 6-35
KEY OPERATING PARAMETERS : HULTI PLE-CHAMBER I EXCESS-AIR INCINERATORS
PARAMETER
W A S T E CHARGE R A T E
--RED B A G
--PATHOLOG I CAL
RECOMMENDED OPERATING RANGE
10-25% OF RATED CAPACITY AT 10-15 M I N U T E I N T E R V A L S
SINGLE L A Y E R ON H E A R T H
SLIDE 6-36
KEY OPERATING PARAMETERS : MULTI PLE-CHAMBER, EXCESS-A I R I NCI NERATORS
PARAMETER
PRIMARY CHAMBER T E M P E R A T U R E
--GENERAL REFUSE --PATHOLOG I C A L
SECONDARY CHAMBER T E M P E R A T U R E
RECOMMENDED OPERATING RANGE
1000 O - 1400" F 1600 O - 1800" F
1800 -2200 O F
SLIDE 6-37
KEY OPERATING PARAMETERS : MULTI PLE-CHAMBER, EXCESS-A I R I NCI NERATORS
PARAMETER RECOMMENDED
OPERATING RANGE
PRIMARY CHAMBER COMBUSTION A I R
TOTAL COMBUSTION A I R
80-150% E X C E S S A I R
120 TO 300% E X C E S S A I R
e COMBUSTION G A S O X Y G E N CON, 10-16%
COMBUSTION CHAMBER D R A F T NEGATIVE olo5 TO 0,1 I N , W a c ,
SLIDE 6-38
SUMMARY OF OPERATI ON
UNITS A R E BATCH OR INTERMITTENT DUTY
PRIMARY CHAMBER IS EXCESS A I R ATMOSPHERE -- H E A T R E L E A S E R A T E IS CONTROLLED B Y C H A R G E R A T E AND
-- FOR PATHOLOGICAL W A S T E H E A T R E L E A S E R A T E I S CONTROLLED BURNERS
B Y PRIMARY BURNERS
SLIDE 6-39
SUMHARY OF HON I TORI NG AND CONTROL
OPERATOR MONITORS :
CHARGING R A T E TEMPERATURES OF B O T H CHAMBERS
TEMPERATURE TRENDS DRAFT ASH BED APPEARANCE ASH Q U A L I T Y O P A C I T Y
SLIDE 6-40
SUMMARY OF MON I TORI NG AND CONTROL
OPERATOR CONTROLS :
CHARGE R A T E AIR DAMPER SETTINGS AUXILIARY BURNER OPERATION
SLIDE 6-41
WASTE CHARGING PROCEDURES
ADJUST CHARGE VOLUME AND FREQUENCY TO ACCOUNT FOR WASTE V A R I A T I O N S
MORE FREQUENT SMALLER CHARGES A R E BETTER THAN O N E L A R G E CHARGE
Do NOT "STUFF" INCINERATOR
ASSURE PRIMARY BURNER I S OFF P R I O R T O CHARGING
GENTLY PUSH OLD WASTE TO B A C K OF H E A R T H ; C H A R G E NEW WASTE AT FRONT OF HEARTH
I
SLIDE 6-42
PROPER CHARGE PROCEDURES
1
SLIDE 6-43
Burn"
IMPROPER CHARGE PROCEDURES
SLIDE 6-44
Stoked To Rear: Load To Front
PROPER L O A D I N G ON HEARTH
SLIDE 6-45
IMPROPER LOADING ON H E A R T H
SLIDE 6-46
PATHOLOG I CAL WASTES
CHARGE W A S T E TO HEARTH I N A SHALLOW L A Y E R --DO NOT P I L E --EXPOSE TO FLAME
TURN O F F P R I M A R Y B U R N E R B E F O R E C H A R G I N G
SLIDE 6-47
PROPER ASH HANDLING PROCEDURES
ALLOW INCINERATOR TO COOL
DO NOT SPRAY WATER I N T O COMBUSTION CHAMBER
U S E F L A T ~ B L U N T TOOL FOR A S H R E M O V A L
P L A C E A S H I N M E T A L CONTAINER
DAMPEN A S H TO P R E V E N T FUGITIVE DUST
PROPERLY DISPOSE OF ASH
I N S P E C T ASH Q U A L I T Y ; MAKE CORRECTIONS I N O P E R A T I O N , IF NECESSARY
SLIDE 6-48
STARTUP AND SHUTDOWN
STARTUP :
PREHEAT S E C O N D A R Y CHAMBER BEFORE INITIATING CHARGING
CHARGE W A S T E
IGNITE W A S T E
SHUTDOWN :
SHUT DOWN BURNERS
ALLOW INCINERATOR TO COOL
REMOVE A S H
SLIDE 6-49
0
0
0
e
0
e
e
e
PREHEAT THE S E C O N D A R Y CHAMBER
SHUT OFF PRIMARY BURNER WHEN CHARGING MONITOR COMBUSTION CHAMBER TEMPERATURES MONITOR COMBUSTION CHAMBER DRAFT MONITOR S T A C K G A S OPACITY--ESPECIALLY AFTER CHARGING
INSPECT A S H QUALITY FOR PATHOLOGICAL W A S T E S , O P E R A T E PRIMARY BURNER A T ALL
P A Y CAREFUL A T T E N T I O N TO CHARGING PROCEDURES AND RATES
T I M E S
I
SESSION 7.
AIR POLLUTION CONTROL SYSTEMS OPERATION
I
SLIDE 7-1
AIR POLLUTION CONTROL SYSTEHS FOR HOSPITAL INCINERATORS
W E T SCRUBBERS -- S P R A Y TOWERS -- VENTURI SCRUBBERS
-- PACKED-BED SCRUBBERS
FABRIC F I L T E R S
D R Y SCRUBBERS DRY I N J ECT I ON --
-- S P R A Y D R Y E R S
ELECTROSTATIC PRECIPITATORS
SLIDE 7-2
RECOMMENDED OPERATING RANGES FOR KEY PARAMETERS
VENTURI SCRUBBER
PARAMETER
PRESSURE D R O P
LIQUID SUPPLY
PH
SUSPENDED SOLIDS
RANGE
20-30 I N , W , C t
7-10 GAL/1,000 ACF
5 ,5 -7 ,0
0-3 P E R C E N T
SLIDE 7-3
VENTURI SCRUBBER PARAHETERS USUALLY MONITORED BY OPERATOR
PRESSURE DROP
LIQUID FLOW R A T E
PH
--
S T A T I c P R E S S U R E
RPM A M P E R A G E
SLIDE 7-4
VENTURI SCRUBBER OPERATI ON
K E Y PARAMETER
PRESSURE DROP
L I QU ID SUPPLY
SUSPENDED SOLIDS
PH
ADJUSTMENT
V A R I A B L E THROAT
FAN SPEED
FAN DAMPER
LIQUID FLOW R A T E
MAKEUP WATER BLOWDOWN
M A K E U P C A U S T I c
SLIDE 7-5
1 1
2 , 3, 4 1 5 1 6 1
7 ,
8 ,
VENTURI SCRUBBER STARTUP SEQUENCE
TURN ON LIQUID SUPPLY AND RECIRCULATION SET LIQUID FLOW T O MANUFACTURER SPECIFICATIONS
S T A R T FAN GRADUALLY OPEN D A M P E R ADJUST LIQUID FLOW TO OBTAIN DESIRED L I Q U I D SUPPLY
ADJUST VENTURI T H R O A T , FAN A M P E R A G E , O R DAMPER TO OBTAIN
ADJUST BLOWDOWN
CLOSE FAN DAMPER
D E S I R E D PRESSURE DROP
SLIDE 7-6
VENTURI SCRUBBER SHUTDOWN SEQUENCE
1, SHUT OFF SCRUBBER F A N
2 , SHUT OFF R E C I R C U L A T I O N
3, SHUT OFF M A K E U P W A T E R
SLIDE 7-7
RECOMMENDED OPERATING RANGES FOR KEY PARAMETERS
PACKED-BED SCRUBBER
RANGE
15-25 G A L / ~ , O O O ACF
PARAMETER
LIQUID SUPPLY
PH
SUSPENDED SOLIDS
INLET G A S T E M P E R A T U R E
PRESSURE DROP
5 I 5-7
0-3 PERCENT
SPEC I F I ED B Y MANUFACTURER
1-5 IN, w lc I
I
SLIDE 7-8
PACKED-BED SCRUBBER PARAMETERS USUALLY MONITORED BY OPERATOR
LIQUID FLOW R A T E
PRESSURE DROP
INLET G A S T E M P E R A T U R E
PH
FAN -- S T A T I C PRESSURE
RPM
AMPERAGE
-- --
SLIDE 7-9
K E Y PARAMETER
LIQUID SUPPLY
PH
SUSPENDED SOLIDS
PACKED-BED SCRUBBER OPERATION
INLET G A S TEMPERATURE
ADJUSTMENT
L I Q U I D FLOW R A T E
CAUSTIC FEED R A T E
MAKEUP W A T E R BLOWDOWN
f NCINERATOR EXHAUST TEMPERATURE
PREQUENCH
I
SLIDE 7-10
RECOMMENDED OPERATING RANGES FOR KEY PARAMETERS
SPRAY TOWER
L I Q U I D SUPPLY
PRESSURE DROP
5 T O 20 G A L / L O O O A C F
1 T O 3 I N , W a c ,
SLIDE 7-11
RECOMMENDED OPERATING RANGES FOR KEY PARAMETERS
PULSE-JET FABRIC FILTER
P A R A M E T E R
FLUE G A S T E M P E R A T U R E :
UPPER L I M I T LOWER LIMIT
P R E S S U R E DROP
CLEAN I NG A I R P R E S S U R E
RANGE
SPECIFIED B Y MANUFACTURER A B O V E DEWPOINT
5-9 I N , W , C ,
60-100 P S I G
SLIDE 7-12
FABRI C FI LTER PARAMETERS USUALLY MONITORED BY OPERATOR
OPACITY
PRESSURE DROP
INLET G A S T E M P E R A T U R E
OUTLET G A S T E M P E R A T U R E
I
SLIDE 7-13
K E Y P A R A M E T E R
FLUE G A S TEMPERATURE:
UPPER LIMIT
LOWER L I M I T
PRESSURE DROP
CLEAN I NG A I R PRESSURE
FABRIC F I LTER OPEMTI ON
ADJUSTMENT
B Y P A S S FABRIC FILTER
LOWER I N C I N E R A T O R ( B O 1 L E R ) EXHAUST TEMPERATURE
INTRODUCE COOL AMBIENT A I R
INCREASE A U X I L I A R Y FUEL
BAG CLEANING FREQUENCY
COMPRESSED A I R S Y S T E M
SLIDE 7-14
FABRI C FI LTER STARTUP
PRECOAT B A G S
USE A U X I L I A R Y F U E L - F I R I N G TO B R I N G SYSTEM T O O P E R A T I N G TEMPERATURE
GRADUALLY BUILDUP DUST C A K E
SLIDE 7-15
FABRIC FILTER SHUTDOWN
STOP WASTE CHARGING
M A I N T A I N SECONDARY CHAMBER BURNER F I R I N G U N T I L WASTE IS COMBUSTED
SHUT OFF INCINERATOR
PURGE REMA IN I N G COMBUST I ON PRODUCTS
CLEAN B A G S
SLIDE 7-16
RECOMMENDED OPERATING RANGES FOR KEY PARAMETERS
DRY INJECTION
PARAMETER RANGE
SORBENT INJECTION R A T E SPEC I F I ED B Y MANUFACTURER
SORBENT PARTICLE SIZE 90 PERCENT BY WEIGHT THROUGH 325 MESH S C R E E N
I
SLIDE 7-17
RECOMHENDED OPERATING RANGES FOR KEY PARAMETERS
SPRAY DRYERS
RANGE
5-20 PERCENT
PARAMETER
SLURRY SORBENT CONTENT
W E T BULB/DRY BULB TEMPERATURE
D I F F E R E N C E 90" TO 180°F
SLIDE 7-18
SPRAY DRYER OPERATI ON
K E Y P A R A M E T E R
SLURRY SORBENT CONTENT
W E T BULB/DRY BULB T E M P E R A T U R E
D I F F E R E N C E
ADJUSTMENT
DRY SORBENTIWATER R A T I O
SLURRY FLOW R A T E
SLIDE 7-19
SPRAY DRYER STARTUP/SHUTDOWN
STARTUP ALTERNATIVES:
1, USE A U X I L I A R Y F U E L - F I R I N G TO B R I N G SYSTEM UP TO OPERATING TEMPERATURE BEFORE I N J E C T I N G SLURRY
2, GRADUALLY INCREASE SLURRY FEED A S EXHAUST TEMPERATURE INCREASES TO M A I N T A I N 90" T O 180°F WET BULB/DRY BULB
DIFFERENCE
1, USE A U X I L I A R Y F U E L - F I R I N G TO M A I N T A I N TEMPERATURE ABOVE
SATURATION U N T I L ALL WASTE IS COMBUSTED
2, SHUT OFF S P R A Y D R Y E R
SLIDE 7-20
RECOMMENDED OPERATING RANGES FOR KEY PARAMETERS
ELECTROSTATI C PREC I P I TATORS
P A R A M E T E R
I N L E T GAS TEMPERATURE -- HOT S I D E ESP -- COLD S I D E ESP
PARTICULATE RESISTIVITY
P O W E R RATIO
RANGE
570" T O 800°F ~ 4 0 0 O F
10' TO 10'' OHM-CM
SLIDE 7-21
KEY PARAMETER
PRIMARY V O L T A G E ~ U R R E N T
SECONDARY V O L T A G E ~ U R R E N T
ESP OPERATION
RESISTIVITY
G A S TEMPERATURE
ADJUSTMENT
POWER SUPPLY
C L E A N ~ A D J U S T ELECTRODES
T/R RESISTIVITY
G A S TEMPERATURE
COMBUST I ON/CARBON CONTENT
COND I T I ON I NG AGENT ADD I T 1 ON
COND I TI ON G A S STREAM
I N C I N E R A T O R / B O I L E R OPERATION
SLIDE 7-22
ESP STARTUP/SHUTDOWN
STARTUP
CHECK HOPPER/ASH HANDLING OPERATION PREHEAT HOPPERS
SET R A P P E R CYCLE CHECK R A P P E R O P E R A T I O N
CHECK T/R SETTING SEQUENTIALLY ENERGIZE T/R B Y FIELD
SHUTDOWN INCINERATOR DEENERGIZE T/R B Y FIELD AFTER 4 HOURS DEENERGIZE H E A T E R S AFTER 8 HOURS SHUTDOWN R A P P E R S
SESSION 8.
MAINTENANCE INSPECTI ON--A NECESSARY PART OF YOUR JOB
S L I D E 8-1
PREVENT I VE MA I NTENANCE
PROGRAM TO CONDUCT MAINTENANCE ON REGULAR SCHEDULED B A S I S
R E S P O N S I B I L I T Y OF MAINTENANCE DEPARTMENT?
YOU CAN HELP -- I N S P E C T U N I T
-- I D E N T I F Y MINOR PFiOBLEMS -- REPORT T O MAINTENANCE DEPARTMENT
SLIDE 8-2
ACT IV I T Y FREQUENCY
HOURLY
DA I LY
WEEKLY
MONTHLY
90 DAY
IYPICAL MAINTENANCE INSPECTION SCHEDULE
INCINERATOR COMPONENT
ASH REMOVAL C O N V E Y O R
W A T E R QUENCH PIT RAM COOLING S Y S T E M
S T A C K THERMOCOUPLES LIMIT SWITCHES
UNDERFIRE AIR P O R T S
O P A C I T Y MON I TOR
O X Y G E N MONITOR
BLOWER INTAKES I NDUCED-DRAFT FANS CONTROL PANELS
REFRACTORY
EXTERNAL SURFACE OF INCINERATOR A N D S T A C K
SHUT DOWN A N D DO COMPLETE WALKTHROUGH
(FIRST Y E A R )
SLIDE 8-3
TYPICAL MAINTENANCE INSPECTION SCHEDULE FOR A WET SCRUBBER
INSPECTION FREQUENCY COMPONENT
DA I LY SCRUBBER LIQUID PUMP
VARIABLE T H R O A T ACTIVATOR
SCRUBBER L I Q U I D L I N E S
KEAGENT FEED SYSTEM
FAN
A P METER
PH METER
MONTHLY DUCT WORK
1
SLIDE 8-4
TYPICAL MAINTENANCE INSPECTION SCHEDULE FOR A FABRIC FILTER SYSTEM
I N S P E C T I O N FREQUENCY COMPONENT
DA I LY STACK MANOMETER COMPRESSED A I R SYSTEM COLLECTOR/CLEAN CYCLE
FAN HOPPERS/DUST REMOVAL SYSTEM
SLIDE 8-5
RECORDKEEP I NG
RECORDS A L L O W TRENDS TO B E T R A C K E D
ASSISTS W I T H E V A L U A T I N G PM P R O G R A M
ASSISTS INVENTORY DECISIONS
SLIDE 8-6
DAILY MAINTENANCE INSPECTION LOG
F a c i l i t y name:
Operator 's name: Date:
Time Equipment inspec ted Notes
Ash removal conveyor Hater quench p i t Opacity mon i to r Oxygen mon i to r Underfire a i r p o r t s Ash p i t / d r o p o u t sump Stack
Scrubber 1 i qu i d pump Var iab le t h r o a t a c t i v a t o r Scrubber l i q u i d l i n e s M is t e l i m i n a t o r p ressure l i n e s Reagent feed system Fan Fan b e l t
SESSION 9.
TYPICAL PROBLEIIS
I
SLIDE 9-1
PROBLMS
IT 'S BETTER TO PREVENT PROBLEMS THAN TO CORRECT PROBLEMS
SLIDE 9-2
I NC I NERATOR PROBLEMS
BLACK SMOKE
W H ITE/BLUE-WHITE SMOKE
WHITE SMOKE/HAZE
PUFFING SMOKE FROM CHAMBER
EXCESSIVE AUXILIARY FUEL U S A G E
POOR ASH Q U A L I T Y
BURNER PROBLEMS
SLIDE 9-3
1 . I
Too Much
Waste
Underfire Air
BLACK SMOKE FROM INCINERATOR STACK
SLIDE 9-4
Secondary Chamber Temperature Too Low
WHITE/BLUE-WHITE SMOKE FROM INCINERATOR STACK
SLIDE 9-5
Hydrochloric Acid Gas Condensing
SMOKUHAZE APPEARING
SHORT DISTANCE FROM STACK
I . r WHITE SMOKWHAZE A SHORT DISTANCE FROM INCINERATOR STACK
1%
SLIDE 9-6
Malfunction In Stack Damper or Fan
1 r 1 I I
SMOKE LEAKING FROM PRIMARY
CHAMBER I 1
I
Too Much Primary Air
SMOKE LEAVING PRIMARY CHAMBER OF INCINERATOR
SLIDE 9-7
TOO MUCH AUXILIARY
FUEL USAGE
Too Much Secondary Air
Leaky Door Seal
1
Underfire Air F u e l L e l I
Underfire Air Distribution
TOO MUCH AUXILARY FUEL USAGE
SLIDE 9-8
4 lnsuff icient Bumout Period/ Too Much Temperature WasteMlet Waste
Underfire Air Underfire Air Distribution
I 1
INCOMPLETE BURNOUTIPOOR
ASH QUALITY
INCOMPLETE BURNOUT/POOR ASH QUALITY
SLIDE 9-9
II n Proper
Pattern Flame
BURNER FLAME PATTERNS'
SLIDE 9-10
1 -ad
Detached Flame; Too Much Burner Air
Smoking Not Enough Flame; Air /-I I I I I' ' I
BURNER FLAME PATTERNS '
I
SLIDE 9-11
a
Flame Impingement On Refractory
BURNER FLAME PATTERNS'
SLIDE 9-12
PREVENT I NCI NERATOR PROBLEMS
PROPERLY CHARGE INCINERATOR
NOTE SMALL OPERATING AND MAINTENANCE PROBLEMS
AND GET F I X E D BEFORE THEY BECOME B I G PROBLEMS
I
SLIDE 9-13
WET SCRUBBER PROBLEMS
CORROSION
PLUGGED S P R A Y NOZZLES
FAN VIBRATION
SLIDE 9-14
PREVENT SCRUBBER PROBLEMS
MAINTAIN CORRECT PH FOR SCRUBBER LIQUID
MAINTAIN LOW LEVEL OF SOLIDS I N RECIRCULATED
SCRUBBING L I Q U I D
USE P R E V E N T I V E MAINTENANCE PROGRAM FOR I N S P E C T I N G / C L E A N I N G NOZZLES I FANS, DAMPERS
SLIDE 9-15
Improperly Installed Bags
Broken Bags
HIGH OPACITY STACK EMISSIONS
BAGHOUSE ’ HIGH OPACITY FROM FABRIC FILTER
SLIDE 9-16
HIGH PRESSURE DROP IN FABRIC FILTER
SLIDE 9-17
PREVENT FABRIC F I LTER PROBLEMS
MAINTAIN PROPER TEMPERATURE RANGE W I T H I N BAGHOUSE
MONITOR AP
MAINTAIN PROPER CLEANING CYCLE
MONITOR OPACITY
SLIDE 9-18
OTHER PROBLEMS
W A T E R COOLING SYSTEMS FOR RAMS - - M A I N T A I N WATER FLOW - - M A I N T A I N COOLER O P E R A T I O N
MI CROSW I TCHES --CHECK MOVEMENT B Y HAND - -LUBRICATE
I
SLIDE 9-19
WHAT PROBLEMS
DO
YOU HAVE?
SESSION 10.
STATE REGULATIONS
SLIDE 10-1
TYPES OF REQUIREMENTS I N STATE REGULATIONS
EMISSION LIMITS
OPERAT I NG P R A C T I CES/L I M I TS
CONT I NUOUS EM I ss I ON MON I TOR I NG
RECORDKEEPING AND REPORTING
O P E R A T O R TRAINING
I
SLIDE 10-2
f 1 Grain
/
I 1
1 Grain Per Dry Standard Cubic Foot
Foot
7000 Grains=l pound
1
SLIDE 10-3
c Contains 1 Million Cubic Meters
100 Parts Per million
SLIDE 10-4
6 I I . - - -_
. - - - 1 grldscf
y- 7% oxygen 12% carbon
Combustion Air 21 % oxygen 79% nitrogen
0% carbon dioxlde
INCINERATOR
4
dioxide
\
Barometric
g Z = l
/
1 0.5 grtdscf --- * I - - - 14% oxygen
6% carbon dioxide
t I 1 scf air
21% 0% carbon oxygen dioxide 'lI{ 7% 1 grldscf oxygen
1 carbon dioxide
Combustion Air 21 % oxygen 79% nitrogen
0% carbon dioxide
1 grldscf @ 7% 4 = 0.5 grtdscf @ 14% O2 1 gr/dscf @ 12% C02 = 0.5 gr/dscf @ 6% CO2
CORRECTION FOR DILUTION
.. . c,
I
SLIDE 10-5
Ringlem's Scale tor Grading the Denslty of Smoke
0% 20Yo 60% 80%
OPACITY AND THE RINGLEMANN CHART
SESSION 11.
SAFETY: AN IMPORTANT PART OF YOUR JOB
I
SLIDE 11-1
TORN "RED" BAG
SLIDE 11-2
WASTE HANDLING SAFETY
HAZARDS
SHARP OBJECTS I N W A S T E BAGS
INFECTIOUS W A S T E SPILLAGE
MICRO-ORGANISMS IN A I R
PRECAUT IONS
MINIMIZE B A G HANDLING
DO NOT OPEN OR CRUSH BAGS
. .
W E A R PROTECTIVE CLOTHING AND SAFETY G E A R
DO NOT EAT OR D R I N K I N THE AREA
W A S H HANDS BEFORE EATING OR DRINKING
I
I
SLIDE 11-3
Ear protectors
I
1
Hard-soled rubber shoes
- Dust mask
Long-sleeved
Safety glasses
\aw shirtlcoveralls
PROPER SAFETY GEAR
SLIDE 11-4
INCINERATOR OPERATION-- INJURIES AND SAFETY HAZARDS
BURNS -- HOT SURFACES -- CARELESS CHARGING -- CARELESS ASH REMOVAL -- O P E N I N G I N S P E C T I O N PORTS
INJURY -- MOVING B E L T S AND H Y D R A U L I C C Y L I N D E R S -- ELEVATED WALKWAYS
EXPOSURE TO AIR CONTAMINANTS/LACK OF OXYGEN -- LEAK I N EQUIPMENT OR DUCTWORK -- POOR V E N T I L A T I O N OF AREA
SLIDE 11-5
BURNER FLAHE SAFEGUARD SYSTEM
CONTROLS BURNER IGNITION
PURGES SYSTEM
PILOT IGNITION -- DETECTOR -- 15 SECONDS -- FUEL RELAY
MAIN BURNER I G N I T I O N
SHUTDOWN FLAME OUT A I R SUPPLY F A I L U R E
-- --
I
SLIDE 11-6
INCINERATOR OPERATI ON SAFETY PRECAUTI ONS
- Do's
W E A R PROTECTIVE CLOTHING AND SAFETY GEAR BE CAREFUL AROUND MOVING BELTS, HYDRAULIC CYLINDERS, AND
AVOID CONTACT WITH HOT SURFACES W A T C H FOR FUEL LEAKS BE CAREFUL ON ELEVATED W A L K W A Y S VENTILATE ROOM IF THERE IS LACK OF O X Y G E N OR UNUSUAL ODORS
LEAVE A R E A IF YOU DEVELOP
DOORS
-- HEADACHE, DROWSINESS, SHORTNESS OF BREATH, NAUSEA
SLIDE 11-7
INCINERATOR OPERATION SAFETY PRECAUTIONS
DON TS
DO NOT OPEN I N S P E C T I O N PORTS DURING O P E R A T I O N
DO NOT PLACE HANDS OR F E E T I N T O FEED RAM ASSEMBLY,OR ASH REMOVAL SYSTEM
DO NOT LEAN ON GUARDRAILS OF WALKWAYS
DO NOT BYPASS BURNER FLAME SAFEGUARD SYSTEM
SLIDE 11-8
I NC I NERATOR OPERATI ON SAFETY PRECAUTI ONS : MANUAL CHARG I NG
- Do's
W A I T FOR PREVIOUS CHARGE TO BURN DOWN TURN OFF PRIMARY CHAMBER BURNER STAND BEHIND AND A W A Y FROM DOOR
DON' TS
D O NOT LOOK I N T O OPEN CHARGE DOOR DO NOT CHARGE BOTTLES OF FLAMMABLE L I Q U I D S
SLIDE 11-9
I NCI NERATOR OPERATI ON SAFETY PRECAUTIONS : ASH REMOVAL
Do's -
U S E PROPER EQUIPMENT TO REMOVE ASH W A T C H OUT FOR HOT SPOTS AND SHARP OBJECTS
SPRAY W A T E R ON ASH IN CONTAINER TO COOL P U T ASH I N T O NONCOMBUSTIBLE CONTAINER
SLIDE 11-10
INCINERATOR OPERATI ON SAFETY PRECAUTIONS : ASH REMOVAL
DON' T S
DO NOT ENTER I N C I N E R A T O R CHAMBER DO NOT DAMAGE I N C I N E R A T O R REFRACTORY DO NOT SPRAY WATER I N T O CHAMBER DO NOT HANDLE ASH D I R E C T L Y
SLIDE 11-11
WET SCRUBBERS: HAZARDS
CHEMICAL BURNS
FALLS
FAN/FAN BELTS
HEARING LOSS
SLIDE 11-12
WET SCRUBBERS: SAFEM PRECAUTIONS
- Do's
KEEP SCRUBBER LIQUOR OFF SKIN AND EYES LEARN LOCATION OF AND HOW TO USE E Y E W A S H GET SCRUBBER LEAKS REPAIRED STAY A W A Y FROM FANS, D R I V E SHAFTS, AND FAN BELT
W E A R EARPLUGS O R EARMUFFS AROUND NOISY EQU I PMENT ASSEMBLIES
SLIDE 11-13
WET SCRUBBERS : SAFETY PRECAUTIONS
DON' TS
Do NOT PLACE HAND IN FAN BELT/PULLEY ASSEMBLY DO NOT C O N T I N U E TO OPERATE I F FAN IS V I B R A T I N G SEVERELY
I
SLIDE 11-14
FABRIC F I LTERS : HAZARDS
TOXIC CHEMICALS IN FINE DUSTS
EXCESSIVE HEAT
FAN/FAN BELTS
HEARING LOSS
INSIDE FABRIC FILTER -- T O X I C GASES AND DUST
-- HOT, FREE FLOWING S O L I D S -- OXYGEN D E F I C I E N C Y -- ROTAT I NG EQU I PMENT -- M O V I N G MECHANICAL PARTS
. .
SLIDE 11-15
FABRI C F I LTERS : SAFETY PRECAUTI ONS
- Do's
PREVENT INHALATION OF DUST B Y WEARING DUST MASK
W E A R EARPLUGS OR EARMUFFS AROUND NOISY EQU I PMENT
S T A Y A W A Y FROM FANS, DRIVE SHAFTS, AND F A N BELT ASSEMBLIES
BEFORE ENTERING A FABRIC FILTER -- CLEAN DUST FROM BAGS AND HOPPER
-- PURGE W I T H A I R
-- HAVE A SECOND T R A I N E D PERSON S T A N D I N G BY
-- P L A N TO STAY I N S I D E AS SHORT A T I M E AS P O S S I B L E
-- EE SURE FAN IS "LOCKED OUT''
I
SLIDE 11-16
FABRI C F I LTERS : SAFETY PRECAUTI ONS
DON I TS
DO NOT PLACE HAND I N FAN BELT/PULLEY ASSEMBLY
DO NOT C O N T I N U E TO OPERATE I F FAN I S V I B R A T I N G SEVERELY
NEVER ENTER FABRIC FILTER WITHOUT PROPER TRAINING AND EQU I PMENT
SLIDE 11-17
EMERGENCY PROCEDURES
POST TELEPHONE NUMBERS FOR EMERGENCY S E R V I C E S
S E C U R I T Y SHOULD I N C L U D E INCINERATOR ON ROUNDS
POST SPILL CONTROL/DECONTAMINATION PROCEDURES
POST PROCEDURES FOR ADDRESSING PUNCTURE WOUNDS
. .
REFERENCES FOR SLIDES
TECHNICAL REPORT DATA Please reaa insmcllons on ine revene oefore comotenna!
I R E P O R T N O . 12. 3. RECIPIENT'S ACCESSION NO.
EPA 450/3-89-004 I I
1. T I T L E A N 0 SUBTITLE 5. REPORT D A T E
Medical Idaste Hospital d&ste Air Pollution Control Tra i n i ng
Hospital Incinerator Operator Training Course: Volume I 1 Presentation Slides
I M a r c h 1489 (6. P E R F O R M I N G O R G A N I Z A T I O N C O D E I I 18. P E R F O R M I N G O R G A N I Z A T I O N REPORT NO. I . AUTWOR(S1
Neul icht, R. M. ;.. Chaput, L. S.; Wallace, 0. D. ; Turner, M. B.; Smith, S. G. I
110. P R O G R A M E L E M E N T NO. ). PERFORMING O R G A N I Z A T I O N N A M E A N 0 AOORESS I
1 68-02-4395 1 68-98-0011
Midwest Research Institute 401 Harrison Oaks Boulevard, Suite 350 Cary, North Carolina 27513
I t 1. C O N T R A C T / G R A N T NO.
113. TYPE O F REPORT A N D PERIOD COVERED 12. SPONSORING AGENCY N A M E A N 0 ADORESS -. ~
U. S. Environmental Protection Agency Control Techno1 ogy Center Research Triangle Park, N. C. 27711
I Final 114. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
James Eddinger, Office of Air Ouality Planning and Standards Justice Manning, Center for Environmental Research
This document is Volume I1 o f a three-volume training course for operators of hospital waste incinerators. Volume I is the Student Handbook (EPA 450/3-89-003), and Volume I11 is the Instructor Handbook (EPA 450/3-89-010). This training course was originally prepared by the Control Technology Center for the State of Maryland. The purpose of this course is to provide hospital waste incinerator operators with a basic understanding of the principles of incineration and air pollution control and to identify, generally, good operation and maintenance (OM) practices. Proper O&M, in addition to reducing air emissions, improves equipment reliability and erfor- mance, prolongs equipment life, and helps to ensure proper ash burnout. TEe course is not intended to replace site-specific, hands-on training of operators with the specific equipment to be operated.
16. ABSTRACT
-
Volume I1 contains classroom materials including a copy of the presentation slides so that students can follow along during the class and worksheets that can be completed during the classroom sessions. The course includes 11 separate classroom sessions covering to ics such as basic combustion principles and incinerator design;
erator operation: maintenance inspec ions; typical problems: and State regulations. ! air pollution contro 7 equipment desi n, function, operation, and monitoring; incin-
-
7 . K E Y WORDS A N D OOCUMENT ANALYSIS
DESCR I PTORS Ib. lOENTIFIERS/OPEN E N O E D T E R M S iL. COSATI klCld / ( ; fOUO I
Medical Waste Incineration Hospital I4aste Incineration Air Pollution Control Technoloqy Incinerator Operator Training
19. SECURITY CLASS iT/ilrS KCDOrf i
i I. CISTRIBUTION STATEMENT :1. K G . 3 F P A G E 5
PART 1 1 , STUDENT WORKSHEETS
WORKSHEET NO. 1
INCINERATOR SYSTEH INFORMATION Can you describe the type incinerator you operate?
Circle the answer that best fits your system. Fill out this
table.
Operator's name
Incinerator manufacturer
A. Incinerator type (Circle)
1. Controlled ("starved") air 2. Multiple chamber "excess" air
3. Rotary kiln 4. Other 5. Don't know
In-line Retort
8. My incinerator is designed especially for pathological waste: Yes No Don't know
C. Operatinq mode
1. Single batch 2. Intermittent duty 3. Continuous duty 4. Don't know
0. Waste feed charge system
1. Manual - I do the work 2. Mechanical hopper/ram
a. Manually operated b. Automatic timer sequence
3. Mechanical hopper/ram with cart dumper 4. Other 5. Don't know
E. Ash removal system
1. Manual - rake and hoe 2. Continuous mechanical 3. Don't know
I NCI NERATOR SYSTEM INFORMATION ( CONT I NUED 1
F. Combustion Gas Flow
1. Natural draft 2. Induced draft 3. Balanced draft
Forced combustion air/natural draft stack Forced combustion air/induced draft fan
G. Waste heat boiler
1. Yes 2. No
WORKSHEET NO. 2
INCINERATOR SYSTEM INFORMATION Monitoring and Control Systems
Operator's name incinerator manufacturer
A. How would you descrit? the operating made o f your incinerator?
1. Single batch 2. Intermittent duty 3. Continuous duty
How would you describe the control system used on your incinerator? 8.
1. Manual 2. Automatic timer sequence 3. Automatic modulated control
C. What operatinq parameters are monitored or used as control parameters on your incinerator?
Funct i on Monitored Controlled Controlled
1.
2.
3. 4. 5. 6. 7. 8.
Primary Chamber Temperature Secondary Chamber Temperature Draft Charge rate Oxygen Carbon Monoxide Opacity Other:
WORKSHEET NO. 3 INCINERATOR SYSTEM INFORMATION
Operating Parameters
Operator's name
Incinerator manufacturer
What are the key operating parameters for your incinerator. operating ranges used?
What are the setpoints or
Key Parameter Setpoints/Operating Range No setpoint
1.
2.
3.
4.
5.
6.
upper
Primary chamber temperature
Secondary chamber temperature
Draft
Charge rate
Oxygen concentration
Carbon monoxide concentration
1 ower -
WORKSHEET NO. 4
OPERATING REVIEW ~~
A. List the things to do when operating your incinerator that you think are the most important:
1. 2. 3. 4. 5.
8. Name the things to watch (monitor) when operating your incinerator that you think are the most important.
1. 2. 3. 4. 5.
C. Name the things not to do when operating your incinerator that your think are the most important:
1, 2. 3. 4,
5.
WORKSHEET NO. 5
OPERATING PROBLEMS REV1 EW
What a r e t h e most f r e q u e n t problems you u s u a l l y have?
A. Prob 1 em:
P o s s i b l e causes:
P o s s i b l e s o l u t i o n s :
B. Problem:
P o s s i b l e causes:
P o s s i b l e s o l u t i o n s :
C. Problem:
P o s s i b l e causes:
P o s s i b l e s o l u t i o n s :
WORKSHEET NO. 6
INCINERATOR SYSTEM INFORMATION Regulatory Limits
Operator's name
Incinerator manufacturer
What requlatory limits are you required to meet during operation o f your incinerator?
A. Emission Limits:
1. Opacity 2. Particulate 3. Other
B. Operating Limits
1. Charge rate 2. Primary chamber temp 3. Secondary chamber temp 4. Oxygen concentration 5. Ash quality 6. Other
C. Record Keeping
Limit
1. Charge rate 2. Primary chamber temp 3. Secondary chamber temp 4. 'Other
WORKSHEET NO. 7
SAFETY REVIEW
A. What personal safety gear do you use?
1. Coveralls 2. Hard soled shoes 3. Eye protection 4. Gloves 5. Dust mask 6. Ear protection
8. L i s t the most serious safety hazards to which you are exposed. How do you minimize your.chances o f injury??
1. 2. 3. 4. 5.
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