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Base Catalyzed Decomposition (BCD) formerly called Base Catalyzed Dechlorination

Base Catalyzed Decomposition (BCD) formerly called Base Catalyzed Dechlorination. Status & POPs application. Commercial operations: Australia, Mexico for last six years. Systems used for short-term projects in Australia, Spain (2 years) and US

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Base Catalyzed Decomposition (BCD) formerly called Base Catalyzed Dechlorination

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  1. Base Catalyzed Decomposition (BCD) formerly called Base Catalyzed Dechlorination

  2. Status & POPs application • Commercial operations: Australia, Mexico for last six years. Systems used for short-term projects in Australia, Spain (2 years) and US • Pilot plant treatment PCCD-and PCDF-soil and waste and at present full-scale plant under construction at Spolana (Czech Republic) • POPs application: All POPs, PCB’s and pesticides

  3. Technology description

  4. Technology description • Principle: Destruction of toxic halogenated + non-halogenated compounds by catalytic transfer hydrogenation. • Process:Mixture hydrocarbon (donor oil) + base (sodium hydroxide) + catalyst formulation of polyalkeneglycol compounds)  300° C Toxic materials pumped into closed treatment vessel. • Toxics decomposition : Atomic hydrogen released from hydrocarbon or donor oil. Conversion toxic compounds to salts + non-toxic residues.=>carbon, some of hydrogen donor, base, and salt (sodium chloride)

  5. Technology description • Complete destruction of toxic materials without release of any toxics into environment. • Watch: No continuous but a batch process! • New in Japan Nov 04: introduction continuous process for oils with low contamination of PCB’s

  6. Catalyst Base Gas Emissions Chiller Carbon Trap CarbonTrap BCD Reactor Condenser 1 Condenser 2 Oil Carbon Trap Oil Solids Salt Carbon Centrifuge BCD Flow Schedule Nitrogen Hydrogen Donor Water Recovered Oil

  7. PART I - Adaptation Technology – Country A. Performance: 1. Minimum pre-treatment: Different types pre-treatment may be necessary: (A) Removal larger particles by sifting + size reduction by crushing; or (B) Adjustment of pH and moisture content For soils often Thermal desorption used as pre-treatment and concentrate into BCD process

  8. PART I: Adaptation Technology - Country A. Performance: 2. Destruction Efficiency (DE): • DEs of 99.99–99.9999 % for DDT, HCH, PCBs, PCDDs and PCDFs. DEs > 99.999 % and DREs > 99.9999 % for chlordane and HCB. • Reduction of chlorinated organics > 2 mg/kg + non detectable

  9. PART I: Adaptation Technology - Country A. Performance: Destruction of HCB & Lindane(Spolana site Czech Rep.) 2004 update Material Inlet mg/kg Outlet Oil Matrix mg/kg HCB Lindane HCB Lindane Chemical waste 29,000 1,500 < 1.0 < 1.0 Chemical waste 200,000 900 < 2.0 < 2.0 Chemical waste 550,000 1,000 < 2.0 < 2.0 Chemical waste 270,000 1,000 < 2.0 < 2.0 Chemical waste 160,000 1,000 < 2.0 < 2.0 Dust 7,60 7 < 2.0 < 2.0 Chemical waste 1,598 19,000 < 2.0 < 2.0 Conc Aqueous 630 < 2.0 < 2.0 < 2.0 Conc Organic 11,000 < 2.0 < 2.0 < 2.0

  10. PART I: Adaptation Technology - Country A Performance: Dioxin Destruction Material Inlet ng/kg I-TEQ Outlet Oil Matrix ng/kg I-TEQ Chemical waste 209,000 0 ( Reported value) Chemical waste 200,000 4.3 Chemical waste 11,000 0.23 Chemical waste 47,000 0 Chemical waste 35,000 0 Dust 1,620,000 0.52 Chemical waste 78,000 0 Conc Aqueous 96,000 0 Conc Organics 876,000 0

  11. PART I: Adaptation Technology - Country A. Performance: Treatment of Solid Matrices in Upstream Desorber (from pre-treatment step) Dioxin Removal Material Inlet ng/kg I-TEQ Outlet ng/kg I-TEQ Soil 46,500 2.9 Brick&Concrete 2,420,000 6.3 Concrete 4,780,000 66.0 Plaster 3,800 5.6

  12. PART I: Adaptation Technology - Country A. Performance: Treatment of Solid Matrices in Upstream Desorber HCB & Lindane Removal Material Inlet mg/kg Outlet mg/kg HCB Lindane HCB Lindane Soil 2,643 1.34 < 1.0 < 1.0 Brick&Concr 49,000 11 < 1.0 < 1.0 Concrete 5,100 18 < 1.0 < 1.0 Plaster 270< 1.0 < 1.0 < 1.0

  13. PART I: Adaptation Technology - Country A. Performance: 3. Toxic by-products: --- 4. Uncontrolled releases: --- 5. Capacity to treat all POPs:Yes, but PCB treatment of capacitors not possible and solvent washing required for transformer components 6. Throughput: quantity [tons/day, l/day] • ca 10 m3 per batch, can treat 3 batches/24 hrs. Last productivity + throughput increase till 1000 t/y high chlorine content PCB’s/Pests possible in single line • POPs throughput : [POPs waste/total waste in %]: 30% and new in Spolana upto 55%, no limit on chlorine content

  14. PART I: Adaptation Technology - Country A. Performance: 7. Wastes/residuals: Secondary waste stream volumes: • Sludge with water, salt, unused hydrogen donor oil + carbon residue =>inert and non-toxic • Heavy fuel oils can be used once only, with the used oil being fed to cement kilns after destruction of POP’s. • New option: re-use 90-95% of donor oil (refined paraffinic oils) • high improvement economics of process and reduction of wastes to a solids stream of sodium chloride and carbon from the breakdown of the POP molecule.  Off gas treatment: activated carbon traps to minimize releases of volatile organics in gaseous emissions.

  15. PART II: Adaption Country – Technology • Resource needs: example 1000 t/y • Power requirements: 110-125 kWh • Water requirements:cooling water 10-15 m3/h • Fuel volumes: Fuel gas 40 m3/h • Reagents volumes:Vary 1-20 % by weight of contaminated medium • Weather tight buildings: • Hazardous waste personnel requirement: Sampling • Requirements/facilities: • Peer sampling: • Laboratory requirements: • Communication systems: • Number of (un/skilled) personnel required:1 skilled chem operator, 1 semi skilled operator

  16. PART II: Adaption Country – Technology B: Costs for: case related in % of total • 1400-1700 US $/t for org. Chlorine 50% & throughput of 150 t/m (Spolana site) • Installation + commissioning: • Site preparation: • Energy & Telecom installation: • Compliance: • Reporting: • Run without waste: • Run with waste: • Decommissioning: • Landfilling: • Transport residues:

  17. PART II: Adaption Country – Technology C. Impact & D. Risks • Discharges to air: 2-5 m3/h 90% Nitrogen rest H2 • Discharges to water: none • Discharges to land(fill): Salt residue 900-1100t/1000 t of 50% chlorine • Risks reagents applied: Hydrogen donor, alkali, bicarbonate, catalyst • Risks of technology: Fire risk low( 1995), as only at 1point oil temp is > flashpoint • Operational risks: most automatic + controls

  18. PART II: Adaption Country Technology E. Constructability & F. Output • Ease of installation & construction of plant: easy fixed recipes • Ease of shipping/transit:container sized • Ease of operation: • Ease of processing: • Generated waste (% of input waste): • Deposited waste at landfill (% of input waste): • Waste quality properties (pH, TCLP)

  19. Mexico PCB plant

  20. Olympic Site, Australia Soil inlet hopper 3000 litre plant

  21. Indirect thermal desorption

  22. BCD Reactor Active carbon filter BCD Plant - Spolana Dumping tank Water cooled primary condensers Collection pots for condensate

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