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Cost estimating for hazar~~rr-- waste incineration

LVINM STAR

Companies aencrating haurdolu wutes should demiddot vclop ~ estimJtes 10 delcrmine if it is pouible 10 imshyprove their wasle management pracciees Once wutc 11ream dlarKtcristia have bun defined tencricdctcrshyminations can be made u 10 whether KCU re Landfil1ina 5urfaoe impoundmenl (pits ponds and IIJOOnl) deepshywell injection landfarminamp or incineratioo is the most appropriiiC disposal option Qcarly certain WUIC disshypont praatccs panicularly llndfil linc have defin ite COSC advanlaampes over the Olhcn however corponte lmiiUIJCmcnl ml$1-eiamph the trade-ofU belween the cnshyYironmenlll risks of chis method of was1c manatement andthccostsforincincralion

Spurred on by rising cow and incrcninamp rcaulation of managing hazardous wastes there Is an incuuinamp trend rowud indnention While many people panicushylarlySocalcitizenrymayclisqruwithincinoentionasa di$polal concept most studies whether baKd on tbeshyory uperimenl or aaual experience have cffectivdy demomtratcd that incineratiorl will e nsure lonamiddottcrm proccction olthe cnvironmcnt

Gcncnlly ~pCampItinJ incincr1tion is the most cff~ivc form of manaaina the dispoul of many wastes It rcmiddot d~MUIfMC elimiutcspotential riskstothe cnvironmiddot mcnt and oftca oonveru the wutcs to a useful recoyenCrmiddot able encro form Comparinl lnciocration to the other dUpolal opcioos the advantaaa ol this method beoocne evident especially IS more wastes~ rcplatcd by the Resource Conservation and Rcltovery Act (RCRA) and IS additional prohibitions ind increasinampIY burdenmiddot IOnCCOSUareplaccdon landdisposal

Incinerat ion reduces the hciaht and volume of the chuaetoasmatiCractioooliuoriainalsizcresidual asb is ICcrile and the I)SCcm rcquira a relatively 1m1ll area few iu Q9Cntion Additionally wutcs can be inmiddot cincntcd onsitc and do Me bave to be transported cbeshywhcre thus minimizioa potential cnvironmcntalliabilimiddot ties Onrent tedlnoioampY cmts to dellroy even the most haurdous material in 1 complete and effective manmiddot ncrand the heat rcltovcry techniques can reduce OJ Offmiddot ~et the cost of opcraOOn IS a result of the sale or u~e of thccncruproduccd

CostsfOtlnclneratlon

1bc central iu11es for ultimately cboosinamp incincrshyationarctcchnicalfcasibilitytoburnthcwastcsand costs Technical fcasibi lity canlarccly be determined on thebasisolawastccharactcriution Suchach3rKtcrmiddot iutfon involves c$1ablishina compositional frltttl ions (percent liquids amplurdes and stKiccs and built and conmiddot taincriud solids) cstinutina the amount whidJ is COIII middot

busttble non-combustible or recoverable dctcrminma physical dlcmical and thermodynamic propcntes and byquantifyinathcwastcsthatarcavltlab1c

POllUTION ENGINEEAING

To estimate rcal~tic capital and operation and mainmiddot tcnance (Oamp M) cosh forhaurdous wutc incineration the followinamp items mull be cuablishcd ( I ) lfCf11JC dailyandannualwallequantitics(2)tochno10Jytobc employed (liquid injection nuidixcd bed multiple hearthrotaryltilnetc)and(l)faciilydcsiampnandopshycrat ion Usually cost estimates depend primarily on the spccirtc size and conliauration of the incineration SYcm Howcvcr before economic judamcnts can be made dcsian auumpcions must be evaluated equipshyment siud and prel iminary encincerina cakulations performed

The followinamp major dcsiampn parameters muse be part of the evaluation to determine capital and OampM costs

bull Space requirements bull Site dcvdopmcnt bull Tanks pumps aDd pipinJ bull Caru convc)Ors and transfer vchkks bull Slnictures and cndosures bull Incinerator aDd Knlbbcr

Unless a facility lw adequate land propcny miUt be acquired with the neccuary area dependent on the tcchnoloampY employed its capacity and the compostmiddot tiona dtaractcristics ol be waste The land aher ICmiddot

quisition midi be dcvclopcd The land can be dcarcd and padcd howcwr permits midi be obtained whida allow fot the further development of the site includinamp aocasroad ufilitics fcnocplaoemcntlandscapinampetc

Waste storace and hlndinamp systems vary as a f11nltmiddot tion of be amount of waste cencntcd its composition dcsian opt~ns aDd other factors lbcre arc innllmcrshyablt waste storace and handlinssystems possible howmiddot ever almost all buardous waste indncntotl will havc tanks pumps and pipinc u components Tanks arc ncoeuary for fCI oil and caustic solution 5toracc and liquid wute stonce holdinamp and blendina Pumps are 11scd for fuel oil caustic solution and liquid waste transfer and fecdinamp PipinJ is neecssary for hook-ups Caru and conveyors arc basically used for transferrinamp bulk scHid wastes from proccuQ9Crations to incincntot feed mechanisms Tnnsfcr vehicles handle drummed wastcs and can place them into the feed mechanisms Typical buildinsand scructure rcq11iremcnts incllldc a warehou~e for built IOiid and drummed wastes pumps eotnpeS$01 and other ancillary system components as wcllu for the control room clcctricalannucs and fllnctionalarcasindudincofriCCandlaboratoryspacc

Thc incinerator oontkts of numerous major composhyncntS thccbarJinampandauJtiliary fucl s)SScmlindudinamp pnmary (and often a Slaquondary) combuscion chamber ash dbullharac qllCnch ca11 U1C absorber and venturi rubber and induced draft fan and Slack Nlturally the IampZi namp and dciiampn of these components arc pnmarily

based on the wute composition quantities and o ther u lient properties The SC111bber system removes p~rti middot culate matter and hydrochlor)c acid (HCI ) with removshyal erflcicncy based on its pressure drop Parametel5 in cvaluatina capital eost C$timates include caustic solution and makeup water feed and blowdown ni les

GapltICo1t1

Capital costs are mmpriscd of depreciable and nonmiddot depreciable elements The ~m total capital costs will determine -ilether buardous IIIUtc iDcinen~tioa wiU be alfordabk as cootpatcd 10 altemaliyenC disposal options as wdl as other investments availabk 10 the mmpany

II Corporate man1acmeatmay abo w1nt to consider

noa-ecoPOCnlc facton in maltina Its loYUUncnt decishydoa All major hazardous wale aeaemor will the inmiddot cinen110t rcduoc coviroomcntalliabUities aad improve the corporate bMFI At orllia times particularly toshydly when the intephy ollaad dispoAI il becomina inmiddot aeuinampJy suspect they mipt eyenCn cwetridc economic considerations Nevertheleu 1n economic analysis should be the fit~~sup

QrpiMI btiGtmmll indude both ditcct aod indirect cosu Depreciable difOCt capital iawstments 11e commiddot prised O( tbe COSU for Jaod deyendopmcot all S)SCCm componeoiS and aocillll) equipment as discuraquoCd a~ and their costs for insallalion l ruliuaCOIII do not involve purebalelinstallatioa ol eqllipment rather they arc iDCUned Ia pladna the ilicinentioa I)Stem in worltinamp order As aiKh these expenses include COlts for conoepuW ptdimiWJ and detailed desian phases of the project amstruetion amplatlup spate parts invenshytory permiuand lcampal matten and continaency NtMmiddot thprteioble upiW costs indude those for land acquisishytionincintnltorllatlupindlldinamponsitcassistanccand minor de5ian modifications by the s)amplem manufacturmiddot er tn~inina and test bums

Bottom-line in5tallcd conceptual level capital cutesshytimates for a commercial liquid waste incinerator are listed in Tablet

As shown rela ted conaptual level COlis can beampin to aP9foad S2 miiUon indudinathe oosts for plaquomitlina 1be costs for permittillamp can vary Oyentr 1 wide ranae demiddot pendina oa the number and yen01 ume of haurdous WISie streams 1nd most impOIIlnt the number of principal Ofampanic haurdous co~itue nts (IOIICs) If haurdous eorutitucnts are present in the waste feed a td1 bum exemption may be obllinabk as a 00$1-uvina me~sure by dcmonstntint criteria similarity of waste equipshyment and operational characteristics of the propo5td

I

incineratorwithanothcrs~temthatalreadyhasaReshyrource Conse rvation Recovery Act (RCRA) fart 8 permit (see Fiaure) Uthereaulatoryaaencyaecepu the findinasofthissubnlissionit mayarant a Part B

permit without requirinc a test burn prototOI In epenmiddot siveilcm preparedby scniorencineerinampcon5ultants workinamp with corporate staff The prepara tion of the protocol is followed by an even more expemive test bum

11lc tat bum protocol is 1 document that u wure the rcJUIIIOf) aJent) thlt the lest bum proocdure will yield sufftdcnttochnical datatodemonstrate thelncinmiddot entKmaystcmsadequK) TheCO$loftestbum ~oshyool preparation by itself can COlt approUmatcly S15000 to S20000 dcpendina on innumuable facton The test bum 1 procedure lo determine -ilether the incincn1tor can meet the required performance bulluDdardJ and if demonstr~ted to kkntify those opcr~linamp ocmditions DCCeUil)tomlintainthesesllndanbwflcatheaystem beeomel opcntional il even more exptftlivc Related costs can easily exceed S75000 As such corporate ~tampbouldnWttftratltmpttodevdopl loaical 1nd well-defined reaulatory Slratel) which would hopefully avoid havinato do a tesc bum which eaneasilyeo~tconsidcnlblymorethanislmaampiiUibleor perhaps warranted

AI indicated earlier COIUicvction cannoc beampin until the oectSSII) permits have been Jf1101ed Permit aJIPimiddot catkin Pfepatation includinamp possible Prevention of Sipdlkant Deterioration (PSD) and other lir and uh disposa l permits completion of the test burn protocol lAd the tCSl bum jtsclf aaency review of the submittals and public hcarinp if netcSUiry can euily take two yean Corporate applicants must therefore perform their economic analyses make the dedsion to proceed nth incineration llOtrtain whether an Environmental lmpact Statement (EIS) is ncct$Slf) and prepare and fi middot naliu it artd submit the permit applications Once the permiu are 1r1nted the appliant must proceed llld oontinuewithcoostiUCtionorthepermiumiJhtberemiddot Kinded

A propoulto const111et a haza rdous waste incinermiddot ator will probably rewlt in wrne form of public opposishytion which willlikelysurfacedurinampthepublicandlor EIS rtvicw PfOOCSS Corporate manaaement may find it best to limit the opposition by informinampthe community of project plans developments and benefits 1nd by maintaininamp a dibullloampue and a dear and accurate public record The ldvantaces to cooperation should be evimiddot dent Partidpationofthepubliewilllikelyscrvecorposhynteinterestsparticularlyiflcplentanamplcmenuareinmiddot csapable at 10me later date

Operation 80d Malntenncbull Costs

OampM costs also tonsist or direct and indiret t demiddot ments Oircet OampM OM elcmenll include labor (opermiddot ational and supervi~y personnel) fuel oi l raw materishyal (chemicalli a ndcaush c soda) residual ash and

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W~~t cwotltf lhSpo~ltfl mllllt ltnOIIIC md C llC IGYCcdits These oosl~ wludo ~ 1 c ho)h ly vori~hk llolt a func tion of waste ~t 1um ch oroch r it~ uld ontgnitultkf the rize and mrxhtnicll mrnpk- lly of the incincrator and how its uKd Di1ltct OkM ctllitS arc typically lughcs t for uptivc inclneraho n ~ystcms operaled by larsc chemical fcilit ic1 which pound(ncrotc waste on either a ronl inuousOf semi-continuous ~sis Operators a these facilitiu usumiddot ally Slrive to muimize online lime IO minimize the anmiddot nual costs of operation and downtime expenses result middot ina from ucessivc thermal cycl inJ Downtime costs include non-use of operator personnel and for eomshymerdal incinerators lost revenue and oosu for the IolSe

of alternative disposal facililics Thus consultants may recommend down-sited units wi th hiJhcr apital costs thll result from a full complement of automatic feed and ash removal equipment and conuols to help eMure continuous efficient and economical operation

Indirect OampM costs consiu of basically fibulled cxshypcMCS for administrat ion wa1es for nonmiddot tcchnieal peoshyple maintenance of and supplies for ancilluy Slrucshyturcs amortization insunnce premiums proputy IIlia andJencnl overllcad Such costs arc arcalerin the New York City mcuopolilan area however they should be a malllaeabte fne1 ion of the annual cost for indncratoropcralion Conecptuallevcl OampM cost e5ti middot malesuclistedinTablc2

Summary

The cost of incineration varies accordinJto the was te composieional characteristics the capadty desian and opcralion of he system and other faccort inllc rent to ccortOmiaof~calf lntangiblcs however must also be eomidtred ~nicularly pcrmillina which is a complu task

lncincnlion provides the ultimate means of disposals for many enecdinaly toailt compounds Considcrinaall the aucnt ion JiYen to hanrdous subsanltes entcrinamp tile environmenl n ~It as the lcJal ramiftca rions 1nd ldYctSC publicity thlll res11IU from this many rorporamiddot tions select this bull~chnoiOJY for wnlt disposal lncinermiddot ~tioncanminimizeehellablliticsofeurrentopcralions an increasingly important tonsidcru ion improve pubshylic relalions and enhance 1hecorpor11e imaJC while managinawastuin~ncnltronmenta11yacceplable and soundmannu PE

AlllfiM ltaru~tttltlrl-nobullttftttfltlaii-JtJmttrllltlllt tltHJIIIIIflfitmrgtfCithh_( llrlll111 Nr )nt k NY

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1. barcode 553179
2. barcodetext SDMS Doc ID 553179

W~~t cwotltf lhSpo~ltfl mllllt ltnOIIIC md C llC IGYCcdits These oosl~ wludo ~ 1 c ho)h ly vori~hk llolt a func tion of waste ~t 1um ch oroch r it~ uld ontgnitultkf the rize and mrxhtnicll mrnpk- lly of the incincrator and how its uKd Di1ltct OkM ctllitS arc typically lughcs t for uptivc inclneraho n ~ystcms operaled by larsc chemical fcilit ic1 which pound(ncrotc waste on either a ronl inuousOf semi-continuous ~sis Operators a these facilitiu usumiddot ally Slrive to muimize online lime IO minimize the anmiddot nual costs of operation and downtime expenses result middot ina from ucessivc thermal cycl inJ Downtime costs include non-use of operator personnel and for eomshymerdal incinerators lost revenue and oosu for the IolSe

of alternative disposal facililics Thus consultants may recommend down-sited units wi th hiJhcr apital costs thll result from a full complement of automatic feed and ash removal equipment and conuols to help eMure continuous efficient and economical operation

Indirect OampM costs consiu of basically fibulled cxshypcMCS for administrat ion wa1es for nonmiddot tcchnieal peoshyple maintenance of and supplies for ancilluy Slrucshyturcs amortization insunnce premiums proputy IIlia andJencnl overllcad Such costs arc arcalerin the New York City mcuopolilan area however they should be a malllaeabte fne1 ion of the annual cost for indncratoropcralion Conecptuallevcl OampM cost e5ti middot malesuclistedinTablc2

Summary

The cost of incineration varies accordinJto the was te composieional characteristics the capadty desian and opcralion of he system and other faccort inllc rent to ccortOmiaof~calf lntangiblcs however must also be eomidtred ~nicularly pcrmillina which is a complu task

lncincnlion provides the ultimate means of disposals for many enecdinaly toailt compounds Considcrinaall the aucnt ion JiYen to hanrdous subsanltes entcrinamp tile environmenl n ~It as the lcJal ramiftca rions 1nd ldYctSC publicity thlll res11IU from this many rorporamiddot tions select this bull~chnoiOJY for wnlt disposal lncinermiddot ~tioncanminimizeehellablliticsofeurrentopcralions an increasingly important tonsidcru ion improve pubshylic relalions and enhance 1hecorpor11e imaJC while managinawastuin~ncnltronmenta11yacceplable and soundmannu PE

AlllfiM ltaru~tttltlrl-nobullttftttfltlaii-JtJmttrllltlllt tltHJIIIIIflfitmrgtfCithh_( llrlll111 Nr )nt k NY

II-

1. barcode 553179
2. barcodetext SDMS Doc ID 553179