PROCESS ECONOMICS

PROGRAM SRI INTERNATIONAL

Abstract

Menlo Park, California

94025

Process Economics Program Report No. 187A

ADVANCES IN HAZARDOUS WASTE TREATMENT

(December 1993)

This report is a supplement to PEP Report 187, December 1966, on the same subject. It brings up to date the environmental legislation in the United States, the European Community, Germany, and Japan. It also summarizes the progress of chemical waste reduction and treatment in the U.S. chemical industry. The report reviews and summarizes the progress of innovative technologies for hazardous waste treatment and waste site remediation currently under develop- ment in the United States.

Besides the qualitative assessments, we have developed capital and treatment cost esti- mates for the following three processes:

l Supercritical water oxidation (SCWO) for treating an acrylonitrile plant wastewater-an emerging technology.

l Wet air oxidation (WAO) for treating an ethylene plant caustic scrubbing liquor at 100 and 400 psig-a commercial technology.

l UV oxidation for detoxifying an organics contaminated groundwater-a commercial technology.

In addition to the cost estimates, we also present in the last section of the report a tabulation of the current market prices for treatment and landfill of chemical wastes at a commercial disposal site in California.

The comprehensive coverage in this report on environmental legislation, technical ad- vances, and economics for selected technologies provides a valuable data source for process engineers, environmental engineers, planners, and administrators who select or operate chemi- cal waste treatment systems.

PEP’90 JJLM

Report No. 187A

ADVANCES IN HAZARDOUS WASTE TREATMENT

SUPPLEMENT A

by JAMES J. L. MA

with contributions by

ANTHONY PAVONE

December 1993

A private report by the

PROCESS ECONOMICS PROGRAM

Menlo Park, California 94025

I I For detailed marketing data and information, the reader is referred to one of the SRI

programs specializing In marketing research. The CHEMICAL ECONOMICS HANDBOOK

Program covers most major chemicals and chemical products produced in the United

States and the WORLD PETROCHEMICALS Program covers major hydrocarbons and their

derivatives on a worldwide basis. In addition, the SRI DIRECTORY OF CHEMICAL

PRODUCERS services provide detailed lists of chemical producers by company, product,

and plant for the United States, Western Europe, Canada, and East Asia.

I 1

CONTENTS

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I....... l-l

2 SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-l

LEGISLATIVE ASPECTS ................................................... 2-1

TECHNOLOGICAL ASPECTS .............................................. 2-2

Supercritical Water Oxidation ........................................... 2-2

Wet Air Oxidation ..................................................... 2-2

UV Oxidation ......................................................... 2-3

ECONOMIC ASPECTS .................................................... 2-3

3 ENVIRONMENTAL LEGlSLATtON IN THE UNTIED STATES .................. 3-l

CLEAN AIR QUALITY ACT OF 1967 AND SUBSEQUENT AMENDMENTS AND REAUTHORIZATIONS ................................................ 3-l

National Ambient Air Quality Standards .................................. 3-1

New Source Performance Standards .................................... 3-4

New Permitting Procedure ............................................. 3-6

Acid Rain ............................................................ 3-7

Emission Credit Trading ............................................... 3-7

Mobile Sources ....................................................... 3-7

Ozone-Depleting Chemicals ............................................ 3-7

Noise Pollution ....................................................... 3-7

Penalties ............................................................. 3-6

FEDERAL WATER POLLUTION CONTROL ACT OF 1967 AND SUBSEQUENT AMENDMENTS AND REAUTHORIZATIONS .................... 3-6

Control Issues ........................................................ 3-6

Permitting and Technology Impacts ..................................... 3-9

Water Pollutant Control Limits .......................................... 3-9

Penalties .; ........................................................... 3-l 0

FEDERAL INSECTICIDE, FUNGICIDE, AND RODENTICIDE ACT OF 1972 AND ITS SUBSEQUENT AMENDMENTS .................................... 3-10

Registration .......................................................... 3-l 1

Reregistration of Pesticides ............................................. 3-l 1

Experimental Use Permits .............................................. 3-l 1

Protection of Trade Secrets and Other Information ........................ 3-l 1

. . . - Ill -

CONTENTS (Continued)

3 ENVIRONMENTAL LEGISLATION IN THE UNITED STATES (Concluded)

FEDERAL INSECTICIDE, FUNGICIDE, AND RODENTICIDE ACT OF 1972

AND ITS SUBSEQUENT AMENDMENTS (Concluded)

Inspection of Establishments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I......... 3-I 1

Imports and Exports ..,,,,,,...,,,,,,,..,.,................III......... 3-11

Enforcement ,,,....,,,..,....,.,,,.......................II.......... 3-11

Penalties . . . . . . . . . . . . . . . . . . . ..I....................................... 3-11

TOXIC SUBSTANCES CONTROL ACT (TSCA) OF 1976 . . . . . . . . . . . . . . . . . . . . . . . 3-12

THE RESOURCE CONSERVATION AND RECOVERY ACT (RCRA) OF 1976 AND ITS SUBSEQUENT AMENDMENTS AND REAUTHORIZATIONS . . . . . . . . . . . . 3-12

THE COMPREHENSIVE ENVIRONMENTAL RESPONSE, COMPENSATION, AND LIABILITY ACT (CERCLA) OF 1980 AND SUBSEQUENT AMENDMENTS . . . . 3-14

Treatment Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Penalties . . . . ..I.........................# m........................... 3-14

Radon Gas and Indoor Air Quality Research ,,............................ 3-14

EMERGENCY PLANNING AND COMMUNITY RIGHT-TO-KNOW ACT OF 1966 . . . 3-15

Penalties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I........................... 3-16

POLLUTION PREVENTION ACT OF 1990 . . . . . . . . I.....,,,,........,......... 3-16

OIL POLLUTION ACT OF 1990 . . . . . . . . . . . . . . . ..I........................... 3-16

PROGRESS IN ENVIRONMENTAL PROTECTION IN THE U.S. CHEMICAL INDUSTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I 3-16

4 ENVlRONYENTAL LEGISLATION IN THE EUROPEAN COMMUNITY,

GERMAW, AND JAPAN .................................................. 4-l

EUROPEAN COMMUNITY ................................................. 4-l

Background .......................................................... 4-l

Laws and Regulations ................................................. 4-l

Penalty .............................................................. 4-7

GERMANY ............................................................... 4-7

Background .......................................................... 4-7

Legislation ........................................................... 4-8

Criminal Liability ...................................................... 4-10

Civil Liability .......................................................... 4-10

- iv -

CONTENTS (Continued)

-

4 ENVIRONMENTAL LEGISLATION IN THE EUROPEAN COMMUNITY,

GERMANY, AND JAPAN (Concluded)

JAPAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Background ..,,...........,I..,....,,,.......................,....... 4-11

Legislation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..II......... 4-11

Criminal and Civil Liabilities . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

5 REVIEW OF INNOVATIVE DEMONSTRATION TECHNOLOGIES .............. 5-1

BIOLOGICAL DEGRADATION PROCESSES ................................. 5-l

MATERIALS HANDUNG PROCESSES ...................................... 5-2

PHYSICAVCHEMICAL PROCESSES ........................................ 5-2

RADIOACTIVE WASTE PROCESSES ........................................ 5-2

SOLIDIFICATION/STABILlZATlON PROCESSES .............................. 5-2

THERMAL DESORPTION PROCESSES ..................................... 5-2

THERMAL DESTRUCTION PROCESSES .................................... 5-3

COST ESTIMATES OF DEMONSTRATED PROJECTS ......................... 5-3

6 REVIRN OF INNOVATIVE EMERGING TECHNOLOGIES ..................... 6-l

BIOLOGICAL DEGRADATION PROCESSES ................................. 6-l

MATERIALS HANDUNG PROCESSES ...................................... 6-1

PHYSICAL/CHEMICAL PROCESSES ........................................ 8-1

THERMAL DESTRUCTION PROCESSES .................................... 6-1

7 TREATMENT OF ACRYLONITRILE PLANT WASTEWATER BY

THE SUPERCRITICAL WATER OXIDATION PROCESS ...................... 7-l

REVIEW OF PROCESS TECHNOLOGY ...................................... 7-l

Patents .............................................................. 7-l

Technical Articles ..................................................... 7-4

Development Activities ................................................. 7-5

Advantages and Disadvantages ........................................ 7-6

Advantages ....................................................... 7-6

Disadvantages .................................................... 7-6

DESIGN BASES .......................................................... 7-6

-V-

CONTENTS (Contlnued)

7 TREATMENT OF ACRYLONITRILE PLANT WASTEWATER BY

THE SUPERCRlTlCAL WATER OXIDATION PROCESS (Concluded)

PROCESS DESCRIPTION ................................................. 7-l 1

PROCESS DISCUSSION .................................................. 7-l 2

COST ESTIMATES ........................................................ 7-12

Capital Costs ......................................................... 7-12

Production Costs ..................................................... 7-13

DISCUSSION OF COSTS .................................................. 7-13

6 TREATMENT OF ETHYLENE PLANT CAUSTIC SCRUBBING UQUOR BY AN AIR OXlDATlON PROCESS ............................................ 8-1

REWW OF PROCESS .................................................... 8-1

.............................................................. ai

Scrubber Liquor Composition .......................................... ai

Chemical Reactions ................................................... 8-2

Proceas Design Parameters ............................................ 8-3

RMEW OF DESIGN BASES ............................................... 85

PROCESS DESCRlPTlON ................................................. 6-4

PROCESS DISCUSSION .................................................. ail

COST ESTIMATES ........................................................ ail

Capital Costs ......................................................... 8-11

Low Pmssurs Oxidizer ............................................. 8-11

Medium Prassure Oxidizer .......................................... al2

Production costs ..................................................... al2

Low Pressure Oxidizer ............................................. a12

Medium Pressure Oxidizer .......................................... 8-12

DISCUSSION OF COSTS .................................................. 8-13

9 TREATMENT OF ORGANICS CONTAMINATED WATER BY AN ADVANCED UV OXIDATION PROCESS ................................. Q-l

RMEW OF PROCESS TECHNOLOGY ...................................... 9-l

Chemical Oxidants .................................................... 9-l

Readions ............................................................ 9-2

Process Design Parameters ............................................ 93

CONTENTS (Concluded)

-

-

l

9 TREATMENT OF ORGANICS CONTAMINATED WATER BY AN ADVANCED UV OXIDATION PROCESS (Concluded)

RMEW OF PROCESS TECHNOLOGY (Concluded)

Process Advantages ..................................................

Process Limitations ...................................................

Patents ..............................................................

Industrial Applications .................................................

DESIGN AND ESTIMATE BASES ...........................................

PROCESS DESCRIPTION .................................................

PROCESS DISCUSSION ..................................................

COST ESTIMATES ........................................................

Capital Costs .........................................................

Production Costs .....................................................

DISCUSSION OF COSTS ..................................................

10 TREATMENT AND DISPOSAL FEES FOR HAZARDOUS WASTES AT AN OFF-SITE COMMERCIAL FACILITY .................................

NON-RCRA LAB PACKS DISPOSAL .........................................

LANDFILL AND SURFACE IMPOUNDMENT ..................................

APPROVAL FEES AND MISCELLANEOUS CHARGES .........................

LIQUIDS TREATED E?W CYANIDE OXIDATION ................................

PRICES ON REQUEST ....................................................

APPENDIX A: DESIGN AND COST BASES .*.....*..........*................. A-l

APPENDIX B: U.S. EPA’S UST OF EXTREMELY HAZARDOUS SUBSTANCES . . . . B-l

APPENDIX c: ClTED REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-l

APPENDIX D: PATENT REFERENCES BY COMPANY . . . . . . . . . . . . . . . . . . . . . . . . . . D-l

APPENDIX E: PROCESS FLOW DIAGRAMS ..,,.....,.....,....,,.....,....... E-l

9-4

9-4

a6

9-6

9-8

9-15

9-15

415

9-15

9-16

9-17

lo-l

lo-l

lo-l

10-2

10-2

10-2

- vii -

ILLUSTRATIONS

4.1 SO, Emission Limits for New Plants Using Solid Fuels- European Community ,..................,........................... 4-5

4.2 SOz Emission Limits for New Plants Using Liquid Fuels- European Community ,........,..,....,.,............,.,,........... 4-6

7.1 Treatment of Acryfonitrile Plant Wastewater by the Supercritical Water Oxidation Process Process Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..m.......... E-3

7.2 Treatment of Acrylonitrile Plant Wastewater by the Supercritical Water Oxidation Process Effect of Capacity on Capital Investment ,..,..,,,,,,,.................I 7-17

7.3 Treatment of Acrylonitrile Plant Wastewater by the Supercriiical Water Oxidation Process Effect of Capacity and Operating Level on Total Treatment Cost . , . . . . . . . . 7-l 8

8.1 Treatment of Ethylene Plant Caustic Scrubbing Liquor by an Air Oxidation Process Process Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I... ,....... . m.. E-5

8.2 Treatment of Ethylene Plant Scrubbing Liquor by an Air Oxidation Process Effect of Capacity on Capital Investment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

8.3 Treatment of Ethylene Plant Scrubbing Liquor by an Air Oxidation Process Effect of Capacity on Total Treament Cost . . . . . . . . . . . . . . . . . . , , . . . . . . . . . . 8-21

9.1 A Typical Lamp Layout in a UV/Ozone Oxidation System . . . . . . . . . . . . . . . . 9-5

9.2 Treatment of Organics Contaminated Water by an Advanced UV Oxidation Process Process Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . ..I.................. E-7

9.3 Treatment of Solvents Contaminated Water by an Advanced UV Oxidation Process Effect of Capacity on Capital Investment . . . . . ..*....................... 9-21

9.4 Treatment of Organics Contaminated Water by an Advanced UV Oxidation Process Effect of Capacity and Operating Level on Total Treatment Cost . . . . . . . . . . 9-22

-ix-

TABLES

2.1 Summaty’of Economics for Contaminated Water Treatment Processes . . . . 2-5

3.1 Major Environmental Legislation in the United States . . . . . . . . . . . . . . . . . . . . 3-2

3.2 U.S. National Ambient Air Quality Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.3 High Risk Carcinogen Pollutants . . . . . . . . . . . . . . . . . . . . . . . ..I............ 3-4

3.4 U.S. EPA Emission Performance Standards for Public Utilities and Industrial-Commercial Steam Boilers . . . . . . . . . . . . . . . . . 36

3.5 U.S. EPA Emission Performance Standards for Petroleum Refineries . . . . . . 3-6

3.6 Water Discharge Pollutant Limits ..,,....,,,,.,....................... 3-10

3.7 Chemical Pollutants Under the U.S. EPA 33150 Program . . . . . . . . . . . . . . . . . 3-15

3.8 Waste Generation and Management Practices by Member Companies of the Chemical Manufacturers Association in 1990 . . . . ..m... 3-18

4.1 European Community Environmental Action Plans and Air and Water Quality Directives .*,................................... 4-2

4.2 SO2 Emission Ceilings and Reduction Goals in the European Community-Existing Plants . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3 NOx Emission Ceilings and Reduction Goals in the European Community-Existing Plants ,......................... 4-4

4.4 Major Environmental Legislation in Germany . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.5 Environmental Legislation in Japan . . . . . . . . ..a........................ 413

5.1 Demonstration Technologies for Hazardous Waste Treatment and Waste Site Remediation . . . . . . . . . . . . . . . . . . . . . . . . . . . ..m........*.. 5-4

5.2 Cost Estimates on Demonstrated Technologies . . . . , . . . . . . . . . . . . . . . . . , . . 5-l 7

6.1 Emerging Technologies for Hazardous Waste Treatment and Waste Site Remediation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

7.1 Hazdardous Waste Treatment by Supercriiical Water Oxidation Patent Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.2 Treatment of Acrylonitrile Plant Wastewater by the Supercritical Water Oxidation Process Design and Estimate Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

TABLES (Continued)

7.3 Treatment of Acrylonitrile Plant Wastewater by the Supercritical Water Oxidation Process Mass Flows . . . . . . ..a.................... m.......................... 7-8

7.4 Traatment of Acrylonitrile Plant Wastewater by the Supercritical Water Oxidation Process

Major Equipment . . . . . . . . . . . . . . m.................................... 7-9

7.5 Treatment of Acrylonitrile Plant Wktewater by the Supercritical Water Oxidation Process Utlliiies Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I...... 7-10

7.8 Treatment of Acrylonitrile Plant Wastewater by

the Supercritical Water Oxidation Process

Total Capital Investment . . . . . . . . . . ..I................................ 7-14

7.7 Treatment of Acrylonitrile Plant Wastewater by

the Supercritical Water Oxidation Process Production Costs .I.,,,,,........,,,,.......,,,.........,.........I. 7-15

8.1 Treatment of Ethylene Plant Scrubbing Liquor by an Air Oxidation Process Design and Estimete Bases . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . , 84

8.2 Treatment of Ethylene Plant Scrubbing Liquor by a Low Pressure Air Oxidation Process Stream Flows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8.3 Treatment of Ethylene Plant Scrubbing Liquor by a Medium Pressure Air Oxidation Process Stream Flows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

8.4 Treatment of Ethylene Plant Scrubbing Liquor by an Air Oxidation Process-Low or High Pressure Major Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I...... 8-8

8.5 Treatment of Ethylene Plant Scrubbing Liquor by a Low Pressure Air Oxidation Process Utilities Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

8.6 Treatment of Ethylene Plant Scrubbing Liquor by a Medium Pressure Air Oxidation Process

Utilllaa Summary . . . . . . . . . . . . . . . . . . . . . . . ..I......................... 8-10

8.7 Treatment of Ethylene Plant Scrubbing Liquor by

a Low Pressure Air Oxidation Process Total Capital Investment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

- xii -

TABLES (Concluded)

-

a

8.8 Treatment of Ethylene Plant Scrubbing Liquor by a Medium Pressure Air Oxidation Process Total Capital Investment *.....,.......m........m..*...........,...... 8-15

8.9 Treatment of Ethylene Plant Scrubbing Liquor by

a Low Pressure Air Oxidation Process

Production Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I........ 8-16

8.10 Treatment of Ethylene Plant Scrubbing Liquor by a Medium Pressure Air Oxidation Process Production Costs . . . . . . . . . . . . . ..I................................... a18

9.1 Hazdardous Waste Destruction by Photocatalytic Oxidation Patent Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.2 Hazardous Pollutants Treated by UV Oxidation . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

9.3 UV Oxidation Systems in Production Applications ,.................. a.. 9-10

9.4 Treatment of Organics Contaminated Water by an Advanced UV Oxidation Process Design and Estimate Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

9.5 Treatment of Organics Contaminated Water by an Advanced UV Oxidation Process Stream Flows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

9.6 Treatment of Organics Contaminated Water by an Advanced UV Oxidation Process Major Equipment ,..........,,,..................................... 9-13

9.7 Treatment of Organ& Contaminated Water by

an Advanced UV Oxidation Process Utilities Summary ~............,,...........,.,,..................... 9-14

9.8 Treatment of Organ& Contaminated Water by an Advanced UV Oxidation Process Total Capital Investment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

9.9 Treatment of Organics Contaminated Water by an Advanced UV Oxidation Process Production Costs ,.............,.................................... 9-l 9

10.1 Landfill and Surface Impoundment Prices ............................. 10-3

10.2 Waste Stream Approval Fees and Miscellaneous Charges ............... 1 O-4

. . . - XIII -