erm-southwsst, inc. · 2020-01-07 · erm-southwsst, inc. 16000 memorial drive • sutte 200 •...

E R M - S o u t h w s s t , inc.16000 Memorial Drive • S u t t e 200 • Hous ton, Texas 77079-4006 • (713) 496-9600

March 2, 1990

Mr. Brent Truskowsk iU . S . Environmental Pro t e c t i on A g e n c y1445 Ross AvenueD a l l a s , T e x a s 7 5 2 0 2 W . O . 192-09S u b j e c t : Review o f the A p p l i c a b i l i t y o f S o l v e n t Ex t ra c t i on to theA r l c w o o d , I n c . S i t eDear Mr. T r u s k o w s k i :At your request, and on b e h a l f of Mass M e r c h a n d i s e r s , I n c . (MMI) ,E R M - S o u t h w e s t , I n c . has p e r f o r m e d an a d d i t i o n a l eva lua t i on o fsolvent e x t rac t i on t o r e a p p r a i s e i t s a p p l i c a b i l i t y f o r r emedia t i onof the A r k w o o d , I n c . site. S p e c i f i c a l l y * we reviewed the sys temde s igned by CF S y s t e m s , I n c . of W a l t h a m , M a s s a c h u s e t t s . Our reviewi n c l u d e d t h e f o l l o w i n g :

1.

2 .

3.

4.

5.

6.

Review of p i l o t test d a t a pre s en t ed by CF S y s t e m s andp u b l i s h e d by the U . S . EPA on two S u p e r f u n d s i t e s :a SITE program test on PCB- contaminated harborsediments f r o m t h e N e w B e d f o r d H a r b o r s i te ( N e wB e d f o r d , M a s s a c h u s e t t s ) , a n dt h e T r e a t a b i l i t y S t u d y report f o r s o i l s f r o m t h ©U n i t e d C r e o s o t i n g s i te ( C o n r o e , T e x a s ) .

Discus s ion o f th e U n i t e d C r e o s o t i n g p i l o t s tu ly wi thC a l v i n S p e n c e r , t h e W e s t o n p r o j e c t manager f o r t h e s t udy .Review of data s u p p l i e d by CF S y s t e m s , I n c . on treatmentof various wastes ( p r i m a r i l y o i l r e f i n e r y s l u d g e s ) .V i s i t to the commercial system at the S t a r E n t e r p r i s e s( f o r m e r l y T e x a c o ) r e f i n e r y , Port Arthur , Texa s to reviewi t s de s ign and opera t i on with CF S y s t e m sCompar i s on of the charac t e r i s t i c s of tha wastes in thef o r e g o i n g t e s t s t o a f f e c t e d s o i l s a t the A r k w o o d , I n c .site.C o m p a r i s o n o f e s t imated r emedia t i on coats for theArkwood , inc. si te for solvent ex trac t ion to costs forsieve-and-v*sh $n,

of 9

New Orleans Office: 3501 North Causeway Boulevard * Suits 200 - Metaine. Louis iana 70002 • (504) 831-6700An aftftatB ol era Enwonmental Resources Management G*oup wan oft $ «

Anncocks. MD • Ann Aiftor Ml • Bloommgion MN • Bostcm. MA • Brentwooti. TN • ChanetKwv WV • Charlotte. NC • C&umtMJt,OH • 0**ri<eW, ft, • Eng&veod CO • Houston. TX • Louwfe. KY - Manetta. GA • McLean. VA • Mowne. LA • Mom. R • Nawtxxi Beam.Z* • e nwew NY • Ra-TOW Conjova CA > nodmoM WA > Tomoa. FL • Walnut Creek CA • w«« Cftosiar. PA • Vancowor BC

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ERM-Southwe s t , inc.

Mr. Brent T r u s k o w s k iU . S . Environmental Pro t e c t i on AgencyMarch 2, 1990 of 9

S o l v e n t ex trac t ion i s d e s igned for recovery of o i l f r o m s l u d g e s .Organic c ons t i tu ent s in the f e e d are d i s s o l v e d in a so lvent in oneor more extraction steps. In the CF Sys t ems process, shown inF i g u r e 1, the o i l - s o lven t mixture is s eparated f r o m the water-s o l i d s mixture a f t e r the extractor. The solvent i s then recoveredf r o m the oil by d i s t i l l a t i o n and the solvent recycled to the pro-cess. The CF S y s t e m s process uses p r o p a n e as the s o lv en t . W a t e ri s s epara t ed f r o m the s o l i d s by d e w a t e r i n g us ing s t a n d a r d techni-ques such as a be l t f i l t e r pre s s . F e e d p r e p a r a t i o n requirementsvary f r o m s i te to s i t e ; the f e e d p r e p a r a t i o n shown in F i g u r e 1 isthat which would be a n t i c i p a t e d for the A r k w o o d , I n c . site.The process creates three produc t streams: o i l , wastewater andtreated s o l i d s . The oil is can be recycled in some s i t ua t i on s ( f o re x a m p l e , in a r e f i n e r y ) ; at the A r k w o o d , I n c . s i te it would requireo f f - s i t e incineration. W a s t e w a t e r would require on-site treatmentb e f o r e d i s charge . T h e treated s o l i d s a r e t y p i c a l l y f u r t h e r treatedby s t a b i l i z a t i o n to immobi l ize metal s and than l a n d f i l l e d . At theA r K w o o d , I n c . s i t e s t a b i l i z a t i o n would not be necessary, and thetreated s o i l s would be c o n s o l i d a t e d on-site and c a p p e d .P i l o t test data for the CF S y s t e m s proce s s has been encouraging.The proce s s a p p e a r s very s u i t a b l e f o r o i l y s l u d g e s (such a sr e f i n e r y w a s t e s ) . H o w e v e r , quest ions about the r e l i a b i l i t y o f thesystem and its a b i l i t y to achieve a c o n s i s t e n t l y h igh removal oforganics have held back its c ommerc ia l i za t i on . CF S y s t e m s hasi n s t a l l e d a 200 b b l / d a y (50 t o n / d a y ) , f o u r - e x t r a c t o r unit at theS t a r Ent e rpr i s e s ( f o r m e r l y T e x a c o ) r e f i n e r y i n Port A r t h u r , T e x a s .A f t a r a p p r o x i m a t e l y nine months on the s i t e , the unit is s t i l l ina ahakedown period and has yet to achieve continuous treatmentmee t ing s p e c i f i c a t i o n s . If the unit i s unable to achieve theagreed acceptance s p e c i f i c a t i o n s , i t i s d o u b t f u l that CF S y s t e m s ,Inc. wil l remain f i n a n c i a l l y solvent.The prob l ems encountered by CF S y s t e m s in o p e r a t i n g the unit att ha S t a r Ent e rpr i s e s r e f i n e r y in c lud e;

- S o l i d s s e t t l i n g in the f e a d s lurry tank;- F e e d p u m p o v e r l o a d , which required pump r e p l a c e m e n t ;- S u f f i c i e n t extractor mixing without cr ea t ing emul s i on s orpropane vapor by cav i ta t i on; and

W A T E R

F E E D S O I LS T O C K P I L E

reeoP U M PFEEDT A N K

RECOVEREDO R G A N i C S T OO F F - S I T EI N C I N E R A T I O N

C L E A NP R O P A N E

RECOVEREDO I L T A N K P R O P A N ERECOVERY( D f S T ( L L A T t Q N )

W A T E R T O T R E A T M E N TA N D D I S C H A R G E

C L E A N E D S O L I D S : C A P P E D O N - S I T EF M E E T T R E A T M E N T G O A L ;O T H E R W I S E R E C Y C L E D F O R - — — —A D D I T I O N A L T R E A T M E N T

C O M P R E S S O RDP R O P A N E & O f L ( E X T R A C T )

C O N D E N S E R

S E C O N D S T A G E

D E C A N T E RF L A S H T A N K(PROPANE RECOVERYF R O M W A T E R / S O L f D S S )

W A T E R & S O L I D S

D E W A T E R I N GS Y S I E M

I N T E R S T A G EB O O S T E R R U M P

N E W O R L E A N S , L O U I S I A M A H O U S T O N , T E X A S

DATE 02/27/90 W.O.NO. 92Q9AQ26B9Q

F I G U R E 1C F S Y S T E M S P R O C E S S( T W O - S T A G E E X T R A C T I O N S H O W I N G F E E D P R E P A R A T I O N )A r k w o o d I n c . S i t eOmaha, A r t c p i f i s a S / ' - 1 1 3

, inc.

Mr. Brent TruskowskiU . S . Environmental Protect ion AgencyMarch 2, 1990 of 9

- Proper s e p a r a t i o n in the decanter , due to several p r o b l e m swith decanter des ign and over-mixing.All of these prob l ems would be of concern at the A r k w o o d , I n c .site. However, the s i g n i f i c a n t d i f f e r e n c e s between the o i l ys ludge s at the S t a r Enterprises r e f inery and a f f e c t e d so i l s at theA r k w o o d , I n c . s i t e would almos t c e r t a i n l y require d i f f e r e n ts o lu t i on s and, t h e r e f o r e , r ede s ign of the proce s s equipment .More r e c e n t l y , the U . S . EPA has a t t e m p t e d to extend use o f thesystem to removal of s p e c i f i c organics f r o m s o i l s with low oi lcontent. The low oil content inev i tab ly decreases the e f f i c i e n c yof the system. CF S y s t e m s solvent e x t r a c t i o n was t e s t ed at theN e w B e d f o r d H a r b o r S u p e r f u n d s i te f o r removal o f PCBs f r o m harborsediments. Data pub l i s h ed by the EPA indicate that the system canremove PCBs f rom soi l s . A p p r o x i m a t e l y six extraction s t ep s wererequired to achieve 90% PCB reduct ion. (In other words , the PCBsoil had to be run through the treatment sy s t em, which had a s i n g l eex trac tor, six times to achieve 90% PCB reduc t i on .) N i n e passeswere required to achieve 98% removal. The p u b l i s h e d da ta containsno i n f o r m a t i o n on m a t e r i a l s h a n d l i n g c o n s i d e r a t i o n s for the t e s t .In the U n i t e d Creoso t ing s tudy, test runs were p er f o rmed on onedrum each o f two m a t e r i a l s : (1) "waste pond soil" h i g h l y a f f e c t e dby creosote c ompound s , and (2) l e s s - a f f e c t e d r e s ident ia l so i l . Thewaste pond soil was treated using nine extraction s t e p s ; since thep i l o t system was bu i l t with two ex trac tor s , th i s consi s ted of 4 1/2pas s e s through the treatment system. The a f f e c t e d r e s i d e n t i a l soilwas to be treated a like number of t imes, but material s handl ingp r o b l e m s f or c ed early termination o f treatment .CF S y s t e m s solvent extraction was pr imar i ly des igned for oilrecovery f r o m s ludge s . U s i n g it to recover const i tuents f r o m so i l swith very low oil content , such as at the A r k w o o d , I n c . s i t e , ist h e r e f o r e s t r e t ch ing the d e s ign use. T h i s is indica t ed by the highnumber of extraction s teps required at the two S u p e r f u n d sitescited above to achieve a c c e p t a b l e removal of c on s t i tu en t s ofconcern. T h i s must s i g n i f i c a n t l y raise the cost of solventextraction treatment. The cost data released by CF Systems isi n s u f f i c i e n t to evaluate how well the degree of treatment has beenaccounted for in CF S y s t e m s ' cost e s t imate s .

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Mr. Brent Truskowsk iU . S . Environmental Protection AgencyMarch 2, 1990 of 9

United Creosoting used creosote for wood treatment. The solventex trac t ion s tudy t h e r e f o r e f o c u s e d on p o l y n u c l e a r aromatichydrocarbons (PNAs), bu t d id include analysi s f or p en ta ch l oropheno l( P C P ) . P C P w a s be low d e t e c t i on l i m i t s f o r t h e r e s id en t ia l s o i l ,so no conclusions can be drawn on solvent e x t rac t i on e f f i c i e n c y forPCP removal f r o m that material . For the waste pond so i l , thesystem achieved 96% removal of PNAs and 83% removal of P C P . Forcomparison to the Arkwood T r e a t a b i l i t y S t u d y , this 83% removalwould t r a n s l a t e into the f o l l o w i n g treated soil PCP concentrationsf or th e Arkwood, I n c . site:

S o i l F r a c t i o n-1/4" +12 mesh-12 mesh-12 sesh

C o n c e n t r a t i o n s , ( m q / k c f ) T r e a t a b i l i t y£d Tr_eated ._So_i l S t u d y T a b l e _930

2,3001,300

160390220

4-14-44-7

For compari son, sieve-and-wash achieved PCP removals for these sameso i l s of between 50% and 90%. ( S e e the Arkwood T r e a t a b i l i t y S t u d yf o r d e t a i l s . )The most s t r ik ing aspect of the Uni t ed Creosot ing s tudy was theserious mat er ia l s h a n d l i n g p r o b l e m s encountered. I n t h e f i r s tp l a c e , not all of the wastes were treated. Only 68% of the wastepond soil and 60% of the r e s i d e n t i a l soil was t r ea t ed . The remain-der was removed by screening during f e e d p r e p a r a t i o n . The s tudyf a i l e d to addre s s the p r o b l e m s which may be expected in crushingor m i l l i n g the f e e d so that all of the waste may be treated. Inthe case of the residential s o i l , sand which s e t t l ed quickly whenthe soil was s lurr i ed with water ( a f t e r s c r e en ing) was al soexc luded from treatment. Y e t , for the Arkwood , I n c . s i t e , i t wouldbe expec t ed that a large p o r t i o n of c r u s h e d / m i l l e d soil would tendto s e t t l e quickly. T h u s , the p i l o t s tudy did not addres s thi sconcern which would be critical to the Arkwood, I n c . site.Despi t e the f e ed screening, the system experienced materialsh a n d l i n g prob l ems throughout t e s t ing . A p p a r e n t l y , these prob l emsp r i m a r i l y consisted of s o l i d s s e t t l i n g in the extractors and l inep l u g g i n g due to s o l i d s s e t t l i n g , in th© case of the r e s ident ia ls o i l , the prob l ems were s u f f i c i e n t l y severe that only sevenextractions (3 1/2 pa s s e s) were made instead of the p lanned nine.

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ERM-Southwe s t . inc.

Mr. Bretit Truskowsk iU . S . Environmental Prot e c t i on AgencyMarch 2, 1990 of 9

The united C r e o s o t i n g report acknowledge s these p r o b l e m s andsugge s t s numerous d e s i g n changes to addre s s them. T h e s e chUaeshave yet to be s u c c e s s f u l l y t e s t e d , however? and so must beregarded as s p e c u l a t i v e . CF S y s t e m s c la ims that h i g h l y s a n d yh g h ls t w o d ™ tinc. s i t e would not cause any p r o b l e m s for the irc on s id e r ing the r e s u l t s o f th e U n i t e d C r e o s o t i n g study!must be viewed with s k e p t i c i s m . y

CF S y s t e m s has a l s o r epor t ed p r o b l e m s in some cases with carryoverof f i n e s which do not s e t t l e in the decanter. The sy S 4Tcane m p l o y cyclone s epara tor s when th i s occurs, but they w i l l not wor"in all cases. T h i s p r o b l e m would occur at the A r k w o o d , Inc s l?e fIn th e T r e a t a b i l i t y s t u d y , dur ing treatment o f th e l a n d / r t n e s i twas observed that most of the f i n e s would not s e t t l e even with Pro-l o n g e d quiescence. It was necessary to use a c e n t r i f u a * ivT«r«,-b ' f u ^ ? ° l i d V n t l W a t e r - A s imi lar tac tniVe couiTpresum^ybe used with solvent e x t ra c t i on , but it is not c u r r e n t l y i n c l u d e din the d e s i g n and c e n t r i f u g e s are h igh-wainLnancetos i t eS i t e .

which « f t« usedwnicn were used

! WOU.ld be ver* cos t lV compareda l t e r n a t i v e s f o r t h e A r k w o o d , I n c .v^l 4 .4 ^ -.*-,. _^j.^^^x. . ^ ' ."1 " ^ e t o u i i u a u t j or a so lvent' U S i n g the same cost a s s u m p t i o n sf o r t h e other a l t e r n a t i v e s - - -

*© 1 *-»r-r»wi rtoa—

Sieve-and-washS o l v e n t e x t rac t i onI n c i n e r a t i o n

0 7.1 m i l l i o n$ 1 7 . 5 m i l l i o n$ 18 m i l l i o n ,

A c c o r d i n g to Dun and B r a d s t r e e t , the company has a net worth of$1.3 m i l l i o n with sa le s o f $3.3 m i l l i o n . T h u s , r e m e d i a t i o n o f t h eA r k w o o d , I n c . s i t s would b e very large p r o j e c t f or CF S y s t e m s , I n c .A p p l i c a t i o n of CF S y s t e m s solvent ex trac t ion at the Arkwood I n c .site would require use of a new and unprovan de s ign. T h i s wouldi n e v i t a b l y require an extensive p i l o t s tudy and resul t ^« ap r o l o n g e d s t a r t - u p per iod b e f o r e actual s i t e r emed ia t i on couldoccur (such as has occurred at the S t a r E n t e r p r i s e s

E R H ° S o u t h w e s $ , inc.R 1 6 9

TABLE 1

S O L V E N T E X T R A C T I O N A L T E R N A T I V EA f K W O O d . i n c . S i t e

Q u a n t i t y u n i t s t r i l lcost

13.50H O

1200

J l . 3 0 0

C A P I T A L & O P E R A T I N G C O S T S :common 11 eswE x c a v a t e s l u d g e s 4 a f f e c t e d s o i l s 20.aao c yreed p r e p a r a t I o n ( I n t l . c r u s h i n g ) 33.580 tonsT r e a t s l u d g e s A a f f e c t e d s o i l sb y s o l v e n t e x t r a c t i o n 33.580 t on sw a s l e w a t e r t r e a t m e n ti n c i n e i A t e r e covered o l I 3 4 0 I o n sp e r c e n t s o i l m e e t i n g t r e a t m e n t g o a l o %R e m a i n i n g washed s o i l f o r c a p p i n g 30.800 c yD i k e around c o n s o l i d a t i o n a r e a 1.006 I ff t e f t A c a p over t r e a t e d s o i l s 65,000 i tT O P s o i l c a p over r e m a i n d e r o f s i t e 586.000 s fS i t e f a c i l i t i e s & u t i l i t i e s - c a p i t a ls i t e f a c i l i t i e s & u t i l i t i e s - o p e r a t i n g l y e a r s ( 1 6 3 . 0 0 0S u b t o t a lc o n t r a c t o r O v e r h e a d . P r o f i t & Bondicent i n g t f t c yE n g i n e e r i n g & c o n s t r u c t i o n S u r v e - i l a n c eE S T I M A T E D C A P I T A L f t O P E R A T I N G C O S T

P O S T - C L O S U R E C A R E C O S T S :C a p m a i n t e n a n c e 1 5 a c / y r l i s af e n c e m a i n t e n a n c e 5.000 l l / y r S o 4 0A n n u a l s u b t o t a l™ { p r e s e n t v a l u e o f a n n u a l s u b t o t a l ( c lG r o u n d w j t e t m o m t o r i n g <net p r e s e n t v a l u e ) I c . d l

cost ( a ] N o t e s

$310.00073.000

336.0006 .716 .000

500.000442.000

1104

10

XXX

71 .000195,000435.00077.000

366 . 000

19.520.0001.201 . 2 51 . 2 0

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$ 2 , 3 0 0 Rounded l o h u n d r e d s2.000

$4.300$66.000163.000

c e n t i n g e n c ye n g i n e e r i n g & c o n s t r u c t i o n S u r v e i l l a n c e, / £ T P R c S E > T V V A L U E P O S T - C L O S U R E C A R E C O S T [ C l

E S T I M A T E D A L T E R N A T I V E C O S T ( N E T P R E S E N T V A L U E ) [ e lN O T E S :f a ] C o s t s a r e r A i < i - i 9 S 9 .! b ) R e f e r e n c e d t a D t & s a r e f o u n d i n A p p e n d i x c o f t h e A r k w o o d f e a s i b i l i t yt c ] A s s u m e s a n m t s r a s t ( d i s c o u n t ) r a l e o f S i ( n e t o f i n f l a t i o n ) .a n d 2 ao-year D G s t - c l o s w e car e p e r i o d .[ d ] A t o m t o r i n g f r e q u e n c y a n d p a r a m e t e r s a s s p e c i f i e d i n s e c t i o n 6o f I h e A f k w c o d f u s i b i l i t y S t u d y .f e l T h e s u a o f c a p l u t a n d o p e r a t i n g c o s t s a n d H i * n s t p i e s e n tv a l u e o f ( h e o o s i - c l o i u r e c i ' c c o s t i -

$ 2 2 9 . 0 0 0f .251.10

$340,000 Rounded$ t 7 . 5 0 0 , o o o Rounded

ERM-Souihws s t , inc.

Mr. Brent T r u s k o w s k iU . S . Environmental Prot e c t i on A g e n c yMarch 2, 1990 of 9

F r o m the procurement s t a n d p o i n t , should the EPA select solventextraction for this s i te, there would be v i r tua l ly no way tocontrol price s charged by the solvent e x t rac t i on contractor. CFS y s t e m s would have the on ly semi-proven process a v a i l a b l e and wouldbe in a po s i t i on to d i c ta t e the treatment price regardle s s of theactual cost of t r ea tment . T h i s would amount to the EPA g r a n t i n gCF S y s t e m s a m o n o p o l y on treatment for th i s s i te .In summary, solvent ex trac t i on does not a p p e a r to be a p p r o p r i a t efor the Arkwood, I n c . site for the f o l l o w i n g reasons:

1. S o l v e n t e x trac t i on is p r i m a r i l y d e s igned for oil recoveryf r o m s ludge s . Use for so i l s is unproven at this time.2 . S e r i o u s m a t e r i a l s h a n d l i n g p r o b l e m s would exist f orsolvent extract ion at the Arkwood , I n c . s i t e ,3 . R e s o l u t i o n o f the m a t e r i a l s h a n d l i n g p r o b l e m s , i f theyare s o l v a b l e , would require p i l o t s tud i e s and an ex t endedequipment d e s i g n and s tar t-up p e r i od .4. The c l ean-up l e v e l s to be a t ta ined by use of so lventex trac t ion for Arkwood s o i l s are unknown and d i f f i c u l tto predic t with ex i s t ing data.5. The EPA would be e f f e c t i v e l > rant ing CF S y s t e m s , I n c .a m o n o p o l y i f i t s e l e c t ed solvent ex trac t ion for thesite.6. The cost of solvent ex trac t ion treatment for th i s s i tewould a p p r o a c h the cost of on-sitr, incinerat ion. Due tothe innovative t e chno logy to be u t i l i z e d , the cost ofsolvent e x t rac t i on could a c t u a l l y exceed the cost of on-site inc inerat ion i f solvent e x t ra c t i on were mandated forthe site.7o ComBercial equipment d e s i g n s for s o i l s remediation bysolvent extraction are not ava i lab l e .8. if a p i l o t study at the Arkwood, Inc . site are succe s s fulwith e x i s t i n g p r o t o t y p e equipment , e x t en s ive equipmentr ed e s i gn , t e s t i n g and m o d i f i c a t i o n s would be required tou p s c a l e the equipment to f u l l - s c a l e operations that woulda l l o w remedia t ion of the Arkwood s o i l s .

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ERM-Southwes t , inc.

Mr, Brent TruskowskiU . S . Environmental Prot e c t i on AgencyMarch 2, 1990 of 9

If you have any quest ions or desire to d i s cu s s th i s matter f u r t h e r ,p l e a s e do not h e s i t a t e to c a l l .S i n c e r e l y ,E R M - S O U T H W E S T , I N C .

L e e K . H o l d e r , P . E .

L K H / s m s : R 3 2 Zcc: Doice H u g h e s , Arkansa s D e p t . o f P o l l u t i o n Control & E c o l o g yD a n M a c L e m o r e , R o y F . W e s t o n , I n c .D. Darman, M c K e s s o n C o r p o r a t i o nG a t a s , M i t c h e l l , W i l l i a m s , S e l i g f i T u c k e rR i t c h i e , M c K e s s o n C o r p o r a t i o nMescher , M c K e s s o n C o r p o r a t i o nBarker, Mas s M e r c h a n d i s e r s , I n c .D i e h l , E R M - S o u t h w e s t , I n c .C. Robison, E R M - S o u t h w e s t , I n c .C a l h o u n , E R M - S o u t h w e s t , I n c .M . P i n o d a , E R M - S o u t h w e s t , I n c .

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