Pure PCB Treatment – Part A

 Destruction of 1,700 tons of pure PCBs, commercial mixture of

PCB dielectric oil with PCB concentration 40% or higher
 Decontamination of 100 tons of porous material from PCB
transformers with PCBs
 Destruction of PCBs having conc. > 50,000 ppm to below 50 ppm
 The PCBs in liquid form will be injected into the plasma arc system
where the temperature at the core will be around 10,0000C
(operating temp. at mixing chamber is 32000C)
 There will be no generation of dioxins and furans.
 Emission control system consists of deionised water cooling
system and a packed column with alkali scrubber
 Main Components of the Part A facility
 Plascon Skid.
 ITD (Indirect Thermal Disorber) System

Operating Standards of PLASCON Unit:

 Operating temp. : 3200 ͦC

 Residence time : 30 milli seconds
 Flow rate : 45 kg/h PCB oil
 Minimum DRE : 99.999 %
 Minimum Acid gas scrubbing : 99.9 % effiency
 PCDD/PCDF/PCB emissions : < 0.1 ng/Nm3 TE.
 PLASCON UNIT.
n The proposed scheme is of high temperature destruction of Pure
PCBs, commercial mixture of PCB dielectric oil with PCB
concentration 40% or higher and other POPs waste.
n PLASCON is one of the most environment friendly, safe and
economical technologies to deal with hard to destroy, hazardous and
environmentally damaging substances.
n PLASCON process is a high-energy DC plasma torch producing a
plasma consisting of atoms, ions and electrons with temperatures far
in excess of those attained by high temperature Incineration. In
PLASCON, plasma is created by passing an electric current through
an Argon gas stream.
n Electric arc plasma use in waste destruction has accelerated in
recent years due to the concerns regarding incineration. In the
PLASCON process the waste is injected directly into the plasma.
n
 PLASMA DESTRUCTION UNIT - PLASCON
67 cm/hr

106 Kg/Hr
360
lit/hr

375 lit/hr
 Indirect Thermal Desorption System
n The Indirect Thermal Desorber (ITD) is for decontamination of
equipment such as capacitors, transformer cores & absorbents.

n After treatment in ITD, the waste is “Free from PCB”. The copper and
steel can be recycled. Other materials can be disposed of as inert
waste following treatment through the ITD.

n The ITD is designed with a diesel burner as its heat source.

n The ITD is fully automated, so once loaded with the contaminated

equipment, it will operate unattended until it is time to unload the
desorber.
The unit comprises of:
n Heating Pot vessel
n Receiver tank with working capacity of 5000 litres
n Oil circulation system including heat exchanger for cooling oil
Indirect Thermal Desorption Process Flow
 Process – Waste Disposal

System Process Waste Disposal

PLASMA Destruction of Salts of Sodium Shall be sent to approved
system pure PCBs 2.00Tons/day TSDF / landfill
HTDS Liquid Evaporation in MEE
Effluents
In-Direct Decontamination Spent Carbon Shall be sent to approved
Thermal of Porous 7Kg/day TSDF / landfill
Desorption materials
system De- Shall be kept for disposal
contaminated in landfill / incinerator
porous material
Pure PCB Shall be sent to Plasma
destruction system
 Part - B Non - Combustion PCB destruction Facility
n Facility is designed to handle 3400 MT of PCB contaminated mineral
oil & metals.
n PCB destruction plant technology is from M/s. Kinectrics International
Inc., which is Sodium based destruction technology .
n The Technology is Low-Temperature, atmospheric-pressure reaction
between chlorinated contaminant & finely dispersed metallic sodium
to form sodium chloride & hydrocarbon residues.
n The destruction efficiency exceeds 99.9999%, based on destruction
of pure PCBs.
n The principle reaction in this process is the direct removal of Chlorine
atoms from PCB molecule by Sodium as below:

n Where RCl is a PCB molecule containing X number of Chlorine

atoms & Na+ is as reactive Sodium atoms,is a PCB molecule with 1
Chlorine atom removed.
Project Details – Decontamination of Transformer oils
(Part B )
Project Non-combustion Destruction facility for PCBs in
contaminated transformer oil

Electricity required 1600 kVA sourced from Chhattisgarh State

Electricity Board
Water Requirement and 32 KLD
Source of Water from existing network of Bhilai Steel Plant.
Water Breakup and Treatment Details
Fresh Water Wastewater Treatment/ Remarks
S. No Description
Required (KLD) (KLD)
1 Domestic 1.5 1.5 Send to Septic tank followed
by soak pit
2 Industrial (Process/ 6.0 5.5 Send to existing ETP network
cleaning / washing) of BSP for further treatment
and disposal
3 Cooling Purpose 17.0 1.5 Send to existing ETP network
of BSP for further treatment
and disposal
4 Greenbelt 5.5 -
Total 30.0 8.5
9
 Process Reaction – PCB Decontamination
Reaction Chemistry

“CLOSED LOOP LOW TEMPERATURE ATMOSPHERIC PRESSURE CHEMICAL

REACTION”.
The principle reaction is the direct removal of the chlorine atoms from the PCB
molecules by sodium;

RClx + Na+  NaCl + R+x-1

where RClx is a PCB molecule containing x number of chlorine atoms (x =1 to

10), Na+ is a reactive sodium atom, and R+x-1 is a PCB molecule with 1 chlorine
atom removed.

R+x-1 is reactive free-radical from the biphenyl structure and combines with H+,
formed by the reaction of sodium with water or donated by the mineral oil, to
form a neutral RH molecule. If RH contains additional chlorine, it is again
attacked by sodium and the process is repeated until all chlorine atoms have
been replaced by hydrogen atoms. The PCB molecule is converted to a biphenyl
molecule and all chlorine atoms combine with sodium to form sodium chloride .
10
Process Flow – PCB Decontamination Facility

Transformer
with oil & PCB

Pure PCB Oil Low & High

Level PCB Oil

Na Solution PCB Reaction

preparation vessel
Oil

PCB Free Oil Settling

Oil Regeneration Solids to TSDF

Regenerated oil
for Recycle

11
 Non Combustion PCB destruction Process
n The advantages of design are:
u Better emissions control
u The batch operation avoids cross contamination of cleaned oil.
u The Sodium based reaction as most PCB destruction reaction, it is
exothermic reaction, generates enough heat increase temperature of
reaction mixture well over the mineral oil flash point.
n The main process mode of operation is to treat contaminated mineral
oil that contains chlorine content < 4000 ppm.

n PCB destruction reaction is based on blend of high level PCB and

low level PCB oil to achieve Chlorine mass of ≤ 35 Kg.
n By-Products – it depends on initial PCB level in the treated batch &
Sodium reagent added, sludge is separated by settling.
 Typical operating parameters

Other pre-treatment
Parameter PCB destruction unit
devices
Temperature 80 - 1450C 60-800C

Pressure 100 kPa 100 torr to atmosphere

Concs. Of reactants Metallic sodium

dispersion in mineral
oil 40% w/w

Other key operating PCB concentration and PCB concentration and

parameters total chlorine in waste total chlorine in waste
 List of Process Units

n PCB destruction system

n Sodium dispersion manufacturing system
n Emission controls
n Transformer / mineral oil decontamination system
n Storage tanks and mineral oil regeneration
n Compressed air supply
n Nitrogen gas cylinders manifold & distribution lines
n Glycol chiller
 List of Equipments.

n Buffer tank
n Settling tank
n Quench water tank
n Sodium dispersion measuring tank
n Mineral oil tanks
n PCB tank
n Reclaimed oil tank
n Regenerated clean oil tank
n Oil washing chamber
n Electrical equipment dismantling tank
n Mixing Vessels/Rectors
u Reactor Continued.
u Dispersed sodium manufacturing tank
u Holding tank
n Pumps
u Quench water pump
u Product pump
u Discharge pump
u Mineral oil
u PCB oil pump
u Clean / reclaimed oil pump
u Cooling pumps
u Glycol pump
n Heat Exchangers:
u Gas Condenser – 54 KW
Continued
u Mineral oil Heat Exchanger – 277 KW
n General Utilities:
u Chiller unit – 100 KW (Water/Glycol) 75 kg/hr.
u PCB oil Degasifier / dehydrator - 4 m3/hr.

u Mineral oil regenerator – 3 m3/hr.

n Emission Control Units:
u Activated Carbon Tank with Filters – 2 Nos.
n Ventilation Fume Hoods:
u Fume vent / exhaust fan – 400 m3/hr.
u Exhaust fan – 400 m3/hr.
u Laboratory – 400 m3/hr.
 Environmental Pollution Control
Pollution Control Measures

Solid waste
Description Quantity/Quality Method of collection method of disposal

Sludge after PCB 100 kg /day Shall be collected in Shall be transferred to

destruction containing Containers. approved TSDF for
mainly Sodium Chloride further treatment and
disposal

Waste gases
Waste gases Case Flow per day Flow /Project Temperature
Gas effluents are Nitrogen is used to 16 m3kg/day 3840 m3 tonne 25-30oC
mainly Nitrogen purge Hydrogen, of nitrogen per year
and Hydrogen produced by Sodium
neutralization reaction
with water

The exhaust gas stream, mainly Nitrogen and Hydrogen coming from the reaction
vessel passes through an air pollution control system before being discharged to
the atmosphere.
18
 Utilities – Part A & Part B
Utilities Demand or pressure Consumption
Electricity 3 ph., 415 V, 50Hz 90 KW-hr /T of PCB waste
165 KW/Hr for Plascon
25 KW/Hr for ITD
Water P = 250 kPa (g) • 60 KLD

Steam 6 Kg/sq.cm(g) 0.5 TPH for MEE

Diesel N/A ITD 312 lit/Ton, Plascon 235 lit/Ton pure PCB

Other utilities Instrument air : • 320 Nm3 compressed air

Compressed air tools • 180 Nm3 compressed air
Cover gas Nitrogen • 30 Nm3 of N2 .
Brine (30% glycol) • Brine is not consumed but used in closed
T = 5/15 0C loop system, 70 TR
Cooling Water • 170 CuM/Hr Circulation rate
.
 OVERALL WATER REQUIREMENT FOR ENTIRE PROJECT

S.No PURPOSE PART A (KL) PART B (KL)

1 Domestic 2 1.5

2 Industrial /Process 0 6

3 Boiler 2 0

4 Cooling Tower 20 17

5 Others (Green Belt) 6 5.5

Total 30 30

20
 Environmental Pollution Control Cont…

Pollution Control Measures

Liquid Waste
 The liquid waste comprises mainly domestic, cleaning / washing, cooling
purpose. The domestic wastewater shall be send to septic tank followed by soak
pit.

 The cleaning / washing and cooling blow down water shall be sent to existing
ETP network of BSP for further treatment and disposal as per stipulated standards.

High TDS effluents from Plascon unit will be evaporated in MEE. Condensate will
be used as cooling tower water make up.

Greenbelt
Greenbelt shall be provided all around the proposed decontamination facility
premises and also at parking areas, wherever vacant places available

21
 Summary of the Facility
Waste Stream Details of waste Stream Treatment Methodology

Pure PCB Transformers Draining, Plasma for pure PCB; ITD

Flushing,Dismantling – for transformer core parts
Pure PCB

Low level PCB Metals decontamination- Non Combustion

transformers, drums, PCB contaminated mineral destruction, mineral oil
tankers oil recovery

Transformer maintenance Retro- filling of recovered

transformer oil -

Liquid , gaseous and solid Liquid effluents MEE

wastes Gaseous emissions Carbon adsorption and
Solid sludge alkali scrubbers
Secured landfill