National Academies Press: OpenBook
Suggested Citation:"Front Matter." National Research Council. 1999. Carbon Filtration for Reducing Emissions from Chemical Agent Incineration. Washington, DC: The National Academies Press. doi: 10.17226/9651.
×

CARBON FILTRATION FOR REDUCING EMISSIONS FROM CHEMICAL AGENT INCINERATION

Committee on Review and Evaluation of the Army Chemical Stockpile Disposal Program

Board on Army Science and Technology

Commission on Engineering and Technical Systems

National Research Council

National Academy Press
Washington, D.C.

Suggested Citation:"Front Matter." National Research Council. 1999. Carbon Filtration for Reducing Emissions from Chemical Agent Incineration. Washington, DC: The National Academies Press. doi: 10.17226/9651.
×

NATIONAL ACADEMY PRESS
2101 Constitution Avenue, N.W. Washington, D.C. 20418

NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The members of the committee responsible for the report were chosen for their special competencies and with regard for appropriate balance.

The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished scholars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. Upon the authority of the charter granted to it by the Congress in 1863, the Academy has a mandate that requires it to advise the federal government on scientific and technical matters. Dr. Bruce M. Alberts is president of the National Academy of Sciences.

The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advising the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achievements of engineers. Dr. William A. Wulf is president of the National Academy of Engineering.

The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an adviser to the federal government and, upon its own initiative, to identify issues of medical care, research, and education. Dr. Kenneth I. Shine is president of the Institute of Medicine.

The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy’s purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the National Academy of Sciences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities. The council is administered jointly by both Academies and the Institute of Medicine. Dr. Bruce M. Alberts and Dr. William A. Wulf are chairman and vice chairman, respectively, of the National Research Council.

This is a report of work supported by Contract DAAD19-99-C-0010 between the U.S. Army and the National Academy of Sciences. Any opinions, findings, conclusions, or recommendations expressed in this publication are those of the author(s) and do not necessarily reflect the view of the organizations or agencies that provided support for the project.

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Limited copies are available from:

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Additional copies of this report are available from:
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Copyright 1999 by the National Academy of Sciences. All rights reserved.

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Suggested Citation:"Front Matter." National Research Council. 1999. Carbon Filtration for Reducing Emissions from Chemical Agent Incineration. Washington, DC: The National Academies Press. doi: 10.17226/9651.
×

COMMITTEE ON REVIEW AND EVALUATION OF THE ARMY CHEMICAL STOCKPILE DISPOSAL PROGRAM

DAVID S. KOSSON, chair,

Rutgers, The State University of New Jersey, New Brunswick

CHARLES E. KOLB, vice chair,

Aerodyne Research, Inc., Billerica, Massachusetts

DAVID H. ARCHER,

Carnegie Mellon University, Pittsburgh, Pennsylvania

PIERO M. ARMENANTE,

New Jersey Institute of Technology, Newark

DENNIS C. BLEY,

Buttonwood Consulting, Inc., Oakton, Virginia

FRANK P. CRIMI,

Lockheed Martin (retired), Saratoga, California

ELISABETH M. DRAKE,

Massachusetts Institute of Technology, Cambridge (until 3/31/99)

J. ROBERT GIBSON,

DuPont Agricultural Products, Wilmington, Delaware

MICHAEL R. GREENBERG,

Rutgers, The State University of New Jersey, New Brunswick

KATHRYN E. KELLY,

Delta Toxicology, Inc., Crystal Bay, Nevada

RICHARD S. MAGEE,

New Jersey Institute of Technology, Newark (until 1/27/99)

JAMES F. MATHIS,

Exxon Corporation (retired), Houston, Texas

WALTER G. MAY,

University of Illinois, Urbana

ALVIN H. MUSHKATEL,

Arizona State University, Tempe (until 3/31/99)

H. GREGOR RIGO,

Rigo & Rigo Associates, Inc., Berea, Ohio

KOZO SAITO,

University of Kentucky, Lexington

ARNOLD F. STANCELL,

Georgia Institute of Technology, Atlanta

CHADWICK A. TOLMAN,

National Science Foundation, Arlington, Virginia

WILLIAM TUMAS,

Los Alamos National Laboratory, Los Alamos, New Mexico

Board on Army Science and Technology Liaison

RICHARD A. CONWAY,

Union Carbide Corporation, Charleston, West Virginia

Staff

DONALD L. SIEBENALER, Study Director

HARRISON T. PANNELLA, Research Associate

WILLIAM E. CAMPBELL, Senior Project Assistant

Suggested Citation:"Front Matter." National Research Council. 1999. Carbon Filtration for Reducing Emissions from Chemical Agent Incineration. Washington, DC: The National Academies Press. doi: 10.17226/9651.
×

BOARD ON ARMY SCIENCE AND TECHNOLOGY

WILLIAM H. FORSTER, chair,

Northrop Grumman Corporation, Baltimore, Maryland

THOMAS L. MCNAUGHER, vice chair,

RAND Corporation, Washington, D.C.

RICHARD A. CONWAY,

Union Carbide Corporation, Charleston, West Virginia

GILBERT S. DECKER,

Walt Disney Imagineering, Glendale, California

LAWRENCE J. DELANEY,

Delaney Group, Potomac, Maryland

ROBERT J. HEASTON,

Guidance and Control Information Analysis Center (retired), Naperville, Illinois

ELVIN R. HEIBERG, III,

Heiberg Associates, Inc., Mason Neck, Virginia

GERALD J. IAFRATE,

University of Notre Dame, Notre Dame, Indiana

KATHRYN V. LOGAN,

Georgia Institute of Technology, Atlanta

JOHN H. MOXLEY, III,

Korn/Ferry International, Los Angeles, California

STEWART D. PERSONICK,

Bell Communications Research, Inc., Morristown, New Jersey

MILLARD F. ROSE,

Auburn University, Auburn, Alabama

GEORGE T. SINGLEY, III,

Hicks & Associates, McLean, Virginia

CLARENCE G. THORNTON,

Army Research Laboratories (retired), Colts Neck, New Jersey

JOHN D. VENABLES,

Venables and Associates, Towson, Maryland

JOSEPH J. VERVIER,

ENSCO, Inc., Melbourne, Florida

ALLEN C. WARD,

Ward Synthesis, Inc., Ann Arbor, Michigan

Staff

BRUCE A. BRAUN, Director

MICHAEL A. CLARKE, Associate Director

MARGO L. FRANCESCO, Administrative Associate

ALVERA G. WILSON, Financial Associate

DEANNA P. SPARGER, Senior Project Assistant

Suggested Citation:"Front Matter." National Research Council. 1999. Carbon Filtration for Reducing Emissions from Chemical Agent Incineration. Washington, DC: The National Academies Press. doi: 10.17226/9651.
×

Preface

The United States has maintained a stockpile of highly toxic chemical agents and munitions for more than half a century. In 1985, Public Law 99-145 mandated an "expedited" effort to dispose of M55 rockets containing unitary chemical warfare agents because of their unlikely, but plausible, potential for self-ignition. This program soon expanded into the Army Chemical Stockpile Disposal Program (CSDP), the mission of which is to eliminate the entire stockpile of unitary chemical agents and munitions. The current baseline incineration system was developed to carry out this mission.

Since 1987, the National Research Council (NRC), through its Committee on Review and Evaluation of the Army Chemical Stockpile Disposal Program (Stockpile Committee), has overseen the Army's disposal program and has endorsed the baseline incineration system for destroying the stockpile. In 1992, after setting several intermediate goals and dates, Congress enacted Public Law 102-484, which directed the Army to dispose of the entire stockpile of unitary chemical agents and munitions by December 31, 2004. As a result of the subsequent implementation, on April 29, 1997, of the international Chemical Weapons Convention, which the United States has ratified, the date has been reset to April 29, 2007.

Incineration processes raise concerns about potentially harmful emissions. Many people fear that substances in the exhaust gas could adversely affect their health and the environment, and some have remained resolutely opposed to the baseline incineration system. When properly operated, however, the incineration system with its pollution control devices releases mostly harmless products: carbon dioxide, water, and other completely oxidized products in their most stable state. However, incinerator emissions also contain small quantities of products of incomplete combustion and other trace contaminants, collectively known as substances of potential concern (SOPCs). For the CSDP, the presence of these SOPCs (and, potentially, trace quantities of chemical agents below the monitoring detection limits) have become matters of concern.

At a workshop sponsored by the Stockpile Committee in 1991, the committee suggested that the Army evaluate a number of modifications to the pollution abatement systems (PASs) for cleaning the incinerator off-gases at sites in the continental United States. One of these technologies involved using activated carbon to adsorb SOPCs. At the time, this technology was already being routinely used at chemical processing plants for the separation and recovery of trace organic products, although it had not been used as an air pollution control system for incinerators in the United States. Hence, activated carbon filters were not included in the PAS at the first full-scale chemical agent disposal facility, the Johnston Atoll Chemical Agent Disposal System (JACADS), or at the Tooele Chemical Agent Disposal Facility (TOCDF).

The Stockpile Committee described public concerns regarding emissions from the baseline incineration system in a 1992 letter report entitled, "Letter Report on Review of the Choice and Status of Incineration for Destruction of the Chemical Stockpile," and again in a February 1994 report, Recommendations for the Disposal of Chemical Agents and Munitions. The Stock-pile Committee found the baseline system to be adequate for the safe disposal of the stockpile but noted that adding activated carbon filter beds to polish all facility exhaust gases could further protect against emissions of chemical agent or trace organic materials,

Suggested Citation:"Front Matter." National Research Council. 1999. Carbon Filtration for Reducing Emissions from Chemical Agent Incineration. Washington, DC: The National Academies Press. doi: 10.17226/9651.
×

even in the unlikely event of a major upset. Consequently, the committee recommended that the use of activated charcoal beds to filter the discharge from baseline system incinerators be evaluated. The assessment was to include estimates of the magnitude and potential consequences of upsets and site-specific estimates of benefits and risks. If carbon filtration was found to have site-specific advantages, the committee recommended that the equipment be installed.

This report reviews the Army's evaluation of carbon filters for use in the baseline incineration PAS, as well as the Army's change management process (the Army's tool for evaluating major equipment and operational changes to disposal facilities). In preparing this report, members of the Stockpile Committee evaluated exhaust gas emissions testing at the two operating baseline incineration systems, JACADS and the TOCDF; evaluated the development of the dilute SOPC carbon filter simulation model; and evaluated the conceptual design of a modified PAS with an activated carbon filter. The two major risk assessments conducted for each continental disposal site that use the baseline system, namely, (1) the quantitative risk assessment, which evaluates the risks and consequences of accidental agent releases, and (2) the health risk assessment, which evaluates the potential effects of nonagent emissions on human health and the environment, were also examined.

In a 1997 NRC report, Risk Assessment and Management at Deseret Chemical Depot and the Tooele Chemical Agent Disposal Facility, the Stockpile Committee first reviewed carbon filters and included findings and recommendations concerning the addition of carbon filters to the baseline PAS. In the present report, the Stockpile Committee has evaluated continuing developments pertaining to these findings and recommendations.

The committee greatly appreciates the support and assistance of NRC staff members, Donald L. Siebenaler, Harrison T. Pannella, William E. Campbell, Carol R. Arenberg, and Margo L. Francesco in the production of this report.

David S. Kosson, chair

Charles E. Kolb, vice chair

Committee on Review and Evaluation of the Army Chemical Stockpile Disposal Program

Suggested Citation:"Front Matter." National Research Council. 1999. Carbon Filtration for Reducing Emissions from Chemical Agent Incineration. Washington, DC: The National Academies Press. doi: 10.17226/9651.
×

Acknowledgments

This report has been reviewed by individuals chosen for their diverse perspectives and technical expertise, in accordance with procedures approved by the NRC's Report Review Committee. The purpose of this independent review is to provide candid and critical comments that will assist the authors and the NRC in making the published report as sound as possible and to ensure that the report meets institutional standards for objectivity, evidence, and responsiveness to the study charge. The content of the review comments and draft manuscript remain confidential to protect the integrity of the deliberative process. We wish to thank the following individuals for their participation in the review of this report:

Gene H. Dyer, Bechtel Corporation (retired)

Stan Kaplan, Bayesian Systems, Inc.

George E. Keller II, Union Carbide Corporation

Frank Mirer, United Auto Workers

Mark J. Rood, University of Illinois

Douglas M. Ruthven, University of Maine

Harrison Shull, U.S. Naval Postgraduate School

Leo Weitzman, LVW Associates, Inc.

Ralph T. Yang, University of Michigan

While the reviewers provided many constructive comments and suggestions, responsibility for the final content of this report rests solely with the authoring committee and the NRC.

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Suggested Citation:"Front Matter." National Research Council. 1999. Carbon Filtration for Reducing Emissions from Chemical Agent Incineration. Washington, DC: The National Academies Press. doi: 10.17226/9651.
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Suggested Citation:"Front Matter." National Research Council. 1999. Carbon Filtration for Reducing Emissions from Chemical Agent Incineration. Washington, DC: The National Academies Press. doi: 10.17226/9651.
×
   

Comparison of Alternative Designs,

 

33

   

Performance of the Carbon Bed,

 

33

   

Water Balance,

 

34

   

Design of the Scrubber Tower,

 

34

   

Blower Equipment,

 

34

   

Summary of Gas Conditioning,

 

35

   

Description of the Carbon Filter,

 

35

   

Safety,

 

36

   

Sampling,

 

38

   

Maintenance,

 

38

   

Disposal,

 

38

   

Summary,

 

39

5

 

RISK ASSESSMENT AND CHANGE MANAGEMENT: AN EVALUATION OF THE ARMY'S DECISION-MAKING PROCESS

 

40

   

Background,

 

40

   

Focus of the Stockpile Committee's Review,

 

40

   

Documents Reviewed,

 

40

   

Risk Assessments for Anniston and Umatilla,

 

41

   

The Anniston PFS Risk Evaluations,

 

43

   

The Anniston Letter Report,

 

44

   

Change Management Process,

 

44

   

Future Evaluations of Major Design Changes,

 

47

   

Summary,

 

48

6

 

FINDINGS AND RECOMMENDATIONS

 

49

 

 

REFERENCES

 

52

 

 

APPENDICES

 

 

   

A Reports of the Committee on Review and Evaluation of the Army Chemical Stockpile Disposal Program (Stockpile Committee),

 

57

   

B Consolidated Exhaust Gas Characteristics for the JACADS and TOCDF Baseline Incineration Systems,

 

58

   

C Commercial Application of Carbon Bed Filters to Combustion Sources,

 

70

   

D Theoretical Modeling of Adsorption,

 

72

   

E Adsorption Separations: Alternative Modes of Operation,

 

80

   

F Alternative Flue Gas Cleaning Systems for Substances of Potential Concern,

 

82

   

G Biographical Sketches of Committee Members,

 

84

Suggested Citation:"Front Matter." National Research Council. 1999. Carbon Filtration for Reducing Emissions from Chemical Agent Incineration. Washington, DC: The National Academies Press. doi: 10.17226/9651.
×

Figures And Tables

FIGURES

4-1

 

Schematic diagram of Alternative 1 for fixed-bed PFS,

 

32

4-2

 

The six PFS filter units and dampers,

 

37

4-3

 

PFS gas reheater,

 

39

D-1

 

Sketch of adsorption equilibrium,

 

73

E-1

 

Typical concentration profile of a material strongly adsorbed on a solid,

 

80

E-2

 

"Favorable" adsorption isotherm for strongly adsorbed species,

 

80

E-3

 

Comparison of maximum adsorption for fixed bed (q) and solids injection (qm) adsorption separation modes,

 

81

TABLES

2-1

 

Emissions Tests at the Two Operational Baseline Incineration Facilities, JACADS and the TOCDF,

 

13

2-2

 

Effect of Data Characteristics on Emissions Characteristics for Different Averaging Times,

 

18

3-1

 

Emission Levels of Chlorinated Dioxins for Some European Incinerators,

 

21

3-2

 

"Before" and "After" Data on Chlorinated Dioxin/Furan Cleanup with a Carbon Filter,

 

21

3-3

 

Chlorinated Dioxins Adsorbed on Powdered Activated Carbon,

 

25

3-4

 

Estimated Carbon Filter Breakthrough Times for Substances of Potential Concern in Stack Gases from the Chemical Agent Disposal Facility Liquid Incinerator,

 

26

3-5

 

Calculated Range of Carbon Adsorption of Agents,

 

27

4-1

 

Pressure Parameters for the Incineration of HD for a PFS-Equipped Baseline System,

 

35

4-2

 

Design Information for the PFS Carbon Filter Unit,

 

36

5-1

 

Effect of the Carbon Filter System on Risk at the Anniston Facility,

 

45

Suggested Citation:"Front Matter." National Research Council. 1999. Carbon Filtration for Reducing Emissions from Chemical Agent Incineration. Washington, DC: The National Academies Press. doi: 10.17226/9651.
×

B-1

 

Exhaust Gas Characteristics for the JACADS and TOCDF Baseline Incineration Systems,

 

59

C-1

 

Partial List of Activated Carbon Bed Filter Installations,

 

70

C-2

 

Performance of Activated Carbon Bed Filters,

 

71

D-1

 

Vapor Pressures for Various Chlorinated Dioxins,

 

73

D-2

 

Calculated Partial Pressures for Chlorinated Dioxins Based on 1 ng/m3,

 

73

D-3

 

Agent Detection Limits,

 

73

D-4

 

Agent Vapor Pressures and p/psat Ratios Based on Agent Detection Limits,

 

74

Page xiii Cite
Suggested Citation:"Front Matter." National Research Council. 1999. Carbon Filtration for Reducing Emissions from Chemical Agent Incineration. Washington, DC: The National Academies Press. doi: 10.17226/9651.
×

Abbreviations And Acronyms


ATV

acute threshold value


BIF

boiler and industrial furnace


CAMDS

Chemical Agent Munitions Disposal System (Deseret Chemical Depot)

CDF

chlorinated dioxin/furan

CFR

U.S. Code of Federal Regulations

CMP

change management process

CSDP

Chemical Stockpile Disposal Program

CWC

Chemical Weapons Convention


DCD

Deseret Chemical Depot

DFS

deactivation furnace system

D-R

Dubinin-Radushkevich (adsorption equilibrium relation)

DRE

destruction and removal efficiency

DUN

dunnage incinerator


EMPC

estimated maximum possible concentration

EPA

Environmental Protection Agency


GB

satin (nerve agent)


HD

mustard agent (distilled)

HE

hazard evaluation

HEPA

high efficiency particulate air

HRA

health risk assessment


ITEQ

international toxic equivalence


JACADS

Johnston Atoll Chemical Agent Disposal System


LC50

lethal concentration resulting in fatality of 50 percent of subjects in a given population

LIC

liquid incinerator


MACT

maximum achievable control technology

MPF

metal parts furnace

MWC

municipal waste incinerator


NODA

Notice of Data Availability

NRC

National Research Council

NSPS

new source performance standards


PAS

pollution abatement system

PFS

PAS (carbon) filter system

PIC

product of incomplete combustion

POHC

principal organic hazardous constituent

PQL

practical quantitation limit


QRA

quantitative risk assessment


RAC

reference air concentration

RCRA

Resource Conservation and Recovery Act

RfD

reference dose

RsD

Risk-Specific Dose


SOPC

substance of potential concern

SOPEC

substance of potential environmental concern


TOCDF

Tooele Chemical Agent Disposal Facility


VX

a type of nerve agent

Suggested Citation:"Front Matter." National Research Council. 1999. Carbon Filtration for Reducing Emissions from Chemical Agent Incineration. Washington, DC: The National Academies Press. doi: 10.17226/9651.
×

ng/dnm3 at 7% O2

nanograms (10-9 grams) per dry normal (32°F [0°C], 1 atm) cubic meter adjusted to a diluent concentration of 7 percent oxygen

ng/dsm3 at 7% O2

nanograms (10-9 grams) per dry standard (68°F [20°C], 1 atm) cubic meter adjusted to a diluent concentration of 7 percent oxygen

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This report reviews the Army's evaluation of carbon filters for use in the baseline incineration PAS, as well as the Army's change management process (the Army's tool for evaluating major equipment and operational changes to disposal facilities). In preparing this report, members of the Stockpile Committee evaluated exhaust gas emissions testing at the two operating baseline incineration systems, JACADS and the TOCDF; evaluated the development of the dilute SOPC carbon filter simulation model; and evaluated the conceptual design of a modified PAS with an activated carbon filter. The two major risk assessments conducted for each continental disposal site that use the baseline system, namely, (1) the quantitative risk assessment, which evaluates the risks and consequences of accidental agent releases, and (2) the health risk assessment, which evaluates the potential effects of nonagent emissions on human health and the environment, were also examined.

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