Prepare a conceptual process design project for a new greenfield hazardous waste processing facility to aid in the project planning and permitting process.
Process Engineering International, LLC (PROCESS) was contracted to lead a conceptual process design project for the ultimate client, a hazardous waste treatment company with operating facilities in multiple countries. The conceptual process designs were to be used to help present the greenfield conceptual facility operations to regulators and to aid in the permitting process.
The project consisted of three areas for which process designs were prepared:
- Wastewater Treatment
- Packing and Unpacking Emissions Capture and Treatment Process
- Bulk Waste Neutralization Emissions Capture and Treatment Process.
PROCESS directed the team to accomplish the following as a part of this project:
- Used AP-42 which is the U.S. Environmental Protection Agency’s (EPA) publication of emission factors on air pollution. This information was applied to non-traditional activities such as combining small liquid packaging containing acids, bases, and volatile organics into larger packaging and the dumping/neutralization of bulk wastes.
- Developed novel criteria for sizing ventilation systems that meet regulatory requirements while keeping equipment sizes reasonable and properly sized.
- Designed an air handling system using the American Conference of Governmental Industrial Hygienists (ACGIH) manual and best practices for dust collection.
- Provided the ultimate client with an extensive list of process options, allowing them to pick the ones that best met their needs taking into account capital costs, operating costs, and land use while minimizing off site impacts.
- Proposed process additions to allow the proposed systems to perform more efficiently without requiring additional energy.
- Proposed a novel organic liquid scavenging and encapsulation technology for VOC removal.
For each area, the following deliverables were prepared:
- Heat and Material Balance
- Estimated Emissions Summary
- Preliminary Process Flow Diagrams (PFDs)
- Process Descriptions
- Preliminary Piping & Instrumentation Diagrams (P&IDs)
- Process Controls Description
- Major Equipment List with expected sizing
- Preliminary Layout Sketch.
Hazardous Waste Processing
- FEL-1 preliminary process design
- Project environmental permitting process engineering support.