PCDD/F and dioxin-like PCB minimization: A 13-year experimental study along the flue gas cleaning system of a secondary aluminium refining plant.

A 13-years study shows that a careful design of the flue gas cleaning system of a full scale secondary aluminium refining plant results in a minimized and very stable emission of Polychlorinated Dibenzo-p-Dioxins (PCDD), Polychlorinated Dibenzo Furans (PCDF) and dioxin-like Polychlorinated Biphenyls (PCB). The value of equivalent toxicity of PCDD/F in the emission was definitely of an order of magnitude less than the regulation limit. In the initial flue gas cleaning system, the PCB mean fingerprint after the slow cooling of the flue gas was typical of de novo synthesis. Instead, in the presence of quenching, there was evidence that the fast cooling of flue gas prevented the PCB de novo synthesis. In fact, the PCB profile was similar to that in the air collected from the aspiration hoods for the quenching. The gas-phase and solid-phase partitioning of PCBs, before and after the fabric filters, highlights the predominant role of the vapor phase with respect to the total removal efficiency. The polycyclic aromatic hydrocarbons breakdown could be an additional de novo formation pathway even in industrial plants.

Lab-scale pyrolysis of the Automotive Shredder Residue light fraction and characterization of tar and solid products.

The general aim of this study is the recovery of Automotive Shredder Residue (ASR). The ASR light fraction, or car fluff, that was collected at an Italian shredding plant was pyrolysed at various temperatures (500-800°C) in a lab-scale reactor. The condensable gases (tar) and solid residue yields increased with decreasing temperature, and these products were characterized to suggest a potential use to reclaim them. The higher heating value (HHV) of tar was 34-37MJ/kg, which is comparable with those of fossil fuels. Furthermore, the ash content was low (0.06-4.98%). Thus, tar can be used as an alternative fuel. With this prospect, the concentrations of polychlorinated dibenzodioxins (PCDDs) and polychlorinated dibenzofurans (PCDFs) in tar were determined. The toxicity of tar changes with temperature (1-5ng I-TEQ/g), and the PCDFs significantly contribute to tar toxicity, which was 75-100% with a maximum of 99.6% at 700°C. Regarding the characterization of the solid residue, the low HHV (2.4-3.3MJ/kg) does not make it suitable for energy recovery. Regarding material recovery, we considered its use as a filler in construction materials or a secondary source for metals. It shows a high metal concentration (280,000-395,000mg/kg), which is similar at different pyrolysis temperatures. At 500°C, polycyclic aromatic hydrocarbons (PAHs) were not detected in the solid residue, whereas the maximum total PAH concentration (19.41ng/g, 700°C) was lower than that in fly ash from MSWI. In conclusion, 500°C is a suitable pyrolysis temperature to obtain valuable tar and solid residue.

The rate-determining step in a low temperature PCDD/F formation from oxidative breakdown of native carbon in MSWI fly ash.

We developed a phenomenological approach to explain the kinetic experimental data of PCDD/F formation/destruction based on a reaction mechanism model at the congener group level. In the present work, we investigated the formation and destruction of PCDD/F on fly ash as a function of time at 280 °C, chlorine mass balance, evolution of the total equivalent toxicity and kinetic modelling. We determined that the volatilization process is negligible and that the reactive processes at short reaction times only become important above 300 °C. The results provide a substantial improvement on existing studies. We experimentally demonstrated, for the first time, that there is a correlation between the oxidative breakdown of native carbon and PCDD/F de novo synthesis. Data processing by our kinetic model showed that the formation of oxygen complexes C(O) was the determining step for de novo synthesis of PCDD/F. Indeed, the calculated reaction time at which the PCDD/F concentration was at a maximum (850 min) was greater than that calculated for the oxygen complexes C(O) (435 min). Moreover, the experimental carbon conversion efficiency for PCDD/F production (0.0032% at 600 min maximum) was in a very good agreement with the theoretical conversion (0.0041%).

Kinetic modeling of the formation and destruction of polychlorinated dibenzo-p-dioxin and dibenzofuran from fly ash native carbon at 300 °C.

The kinetics for the oxidative breakdown of native carbon in raw fly ash samples (RFA) and for the formation and destruction of polychlorinated dibenzo-p-dioxins (PCDD) and polychlorinated dibenzofurans (PCDF), abbreviated PCDD/F, were investigated using a flow-over solid system in which the RFA samples were thermally treated at 300 °C under synthetic air. This study investigated the correlation between the disappearance of the reagent and the formation of the products to gain insight into the underlying mechanisms that govern these reactions at congener groups level. The detailed analyses of the experimental concentration-time data revealed significant differences in the behavior between the 2,3,7,8-substituted PCDD and the 2,3,7,8-substituted PCDF, non-2,3,7,8-substituted PCDD and PCDF. The chlorine balance for the former was always negative, that is, chlorine was released regardless of reaction time and primarily resulted from the dechlorination of the hepta- and octa-homologues. However, for the others, the balance was substantially positive up to approximately 240 min and became negative at longer intervals when the dechlorination reactions took over. The processes involving PCDD and PCDF in which the thermal destruction was only partial were found to increase the total equivalent toxicity (TEQ) levels rather than reduce them.

Kinetics of carbon degradation and PCDD/PCDF formation on MSWI fly ash.

The native carbon oxidation and PolyChloroDibenzo-p-Dioxins and PolyChloroDibenzoFurans, PCDD/F, formation were simultaneously studied at different temperatures (230-350 degrees C) and times (0-1440 min) in order to establish a direct correlation between the disappearance of the reagent and the formation of the products. The kinetic runs were conducted in an experimental set up where conditions were chosen to gain information on the role of fly ash deposits in cold zones of municipal solid waste incinerators in PCDD/F formation reaction. The carbon oxidation measured as the decrease of total organic carbon of fly ash was in agreement with the carbon evolved as sum of CO and CO(2). The carbon mass balance indicated an increase in the efficiency of carbon conversion in CO and CO(2) with temperature. The CO and CO(2) formation was the result of two parallel pseudo first order reactions thus giving significant information about the reaction mechanism. PCDD/F formation as a function of temperature showed that the maximum formation was achieved in a narrow range around 280 degrees C; the time effect at 280 degrees C was a progressive formation increase at least up to 900 min. The PCDF:PCDD molar ratio increased with temperature and time, and the most abundant homologues were HxCDD, HpCDD, OCDD for PCDD, and HxCDF, HpCDF within PCDF. These experimental results supported the hypothesis that the formation mechanism was the de novo synthesis.

Prevention of PCDD/F formation and minimization of their emission at the stack of a secondary aluminum casting plant.

Results of an extensive 5 year study on a full-scale plant with the specific aim to investigate polychlorinated dibenzo-p-dioxin (PCDD) and polychlorinated dibenzo furan (PCDF) formation and release in a secondary aluminum casting plant are reported. PCDD and PCDF concentrations were evaluated for all the gaseous and solid streams (no liquid stream was present) as well as for the flue gas upstream and downstream of every single unit of the flue gas cleaning system. The study highlights PCDD and PCDF formation particularly in the narrow 320-360 degrees C range. To prevent formation reactions and/or minimize PCDD and PCDF concentration at the stack, effects of the fabric filter substitution, a quenching chamber and a postcombustor installation together with working conditions are investigated. The flue gas cleaning system results in PCDD and PCDF emission at stack of 0.1-0.2 ng I-TEQ/N m3 and in a mass flow of 250-550 nmol/h. The total PCDD and PCDF release into the environment is 0.06 g I-TEQ/yr and the corresponding emission factor, 0.35 microg I-TEQ/ton. It is shown that the global effects of the technological innovation on the reaction mechanisms are the prevention of PCDD/F formation by de novo synthesis and the minimization of their emission.