e Ha 0 0 0 0 1 0 8OFFICES

eder associates ^cust vallev NY

consulting engineers, p. c.M.idsson. WlACM Arhor. MlAUI_JUST,-I GA

May 18, 1992File #497-8

Mr. Michael GiffordUSEPA Region V230 S. Dearborn StreetChicago, IL 60604

Re: National Presto IndustriesPorcupine Processor Testing Results

Dear Mike :

Enclosed is a copy of Bethlehem Corporation's laboratory reportwhich presents results of testing conducted on the waste forgecompound using the Porcupine Processor. The results of thePorcupine Processor tests will be evaluated as part of thefeasibility study.

On April 28, we sent you a copy of the analytical report fromWadsworth/Alert Laboratories which presented the results of theTCLP analysis conducted on two samples of dewatered waste forgecompound collected during the Porcupine Processor tests. Analysesof the air emission samples collected during the PorcupineProcessor have been completed and will be forwarded to you by NoraBrew of our New York office this week.

During the week of May 11, we received the results of thewastewater samples which were collected from the condenser duringthe Porcupine Processor tests and analyzed for TCL organics andsemi-volatiles and TAL inorganics by Hazleton Laboratories. On May18, we received the results of the raw and dewatered waste forgecompound samples Wadsworth/Alert Laboratories analyzed for the TCLorganics and semi-volatiles and TAL inorganics. We are currentlytabulating these results and anticipate forwarding them to youduring the week of May 26.

If you have any questions, please call me.

Very truly yours,

EDER ASSOCIATES CONSULTING ENGINEERS, P.C.

Dennis F. Kugle

DFK/skkEnc.

cc w/o enc: R. Naumancc w/ enc: G. Rozmus

J. Boettcher4L497-8.011

8000 EXCELSIOR DRIVE, SUITE 302, MADISON. WISCONSIN 53717-1914 • (608) 836-1500 • FAX (608) 836 333 7

BethlehemCorporation

May 08, 1992

ZSt-

MAY I 4 1992

NATIONAL PRESTO INC.3925 N. Hastings WayEan Claire, WI 54703

ATTENTION: MR. RICHARD NAUMANProject Coordinator

REFERENCE: PO 33844Test Work Spent Forge Compound

Dear Mr. Nauman;

Please find enclosed with this transmittal two copies of our Laboratory TestReport No. 847 performed in accordance with the referenced Purchase Order.

We have forwarded two copies of this report directly to EDER Associates.

Included in the report are actual calculations verifying the heat transfer ordrying rates we obtained on your materials.

Please contact the writer if you have any questions.

Sincerely;

Robert P. AllweinManager or Research & Development

cc: M. JoachimD. Kugle, EDER Assoc. (2)

RPA/njw/LABA/LAB#847

25th & Lennox Streets • P.O. Box 348 • Easton, Pennsylvania 18044 • (215)258-7111 • Fax (215) 258-8154

NO. 847

LABORATORY REPORT*:CUSTOMER:TEST DATES:

EQUIPMENT TESTED:

MATERIAL TESTED:

PRESENT TO WITNESS TESTS

94-0805NATIONAL PRESTO INDUSTRIES INC.APRIL 1 & 2, 1992

BETHLEHEM MODEL 1P1203JTBPORCUPINE PROCESSOR

SPENT FORGE COMPOUND FROMEXISTING POND AT SITE

MR. DENNIS KUGLE - EDER ASSOC.MR* MICHAEL GIFFORD - EPA REGION5 OFFICE CHICAGO, IL

OBJECTIVE:

To determine the process viability of thermal vaporization of water and mineraloil from the customer supplied material. The test program is to includedetermination of the heat transfer coefficient, handling requirements, retentiontime requirement and power requirement for continuous operation of productionsize equipment.

CONCLUSIONS:

The material as received, could be thermally dewatered in the PorcupineProcessor. In the drying operation a small fraction of organic solvent, with aboiling point of less than 200 C/390°F., was removed. Process bed temperaturesabove 200 C did not produce any significant removal of mineral oil from theprocess bed. A maximum bed temperature of 275C did not generate anyvaporization of the mineral oil fraction. The volume removed at thesetemperatures indicate the practical remediation of this material would be water-removal only.

Using oil at 365°F verifies that either 150 psig steam or hot oil can be used toremove the water fraction from the spent forging compound. This will provide a30% mass and 30% volume reduction.

Using condensate collection data heat transfer coefficients were calculated forRuns 2 and 3 of the test program.

Overall heat transfer coefficients of 30.5 to 36.8 BTU/hr ft"°F. were obtained.These values include the sensible heat input to the mineral oil graphite fractionthat would be required for thermal dewatering.

>Bethtehem

LABORATORY REPORT # 94-0805NO. 847NATIONAL PRESTO IND. INC.Page 2

CONCLUSION: (CON'T'H)

A design U value of 33.5 BTU/hr. ft.'F. can be used for scale up purpose ofmobile thermal dewatering the spent forge compound Lagoon. A residence time of30 minutes or more will be required due to the materials viscosity over the fullrange of drying temperatures.

Standard Porcupine Processor drive systems will provide sufficient motor-horsepower for successful dewatering.

If steam at 150 psig is available on site at minimal cost it can be used as theheat source. Consideration should be given to the lower driving forcetemperature this will produce when companied to hot oil at 550T inlettemperature. For a specific size Porcupine Processor Dryer, the capacity wouldbe reduced by 45% which is the ratio of mean temperature differential of the twoheat source options.

At time 30 minutes the cover was opened and a sample taken from the bed. Whilethe unit was being resealed an additional sample from the receiver was removedto ensure that all material vaporized during the initial 20 minutes of heatingwere removed.

Oil was reheated in the recirculation system to 600UF. and the run restarted atthe 53.5 minute. An additional 25 minutes of thermal processing were thenaccomplished. As the bed temperature reached 470 . the customer performed asecond air sample from the condenser system.

A total of . 4# of water were removed from the bed in the second heating portionof the test run. From evaluation of the condensed recovered sample both thecustomer's representatives and Bethlehem Lab Staff concluded that volatilizationof organics would require temperatures beyond the practical limit of lowtemperature thermal treatment systems.

The test bed was cooled and examined before emptying the test unit.

PROCEDURE:

One feasibi1ity and three process runs were conducted in The BethlehemCorporation test facility on the customer supplied material. All runs wereconducted on a batch basis in a Model 1P1203JTB Porcupine Processor. This testunit was equipped with a conventional dual side breaker bar assembly, mounted ofboth side wall at a 45" angle into the process bed. Hot oil was used as tile heattransfer medium for all runs supplied to both the Porcupine Rotor and jacket.Product removal was accomplished through a 3 inch diameter ball valve mounted unthe bottom center of the trough.

Bethlehem

LABORATORY REPORT #94-0805NO, 847NATIONAL PRESTO IND. INC.Page 3

PROCEDURE: cont'd

Hot oil used as the heat source for testing was Dowtherm Liquid heated in amodified volcanic heater to 335°C, 630°F. The heater was filled with NO.2 fueloil. Fluid flow through the heater and piping network was accomplished using aDean water jacketed pump. Flow rates of 65 gpm at 90 psig were used for alltests. Actual flow too the test unit at a rate of 15 to 18 gpm was accomplishedthrough a Johnson Model 2400 Rotary joint mounted on the Porcupine rotor shaft,A separate line was run from the laboratory oil header to the vessel jacket toprovide flow separate from the oil flow to the rotor. Oil flow to the vessel wascontrolled too minimize the flow and thereby balance the oil outlet temperaturewith rotor oil outlet temperature.

All vapor liberated from the process bed was educated from the test unit throughan 8 inch diameter oil traced line, A shell and tube heat exchanger was used asthe condensing unit employing city water at 65 F for cooling. The condenser wasoperated in a top entry, bottom drain and bottom vent manner. Flow from thecondenser was directed via 1' flex hose to a 20 gallon receiver separator.Liquid was collected in the receiver for periodic removal. All noncondensiblevapor was educated from the receiver to a carbon bed filter before exhausting tothe atmosphere. An induced draft fan rated at 7 ACFM was used to draw vaporthrough the carbon bed.

Material charging was accomplished through the top cover opening of the testunit. The feed material was weighed, prior to charging on a digital scaleaccurate to .1 Ib. Product and condensed vapor samples were weighed on the samedigital scale.

Power to rotate the Porcupine agitator shaft was provided from a Carter VariableSpeed Hydraulic Drive System. A 2Hp, Class II, Group D, Division 2 motorprovided input power to the hydraulic unit. Final power transmission wasaccomplished by shaft coupling to produce a direct drive system. Output powerconsumption of the septum was measured using a hydraulic pressure gage connectedto the hydraulic rotor. All runs were made at 20 RPM porcupine Rotor Speed,using a stopwatch for timing.

Bethlehem

LABORATORY REPORT #94-0805NO. 847NATIONAL PRESTO IND. INC.Page 4

PROCEDURE: cont'd

Temperatures were monitored by means of T type thermocouples and a 24 pointrecording potentiometer. Location of thermocouples was as follows:

FEASIBILITY RUN & RUN NO. 1

THERMOCOUPLE NO.

1,4,7,10,13,16,19,222,8,14,203,9,15,21

5,176,11,18,23

12,24

LOCATION

MID BED OF PORCUPINEROTARY JOINT INLET (OIL)ROTARY JOINT OUTLET (OIL)JACKET INLET (OIL)JACKET OUTLET (OIL)AMBIENT

The recorder was connected in parallel to a digital timer. All runs were startedby powering both the recorder and timer, timer reset to 0 prior to beginning therun.

After Run #1 the oil inlet and outlet thermocouple line were switched.Thermocouple location for Runs 2 & 3 were as follows:

THERMOCOUPLE NO.

1,4,7,10,13,16,19,222,8,14,205,6,11,18

11,2312,24

3,9,15,21

LOCATION

BEDOIL INLET TEMP-AGITATOR AND JACKETOIL OUTLET ROTARY JOINTOIL OUTLET JACKETAMBIENTNOT IN SERVICE

FEASIBILITY RUN:

Conducted by Bethlehem Staff only on March 24, 1992.

129 Ib. of feed material were weighed and charged to the unheated test unit. Thebed level was measured and the agitation pattern studied for several minutes.During this time the oil heater circuit was preheated to a temperature of

Shaft speed was set at 20 RPM and the unit was sealed.

feBethtehem

LABORATORY REPORT #94-0805NO. 847NATIONAL PRESTO IND. INC,Page 5

FEASIBILITY RUN: cont'd

At time 0 the timer and recorder chart were started coincident with opening theoil inlet valve. At 10 minutes the receiver drain valve was opened to remove allmaterial vaporized from the process bed. The large volume of condensaterecovered required 2 minutes drain time. During this period all low boilingmaterial had been removed and the bed temperature began to increase. Additionalcondensate mass samples were taken at times 20 and 30 minutes before ending therun.

Condensate recovery data recorded in the laboratory notebook was as follows:

10 rain. - 41.8#20 min, - 1.4130 min. - .8#

Upon cooling the bed to 200 F the recorder was shut off and the top cover openedfor visual observation. A liquid free flowing bed was observed. No fouling ormaterial build-up of the heat transfer surface was detected before or afterdischarge.

RUN #1: April 01, 1992

The unheated test unit was charged with 145.8ft of sample material. A measurementof the bed level and a sample were taken before closing the top cover. Oil waspreheated to 350 /360 F. during the charging process.

At time 0 the oil valve was opened to supply a heat source equivalent to 150 psigsteam. The receiver was emptied at time 15, 28.4 and 48 minutes before endingthe run. At this time the oil burner was shut off and cooling water started tothe heat exchanger in the oil circuit. After 30 minutes the bed had cooled tobelow 200 F and the dryer opened. As with the initial run the residual bed inthe dryer was still a low viscosity liquid that was readily removed from thedryer. No fouling or material build-up was observed before or after removing thebed.

The test unit was charged with 146.8# of spent forge compound received from thecustomer. During charging the oil circuit was heated to 370°F. to simulate 150psig steam. After sealing the top cover the oil valve was opened and timer resetto begin the test run.

Condensate samples were removed from the receiver at times 10 and 20 minutes.After removing the second sample from the receiver the burner was again shut offat time 22 minutes. The oil was cooled to reduce the bed temperature.

Bethlehem

LABORATORY REPORT #94-0805NO. 847NATIONAL PRESTO IND. INC.Page 6

The test unit was charged with 156 Ibs. of spent forge compound. While chargingthe oil circuit was again preheated to 370eF.

A sample of condensate was taken at time 10 minutes. This included an air sampleas well as water samples for customer analysis. This required 10 minutes,causing the condensate volume recovered to be reported for a 20 minute period.A second sample was removed at 28 minutes before ending this run.

The material balance was checked for this run to verify no build-up of solids inthe dryer.

When the weight of sample containers from the customers were removed fromcondensate weights a 99% recovery value was achieved.

Bethlehem

TABLE NO. 1

CONDENSATE RECOVERED DATA

RUN NO. TIME VOLUME/WT.OF CONDENSATE BED TEMP,

Evaluation Run

Run 1

Run 2

0122030

1529.9

Tailings

1020

Tailings130

41.8#1.4#

13.8#24.5#.51

19.8#20.0#3.7#

43.2* Total44.0? Total

38.3# Total39,2# Total

39.8# Total43.5# Total43.9# Total

Run 3 10 to 2028

Tailings

24.6#18.4#3.2#

43.0*46.2#

TotalTotal

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