Full Scale Operational Design

Based on the information generated from these studies, a full scale treatment process was designed. The processing units will be located next to the final solidification cell so that the final treated material can be placed directly into the cell. In the treatment of contaminated soil, the soil will be excavated from the original site prior to processing and stockpiled near the CTI processing unit. 

After soil washing wash water could be reintroduced into the CHEMFIX process later for hydration purposes thus eliminating the need for any post-washing water treatment. 

It was estimated that a treatment rate of 250-350 cubic yards/day by the CHEMFIX process can be achieved. However, the prescreening rate of the material would vary depending on the nature of the material. 

The treatment cost was estimated to be 65- 125/cubic yard. Actual costs for other work will vary from lower to higher unit costs shown depending on job size. 

The laboratory data from both parts of this study proved that the CHEMFIX process was capable of treating contaminated soils, rendering them non-hazardous. The results from the kinetics experiment on the Synthetic Soil Matrix (SSM) showed that the metal-binding reactions took place almost instantaneously. This should eliminate any concern 

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Scale-up is the process of developing a plant design from experimental data obtained from a unit many orders of magnitude smaller. This activity is considered successful if the commercial plant produces the product at plaimed rates, for plaimed costs, and of desired quaUty. This step from pilot plant to full-scale operation is perhaps the most precarious of all the phases of developing a new process because the highest expenses ate committed at the stages when the greatest risks occur. 

The combination of highly exothermic reactions with a sharp increase in viscosity as conversion proceeds controls reactor design and operational conditions in full-scale operations. The art of sulfonation is to maintain the optimal reaction temperature and reaction time, resulting in products with small amounts of byproducts and good color. 

Full-scale operation costs were compared for the Brayton cycle at varying VOC concentrations. The unit costs for VOC recovery are compared in Table 2. The total capital required is 156,173. This price encompasses the equipment costs, including building, site preparation and freight, and capital costs, which include design, inspection, and management (D14334A, p. 64). 

According to the vendor, the capital costs for full-scale plant designed to compact 100 tons of fiy ash per 8-hr shift would be approximately 1,000,000. The operating costs were range from 100 to 500 per ton (D225058, p. 4 D225047, p. 2). 

The previous examples show that if we know the molar flow rate to the reactor and the reaction rate as a function of conversion, then we can calculate the reactor volume necessary to achieve a specified conversion. The reaction rate does not depend on conversion alone, however. It is also affected by the initial concentrations of the reactants, the temperature, and the pressure. Consequently, the experimental data obtained in the laboratory and presented in Table 2-1 as -ta for given values of X are useful only in the design of full-scale reactors that are to be operated at the same conditions as the laboratory experiments (temperature, pressure, initial reactant concentrations). This conditional relationship is generally true i.e., to use laboratory data directly for sizing reactors, the laboratory and full-scale operating conditions must be identical, Usually, such circumstances are seldom encountered and we must revert to the methods described in Chapter 3 to olrtain — ta as a function of X. 

The design of laboratory reactors and similarly small vessels can be completed with consideration of only the effects of internal pressure. As vessels and tanks get larger for full-scale operations, the design must also consider the effects of additional external loads. Typically, these factors need to be included in vessels larger than 40 L. These loadings include ... 

This book assesses soil vapor extraction (SVE) technology and summarizes an expert workshop on SVE sponsored by EPA. This summary identifies current SVE technologies as welt as additional research needed In such areas as site characterization, pilot systems, full-scale system design and operation, attainment of cleanup criteria, and closure monitoring. 

Developed design criteria for scrubber media and validated them during full-scale operation of fuel processor and STAR systems. 

Even with the automatic reversing feature, jamming of the shredder could occur, and lodging of itans in the feed chute should be anticipated. Therefore, the feed chute to the shredder must be large enough to ensure that the largest feed item (probably a pallet) cannot become trapped in the chute. Tests must be run with chutes and shredders of the same dimensions as those planned for full-scale operation to ensure that the design of the feed chute is adequate. 

Recommendation (Pueblo) PH-4. The feed chutes to the shredders used in the Parsons/Honeywell process must be designed to avoid jamming. Tests should be run with chutes, shredders, and feed materials the size of those in the full-scale operations to ensure that the chute design is adequate. 

Inspection is of importance to ensure that fabricators are working according to design codes and quality control. Assembled items are of the right material and specifications for common items such as valves, piping, and welding electrodes must correspond to the standard prescribed specifications. It may be necessary to perform trial runs with the equipment supplied by manufacturers before full-scale operations. 

Recommendation DIIFEK-2. Long-term testing of appropriately designed SCWO reactor liners under the new operating conditions for the proposed full-scale operation will be necessary to prove the reliability and effectiveness of the TW-SCWO unit. 

No major changes have been made to the SCWO system, but there are some differences between the SCWO unit previously tested and the SCWO units proposed for EDS and for full-scale operation. Changes have also been made to equipment downstream of the SCWO reactor to facilitate processing of the suspended solids in the reactor effluent, especially for aluminum-rich feeds. The effluent flows from the pressure letdown valves to a knockout drum that contains a venturi scrubber, which separates liquid and suspended solids from the uncondensed vapor. The slurry is pumped to an evaporator/crystallizer system that replaces the flash separator in the original design. 

As the authors note, scale up from bench-scale tests to full-scale operation can iutroduce difficulties and a degree of flexibility must be incorporated in any design. 

A number of planar cell stack designs have been developed based on planar anode-supported SOFC with metal interconnects. Typically, cells for full-scale stacks are about 10 to 20 cm mostly square or rectangular (though some are round). Stacks with between 30 and 80 cells are the state-of-the-art. Figure 7-26 shows examples of state-of-the art planar anode-supported SOFC stacks and selected performance data (68,78, 79). The stacks shown are the result of three to seven generations of full-scale stack designs by each of the developers. The capacities of these stacks (2 to 12 kW operated on reformate and at 0.7 V cell voltage) is sufficient for certain small-scale stationary and mobile (APU) applications. 

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