sediment - ITRC

Cement-Lock SM
Technology
for
Decontaminating Dredged Sediment
Amir Rehmat, Anthony Lee
Gas Technology Institute
Michael Mensinger, Anil Goyal
ENDESCO Services, Inc.
Fall 2000 ITRC Conference
October 18, 2000

Cement-Lock SM
Technology
An advanced thermo-chemical manufacturing
process for decontaminating dredged
sediments, soils, wastes, and sludges and
transforming these wastes into resources:
● Sediment is transformed into constructiongrade
cement
● Organic contaminants are destroyed with
DRE’s > 99%
● Heavy metals are immobilized in the cement
matrix

Cement-Lock SM Technology
Description
STEAM
SEDIMENT
FUEL
AIR/O 2
MODIFIERS
ECOMELT
GENERATOR
2400° - 2600°F
SECONDARY
COMBUSTION
ADDITIVE
HEAT
RECOVERY
GAS
CLEAN
UP
CLEAN
FLUE
GAS
ECOMELT
QUENCH
PULVERIZER/
MIXER
High Quality
CONSTRUCTION-
GRADE CEMENT

Cement-Lock SM
Technology Supporters
● U.S. EPA Region 2
● Brookhaven National Laboratory
● U.S. Army Corps of Engineers
● U.S. EPA Region 5 / GLNPO
● MI Dept. of Env. Quality
● NJ Office of Maritime Resources
● NJ Dept. of Transportation
● GRI
● Unitel Technologies, Inc.
● Private Corporations

Cement-Lock SM Technology
Applications
● Harbor & river sediments
● MGP site soils
● Brownfield soils, debris
● Superfund site soils
● Military BRAC wastes, debris
● Municipal solid wastes & sludges
● Petroleum sludges
● Tank / tanker bottoms
● Spent molecular sieves, etc.
● Coal ash, etc.

Cement-Lock SM Technology
-- Wastes Tested
● Dredged estuarine sediments
● Dredged river sediments
● Municipal solid waste
● MSW incinerator ash
● Contaminated concrete
● Coal fly ash
● Coal bottom ash
● Oil-contaminated soil
● PCB-contaminated soils
● U-containing wastes

Technology Development
Status for Dredged Sediment
● Bench-scale data with Newtown Creek
(NY) sediment - WRDA (COE/EPA2/BNL)
and Black Lagoon (Detroit River) sediment
- MI-DEQ
● Pilot-scale (1-ton/day) data with Newtown
Creek sediment and contaminated soil -
WRDA (COE/EPA2/BNL), private sector
● Demo plant (30,000-150,000 cy) for
dredged sediment currently under
construction for NJ - WRDA
(COE/EPA2/BNL), NJ-MR, private sector

Technology Development
Status for Dredged Sediment
● Demo plant (2,000 - 5,000 cy) for Black
Lagoon (Detroit River) sediment - EPA5,
GLNPO, MI-DEQ, private sector
● Engineering completed for 100,000 cy/yr
plant module and 500,000 cy/yr plant
● Cost for complete dredged sediment-tocement
production plant (1 module of
100,000 cy/yr capacity) is $20 million.

Independent Data
Verification
● Organic Contaminant
Destruction
– Triangle Laboratories,
Durham, NC
● Metals Immobilization
– Triangle Laboratories,
Durham, NC
● Air Sampling Data
– AirNova, Pennsauken, NJ

Cement-Lock SM is Very Effective in
Destroying Organic Contaminants
Contaminant
------ Estuarine Sediment ------ ---------- River Sediment ----------
Untreated Cement
Untreated Cement
Sediment Product Destruction Sediment Product Destruction
----- mg/kg (dry) ----- --%-- ----- mg/kg (dry) ----- --%--
Oil & Grease - - - - - - 18,000 < D.L.* > 99.99
PAHs 370 0.22 99.93 51.2 < D.L. 99.99
------ m g/kg (dry) ----- ------ m g/kg (dry) ------
PCBs 8,585 < D.L. > 99.99 1,100 < D.L. > 99.99
----- ng/kg(dry) -----
Dioxins/Furans
2,3,7,8 TCDD/F 262 < D.L. > 99.99
Other TCDD/F 2,871 < D.L. > 99.99
PeCDD/F 4,363 < D.L. > 99.99
Hx/Hp/OCDD/F 34,252 < D.L. > 99.99
* Below the analytical method detection limit.

Cement-Lock SM is Very Effective in
Immobilizing Inorganic Contaminants
Metal
Untreated Material
Estuarine
Sediment
River
Sediment
Toxicity Characteristic Leaching Procedure
Cement Produced From
Estuarine River Regulatory
Sediment Sediment Limit
------ mg/kg (dry) ------ -------------------- mg/L --------------------
Arsenic 39 7.8 < 0.005* < 0.01 5
Cadmium 27 9.5 < 0.001 < 0.002 1
Chromium 298 138 0.15 < 0.072 5
Copper -- 180 -- < 0.01 --
Lead 542 218 < 0.002 < 0.01 5
Mercury 2.9 0.55 < 0.0004 < 0.0004 0.2
Selenium 6.2 -- < 0.003 -- 1
Silver 13 -- < 0.001 -- 5
* Analytical method detection limit.

Cement-Lock SM Pilot-Scale Unit

Ecomelt
produced during
pilot-scale
testing

Cement-Lock SM Technology
Pilot-Scale Air Emissions
Flue Gas Composition*
Outlet
CO2, mol % 8.1
CO, ppm 25
HCl, ppm 14.2
NOx, ppm 67.7
SO 2 , ppm 44.1
Total Hydrocarbons, ppm 10.6
PCBs
< 1.1 x10 -6 lb/hr
Pesticides < 2.8 x 10 -7
Chlorobenzenes/Chlorophenols < 6.8 x 10 -5
SVOCs
BDL**
Total 2,3,7,8-CDDs (TEF) < 4.0 x 10 -12
Total 2,3,7,8-CDFs (TEF) < 8.1 x 10 -12
Particulates, grains/dscf < 2.0 x 10 -4
Particulate Phase Composition
PCBs < 5.3 x 10 -7
Total 2,3,7,8-CDDs (TEF) < 8.0x10 -12
Total 2,3,7,8-CDFs (TEF) < 7.3x10 -13
___________________________
* Adjusted to 7% oxygen
** Below detection limit, some phthalate compounds detected

Cement Certification
& Testing
● Construction Technology Laboratories,
Inc. (CTL, Skokie, IL, subsidiary of
Portland Cement Association)
● Prairie Cement Group (Chicago, IL, cement
manufacturer)
● New Jersey Department of Transportation
(NJ-DOT, public project applications)
● Sor Testing Laboratories (Cedar Grove,
NJ, cement/concrete testing services for
NJ/NY area)

Compressive Strength of Cement
from Sediment and Debris
Compressive Strength, psi
6000
5000
4000
3000
2000
1000
3 Days 7 Days 28 Days
28-day portland cement
requirement: 4060 psi
0
Estuarine Sediment River Sediment Concrete Debris
Feedstock

Compressive Strength of
Cement from Ash
Compressive Strength, psi
6000
5000
4000
3000
2000
1000
0
3 Days 7 Days 28 Days 28-day portland cement
requirement: 4060 psi
CF1* CF2* CF3* CB1* CB2* CB3* MSW1**
Formulations
*Cement made from grinding various formulations of Ecomelt with 75 wt% additives.
**Cement made from grinding Ecomelt with 60 wt% additives.

Compressive Strength of Cement
from Contaminated Soils
Compressive Strenght, psi
6000
5000
4000
3000
2000
1000
28-day portland cement
requirement: 4060 psi
3 Day 7 Day 28 Day
0
Petroleum
Contaminated Soils
Soils Contaminated
with 9,100 ppm of PCB
Equivalent
MSW
Feedstock

Comparison of Trace Elements in Cement-
Lock SM Cement & Portland Cement
Element
Cement-Lock
Cement
Portland Cement*
---------- Range ----------
-------------------------- mg/kg --------------------------
Mercury < 0.07** < 0.001 0.039
Selenium < 0.94 0.62 2.23
Cadmium 1.59 0.03 1.12
Lead 35.8 1 75
Silver 2.66 6.75 19.9
Arsenic 9.22 5 71
Barium -- 91 1402
Chromium 196 25 422
Nickel 133 15 129
* Portland Cement Association, 1992
** Below analytical detection limit

Factors Affecting
Technology Performance
Factor
• Moisture content
• Variations in type & quantity of
organic contaminants
• Variations in type & quantity of
heavy metals
• Sediment quality (clayey, loamy,
sandy)
• Sediment particle size
Effect
• No effect
• No effect
• No effect
• No effect
• No effect

Factors Affecting
Technology Economics
Factor
• Moisture content
• Non-steady supply
• Use of alternate fuels
(sewage sludge and/or
refinery tank bottoms)
• Non-continuous batch
processing of sediment
aliquot
Effect
• Affects quantity of
cement / revenues
• Larger storage
required - affects
capital costs
• Considerably reduces
sediment treatment
costs
• Capital attributed to
batch increases
processing cost

Logistical & Regulatory
Requirements
● Permit requirements - similar to those
for manufacturing process plants
● Air permit required
● Net water user - No process water
discharge permit needed
● Large-scale plant (>500,000 cy/yr)
incorporates engineered transportation
and logistics system so that dredged
sediment is moved from the channel to
the cement market seamlessly

Logistical & Regulatory
Requirements
● Small-scale plant (

Net Cost of Sediment
Treatment - 3 Scenarios
1. Dedicated 500,000 cy/yr sediment treatment
facility; 20-year life span; fueled by natural
gas; cement commanding the same price as
portland cement.
2. Dedicated 500,000 cy/yr sediment treatment
facility; 20-year life span; fueled by sewage
sludge and/or refinery tank bottoms;
cement commanding the same price as
portland cement.
3. Case 2 except with cement commanding
50% of the price of portland cement.

Unit Processing Costs for a
500,000 yd 3 /year Capacity Plant
Case 1 Case 2 Case 3
Credits ---------------------- $1000’s ----------------------
Sale of Cement ($70/ton) $17,440 $23,100 $11,550
Tipping Fees From Other Wastes -- 18,810 18,810
Total Credits $17,440 $41,910 $30,360
Expenses
Labor $930 $930 $930
Raw Materials 3,470 4,035 4,035
Utilities 12,110 6,055 6,055
Maint./Misc. 5,775 5,775 5,775
Total Expenses $22,285 $16,795 $16,795
Provision for Lease $1,500 $1,500 $1,500
Depreciation $10,500 $10,500 $10,500
Net Processing Cost $16,845 ($13,115) $1,565
Break-Even Tipping Fee, $/yd 3 $33.69 ($26.23) $3.13
Case 1: 100% harbor sediment feed
Case 2: 75% harbor sediment feed + 25% other waste feed
Case 3: Case 2 except cement sale price reduced by 50%

Commercial Readiness
● All equipment is commercially
available
● Vendors are willing to provide
turnkey plants:
– ABB, Svedala, Andersen 2000
● Pilot plant data sufficient for
detailed design and construction

Commercial Readiness
● Modular plant construction
– 100,000 cy/y modules
– Modules can be added as needed
● Additional environmental and cement
utilization data will be generated at
the NJ demo facility

Cement-Lock SM Technology
-- Summary
● Simple, one-step method for processing large
volumes of sediment, soil, MSW, etc. with
practically no restrictions on their content.
● All processing equipment is commercially
available.
– No development required
● Provides a permanent solution for disposing
of dredged sediment
● Favorable economics
– Tipping/processing fees
– Finished product sales (ASTM quality
construction-grade cement)
– Industrial wastes co-processing