PACT SYSTEM

TECHNICAL BRIEF
SISTEMA PACT
RESUMO TCNICO

AND
E

FAQ
PERGUNTAS MAIS FREQUENTES

PREPARED BY:
PREPARADO POR:

RETECH SYSTEMS LLC

MARCH 6, 2002
THE TECHNOLOGY

The Plasma Arc Centrifugal Treatment (PACT) system is designed and

manufactured by Retech Systems LLC in the USA. Plasma provides the energy
needed to convert non-organic materials into vitrified slag and organic materials
into simple molecules, with high destruction and removal efficiencies (DREs).
Processing temperatures are usually in the range of 800C to 1600C. Note that
the fraction of energy released that is available at high temperatures is much
greater with electric arcs than for combustion energy. More than 91% of plasma
gas sensible heat is available above 1200C when the plasma gas is nitrogen, air
and other di- and poly-atomic gases. Only about 23% of the theoretical heat of
combustion is available above 1200C when burning methane with air at 140% of
stoichiometric oxygen.

The PACT system can accept a wide variety of heterogeneous wastes while
producing a volume-reduced durable slag that needs no further treatment.

A TECNOLOGIA

O Sistema de Tratamento de Arco de Plasma Centrfugo (PACT) projetado e fabricado

pela Retech Systems LLC nos EUA. O Plasma oferece a energia necessria para converter
materiais no-orgnicos em escrias vitrificadas e materiais orgnicos em molculas
simples, com alta eficincia na remoo e destruio (DRE's ). Temperaturas de
processamento so normalmente na faixa de 800 C a 1600 C. Note-se que a frao de
energia liberada disponvel em altas temperaturas muito maior com arcos eltricos do que
com energia de combusto. Mais de 91% de calor sensvel de gs plasma est disponvel
acima 1200 C quando o gs plasma nitrognio, ar e outros di- e poli-gases atmicos.
Apenas cerca de 23% do terico calor de combusto est disponvel acima 1200 C quando
queima o metano com ar a 140% de oxignio estequiomtrico.

O sistema PACT pode aceitar uma grande variedade de resduos heterogneos ao produzir
um volume reduzido de uma escria durvel que no precisa de nenhum tratamento
adicional.

PACT PRINCIPLES

The plasma gas transfers energy from the arc to the molten slag, which acts as one
arc termination. The rotating crucible (centrifuge) moves the molten waste material
beneath the torch at about 20 to 40 times per minute. Centrifugal force keeps the
molten slag away from the pour nozzle in the center during processing. The
centrifuge is housed within a sealed, water-cooled Primary Processing Chamber
(PPC, Fig. 1). Pouring is achieved by slowing the centrifuge so slag moves toward
the center, then flows through the pour nozzle into a mold positioned inside the Slag
Collection Chamber. The bottom part of the centrifuge shell is spray-cooled with
water. All chambers are kept under negative pressure (-25 to 50 mbar) to prevent
outward leakage of potentially hazardous gases.
PRINCPIOS DO SISTEMA PACT

O gs de plasma transfere energia do arco para a escria fundida, que actua como
terminao de um arco. O cadinho rotativo (centrfuga) move o resduo de material fundido
sob a tocha cerca de 20 a 40 vezes por minuto. A fora centrfuga mantm a escria fundida
longe do bocal de despejo no centro durante o processamento. A centrfuga est alojada
dentro de um selado, water-cooled primrio processamento cmara (PPC, Fig. 1). O despejo
conseguido retardando o centrifugador para que escria se mova em direo ao centro e,
em seguida, flui atravs do bocal de despejo em um molde posicionado dentro da cmara de
coleta de escria. A parte inferior do reservatrio da centrfuga refrigerada com spray de
gua. Todas as cmaras so mantidas sob presso negativa (-25 a -50 mbar) para evitar
fugas para o exterior dos gases potencialmente perigosos.

Tubulao de gs
de escape

Cmara de
Processamento
Primrio

Fuso Alimentador

Tocha de
Plasma

Centrifugador
Arco de Plasma

Escria
Bocal de Despejo Fundida

Figure 1. General PACT schematic

Esquema Geral PACT
Waste is fed from above, dropping onto the molten slag surface. As the torch
continuously heats the rotating slag, waste "sees" a newly heated surface. This
principle provides throughputs that have been demonstrated to be twice that of fixed
hearth plasma systems with the same power. Gaseous oxidants, frequently needed
to avoid soot formation in the primary chamber, are injected through in-wall nozzles.
Gases pass from the PPC to a Secondary Treatment Chamber (STC), sized to retain
gases for a minimum of 2 seconds at 1000C, which achieves a minimum DRE of
99.99%.

Generally, the primary chamber volume limits the organic material feed rate while
PPC bath area in combination with plasma power determines inorganic feed rates.

System simplification possible with PACT melters (due to minimal pre- and post-
treatment) reduces overall capital cost and requires fewer operating personnel.
Reducing exposure to hazardous waste remains important for worker safety, so
reduction of material handling made possible by the PACT process is an important
advantage.

DUAL MODE OPERATION

Mixed oxides are generally conductive when hot so that torch current can transfer
directly into the slag. However, such materials have much lower conductivity near
room temperature, and some materials such as spinels have poor conductivity even
when heated to melting temperature.

The patented torch has been designed and tested to operate in both transferred
and non-transferred modes at the same time. The torch, not the operator,
automatically seeks the mode combination that suits the conditions. With prior
transferred arc torch designs, cold heterogeneous feed material would cause a
high voltage spike with visible instability as the arc sought a better ground path.
Repeated instability, such as with a large amount of bulky feed material, would
cause arc-outs and lost visibility inside the PPC. With the dual mode torch, the
plasma gas envelope maintained by the non-transferred arc stabilizes transferred
arc voltage so that arc-outs and arc instability are eliminated. In some 650 kg
batch tests, feed times were decreased from 200 minutes with only transferred
mode operation, to 60 minutes with dual mode.

The torch can now "pull" a one meter arc length, making it possible to batch melt
multiple 200 liter drums weighing >500 kg in the centrifuge. Before dual mode torch
development, a stable arc of this length was not practical. Longer arc length or
processing in non-transferred mode also means the system can be operated at
reduced heat when processing more volatile materials.
FEED SYSTEMS

The choice of feed system has a direct effect on processing rate. Table 1 shows the
feeds and systems that have undergone full scale testing. The Toyo Engineering
vertical drum feeds are the only ones batch loaded owing to their excessive weight
(>500 kg)

Shredders allow a 200 liters storage drum to be fed into a system that would
otherwise be too small to accept directly. Another advantage of shredders is
acceptability of varied forms and chemistries and metering of organic material such
as dry active waste so downstream flue gas treatment can be economically sized.
 Table 1. Feeder Summary

Project Feeder Waste Physical Form Feed Rate

Kg/hr
US EPA SITE Tests Archimedes Soil Loose 175
Muttenz Drum Feeder Organic 200 liter drums 1000
chemical
ZWILAG Horizontal Drum Dry Active 200 liter drums 2-3 drums/hr
Waste at (organic evolution
40 MJ/kg rate = 200-250
kg/hr)
Munster Loose Material Aqueous Loose 1000
Soil
Washing
Slurry
Lockheed Archimedes Soil Metals Loose 1000
U. S. Navy Shredder Paint, Oily 20 kg drums 450
Rags
U.S. Navy Pump Solvents Liquid 450
Toyo Engineering Vertical Drum Concrete, 200 liter drums Four 400 kg
Metal, drums in 2 to 3
Insulation hours
Toyo Engineering Horizontal Drum Concrete, 200 liter drums 3 drums /hr
Metal, (525 kg/hr)
Insulation
Toyo Engineering Archimedes Concrete, Loose Material 560 to 660
Metal,
Insulation

Feeding whole drums of organic materials such as dry active waste is possible as
proven in the ZWILAG pre-commissioning tests, but correctly sizing the flue gas
system and controlling oxidizing gas flows to the primary and secondary chambers
are critical to success.

Feeding non-organic wastes was demonstrated in a Toyo Engineering Corporation-

Retech Cooperative Research and Development Program. The PACT-8 recently
delivered to Toyo at Tsuruga, Japan uses both a vertical and a horizontal drum
feeder to introduce drums of inorganic wastes to the PPC. The drums rotate in the
horizontal feeder and are cut open (oxy-LPG gas) as they advance, thus effectively
controlling the feed rate. The capital cost is significantly lower for the horizontal drum
feeder than for a drum shredder, as is the cost of maintenance.

Slurries and liquids should be fed at a metered rate through a lance into the furnace.
When feeding liquids, no effort is made to get small droplets in the head-space above
the bath, since volatilization at the bath surface results in best overall mixing and
destruction of toxics.
PRETREATMENT OF WASTE

Essentially the only pre-treatment of wastes needed for the PACT process is to
enable feeding. Container contents can either be dumped into a hopper, then screw-
fed, or the containers can be fed and destroyed along with the contents.

POST-TREATMENT OF SLAG, OFF-GAS AND SECONDARY WASTES

Molten slag is poured at intervals (typically ranging between 0.5 and 8 hours) into
molds, then cooled to room temperature. When the material treated is radioactive,
the molds are usually put into other containers for permanent storage. When wastes
do not contain radioactivity, the slag can usually be removed from the casting molds
and discarded.

When hazardous wastes are destroyed, the permitting agency will want verification
that no toxic substances are being released into the environment. This means that
monitoring equipment must keep track of the concentration of potential contaminants
and that the gas clean-up system must be designed to meet the standards set by the
regulatory agency. Because plasma-treatment systems have lower off-gas flow rates
than combustion-heated systems, there is usually a somewhat higher percentage
flow variation (but lower absolute flow rate variation) than with combustion systems.
This requires attention in the design of the off-gas system.

The plasma system is usually designed to sequentially remove particulates and acid
gases from the off-gas leaving the SCC. The particulates can be re-introduced to the
furnace, thus achieving essentially 100% removal of metal, oxide and phosphate
products, while acid gases wind up as neutralized compounds in the water used in
gas cleanup.

1.0 Technology Questions

1.1 What types of wastes can be processed by the PACT system?

Almost all types of wastes can be processed by PACT, including solids,

slurries, liquids, gases and mixtures of thereof. The thermal flywheel effect of
the slag bed in the centrifuge makes operation more stable, even if feed
composition varies suddenly and/or widely. However, the molten bath in the
centrifuge is hot enough that mercury, halides and sulfates are not retained in
the slag; thus feed streams containing large quantities of these substances
are frequently best treated by other methods.
 Wastes containing up to 50% halides and sulfates can be processed with
PACT, but almost all of these compounds will be removed in the scrubbing
system and will not be stabilized in the slag. Chlorine feed rates up to 55
kg/hr (from chlorinated organics) were used with satisfactory results in tests
run at Ukiah for one of our customers.

Wastes containing arsenic and lead have been successfully treated and
stabilized into leach-resistant slags.

1.2 What destruction efficiency does the PACT process achieve?

The temperatures and residence times for the slag and the off-gas are such
that by properly controlling the oxygen potential in primary and secondary
chambers Destruction and Removal Efficiency (DRE) values exceeding
99.9999% (six 9s) are achievable. Of special relevance is the excellent
homogeneity of the slag, which assures low carbon levels in the solid
treatment product.

During the waste feed part of processing, a safety mold is positioned below
the primary chamber to catch and hold for later treatment any material that
falls through the pour nozzle opening. After feeding stops in preparation for
pouring, the safety mold is removed and a casting mold positioned.

1.3 Is it possible to pour metal and slag as separate layers in the same mold?

Double layer pouring of metal and slag or two phase pouring and separation
in the mold has been accomplished in the PACT system (PACT-1, PACT-2, and
PACT-8). The operational parameters are well established that include, but are
not limited to: torch power, PPC refractory design, feed sequence, and process
temperatures.

1.4 Is it possible for the system to switch from double layer pouring (metal and
slag) to single layer pouring (oxidized metal) without modifying the hardware?

Pouring two phases or a single phase is not dependent on overall plant

architecture. It depends on operational parameters such as torch plasma gas
pressure, PPC temperature and oxygen concentration, and processing time. If a
single homogeneous slag is desired in the mold rather than metal plus slag, an
oxygen lance is useful to permit penetrating the slag layer to oxidize the metal
phase (the metal phase is usually higher density and mostly iron).
 1.5 How do you minimize soot formation and avoid formation of dioxins?

Soot formation is prevented by by supplying both sufficient oxidant gas and good
mixing conditions in the primary chamber to oxidize carbon-containing
compounds at least to carbon monoxide. Baking organic feeds in oxygen-starved
conditions must be avoided, since soot, once formed, is difficult to burn.

Temperatures in the primary and secondary chambers are high enough to

destroy dioxins, but the gas cleanup system must be carefully designed and
operated to avoid removing dioxins and furans in the critical temperature region
around 450 C.

1.6 Is the process continuous or batch?

The PACT process is semi-continuous. When starting up for the first time, or
after refractory repair or renovation, a preheat period of a few days is needed to
obtain maximum refractory life. Then tests are conducted, usually around the
clock, with process feed for a time of order one or a few hours during which the
predominately oxide content of the wastes accumulates in the centrifuge. When
an appropriate avoid of molten slag has accumulated, feeding is stopped for a
few minutes while the last material added is heated and homogenized in the slag.
Then some of the slag is poured into a mold, and feeding resumes. The duration
of uninterrupted feeding and pouring cycles is limited to about 300 hours by
electrode life. However, campaigns are frequently run for 120 hours (five days)
depending on customer preference, followed by a week-end period at reduced
primary chamber temperature. Electrodes are usually replaced during the week-
end period.

2.0 Operation Questions

2.1 How many years have PACT systems been operating?

The first PACT system started operating in Ukiah in 1987. The second system
was built in 1989 and the third delivered in 1990.

The table below gives estimated operating hours for almost all of the PACT
systems Retech has built. Retech has been operating a PACT-8 system in
Ukiah for production scale testing since 1997.
 Table 2. PACT Annual Operation Hours

Location System Operational hours, Comment

yearly

Retech, USA PACT-1.5 250 R & D issues

Retech, USA PACT-2 750 R & D, process issue

Retech, USA PACT-8 1,500 R &D, Production scale

processing

Retech, USA Norfolk 400 Acceptance testing at Retech

PACT-8

TEC, TUPL PACT-8 1000 Estimate, acceptance testing

at Tsuruga

MGC, Switzerland PACT-2 500 Estimate for 1992-2000,

system is currently idle

MGC, Switzerland PACT-8 2000 Estimate for 1990-2000,

system is currently idle

ZWILAG, Switzerland PACT-8 500 Initial testing Program

Munster, Germany PACT-8 4,500 Ministry of defense, one year

testing

CEA, France PACT-2 120 Average over five years

MSE, USA PACT-6 1,500 Estimate

NRL, USA PACT-1 600 Estimate

2.2 How reliable are PACT systems?

Retechs production-size PACT has been used in several series of customer-

funded test programs. The information in Table 3 summarizes Retechs
experience in these tests. Malfunction is defined as a significant delay or
stoppage during operation. Often, testing is designed at the extreme limits of
the capability of the system. Table 4 lists some abnormal events that
occurred during the same time period.
 Table 3. Malfunctions, Retech PACT-8

Subsystem Malfunction Cause Corrective Hours

Action

Slag Collection Mold transfer cart Bad transfer cart Remove and 1
out of position limit switch replace limit
switch; Insulate
limit switch from
heat

Slag Collection Mold would not PLC logic Reset manually, 1

go into pour fixed PLC logic
position

Quench System Not controlling Bad outlet TC Replaced TC 3

Centrifuge Tachometer Bearing Installed new 1.5

failure breakdown due to tachometer with
rigid mount flex coupling
mount

Centrifuge closed Filter plugging Inadequate purge Purge changed 4

water for centrifuge form 1 position to
rotary gap 4 positions at 90
from each other

Centrifuge Seizure Lid refractory Replaced castable 40

slumping onto refractory with
centrifuge top brick on cylindrical
surface due to portion of lid and
failed anchor deployed a gusset
system system for better
support

Torch Water leak Gas ring failure Removed torch 1.5

during gas ring while maintaining
research testing system vacuum,
program (high placed isolation
volume flow tests) plate on torch port,
installed new gas
ring and electrode,
installed torch,
and continued
 Table 4. Abnormal Events, Retech PACT-8

Subsystem Abnormal Event Cause Corrective Action Hours

Source Power Loss of power to Weather, storm Started back-up N/A

facility power system to
(this has occurred control cool-down
twice in four years)

PLC Computer Shut off Data acquisition Rebooted computer About 1

system overload minute

Slag Collection Crane lowered PLC logic PLC logic 16

Crane while transferring sequence after sequence corrected
mold; moved abort cycle was (1 for PLC
bridge crane off initiated logic)
track

2.3 What wastes have been treated so far, in particular organic materials and
glass produced?

A wide variety of military wastes, surrogates for radioactive wastes and toxic
chemicals have been treated. Achieving adequate destruction efficiency for
substances in the off-gas is not a problem in systems with a secondary
combustion chamber operated at licensed conditions, but adequate destruction in
the solid phase can be a problem with fixed hearth melting systems. The PACT
system shows a factor of 10 improvement in carbon destruction compared to a
fixed hearth plasma system. Durability of slags is especially important in
stabilizing radioactive wastes, and the relatively high melting temperature
achievable with PACT (1300 to 1500 C) results in durability greater than that of
the glasses (melting at 1100 to 1200 C) used in the US DOE Savannah River
melting system. PACT slags also have very good leach resistance in US EPA
leach tests.

2.4 What can you say about the ability of the system to cope with unforeseen
and/or unknown variations in the physical and chemical characteristics of the
waste feeding system?

In general, the PACT system design can handle a wide variety of feed variations
and combinations. This is enhanced by several closed loop controls that are
 automatically adjusted during operation. Furthermore, we have utilized predictive
algorithms in certain cases to control processing. The most noticeable changes to
operational variables are torch transferred voltage and system pressure. To
examine torch voltage issues see paper presented at Waste Management 2001,
Tucson, Arizona (Appendix B). System pressure variations are usually due to
organic feeding, particularly drum feeding, and can range from 1 mbar to 10
mbar. This range of pressure fluctuation does not pose a problem with the PACT
system.

Note that optimizing slag properties can be done by changing operating

conditions for a few minutes just before pouring slag. Also, the oxygen potential
in the primary chamber (which is automatically controlled to a pre-determined
value) can be chosen to optimize slag properties or to minimize energy needed to
maintain secondary chamber temperature.

2.5 Operational flexibility of the system?

The PACT system can process many types of feed and combinations of feed.
Example: simultaneous feeding of organic and inorganic materials. In order to be
able to process a wide range of materials a system has to be operationally
flexible. From an operator perspective, there are few process variables that need
to be adjusted to process different waste forms. For example, processing
inorganic materials of high melting point, torch current can be increased to rapidly
melt the materials and compensate for heat losses. Processing organic materials,
the torch current is lowered to minimize input energy. Combination feeding of
organic and inorganic materials can be done by monitoring torch current, and
adjusting it to maintain a desired temperature for processing. Additionally, optimal
processing rates can be achieved by combining organic and inorganic materials
in appropriate proportions. In general, process specifications can be derived for
various waste forms and PLC programming can help reduce operator activities.

2.6 What are the process control parameters?

Process sensitivity as it relates to final waste form can best be described in

terms of slag homogeneity. We often feed heterogeneous mixtures of waste
and it takes time to reach a homogeneous slag product. The mixed wastes
must be fully liquid in order to achieve homogeneity, and in most cases after
stopping feeding, a dwell time at temperature is needed to achieve this. The
dwell time is usually short (10-30 minutes) due to the mixing action of the
plasma gas momentum, and can be decreased by increasing plasma gas
flow. During this period the PPC temperature should be maintained near the
predicted ceramic alloy liquidus temperature by controlling torch current and
the vertical height of the torch (slag surface to torch nozzle distance.
 Close to the arc termination, the temperature is sufficiently high to achieve what is
known as high temperature homogenization. In general, this means developing
fine dispersions of the phases and impurities present, or better stated as
achieving a high degree of slag homogeneity.

Table 5. Effects of Main Process Parameters

Parameter Effect on Feeding Effects on Processing Effect on Final Waste

Form

Torch Current Throughput Energy transfer, slag liquidus, Homogeneity

PPC temperature

Plasma gas Throughput Energy transfer, increased Homogeneity

pressure mixing, PPC temperature

Centrifuge speed Mixing Waste transfer, assist mixing Mold fill volume

PPC input oxygen Throughput Oxidation of inorganic and Composition

organic wastes, PPC
temperature

Feedback loops responding to sensors control centrifuge rpm, arc current,

oxygen potential of the gas leaving the primary chamber and torch position. Feed
systems are usually under manual control, but subject to certain safety system
overrides. Initiation of a pour sequence is under operator control, but the pouring
operation is usually preprogrammed.

2.7 Why does Retech use nitrogen as the arc gas?

Nitrogen results in longer electrode life and reduced NOx than does air.
Both are much cheaper than other choices of plasma gas, and monatomic
gases are not as effective in melting solid feeds as di- or poly-atomic
gases. It is, however, true that monatomic gases extend electrode life.

2.8 How does the transferred arc current get through the torch refractory?

Conductive refractory bricks are used in part of the centrifuge refractory

lining. The internal torch electrode functions as arc anode (positive
terminal). The partially ionized plasma gas conducts current to the slag,
which functions as the arc cathode (negative terminal). The conductive
bricks are in contact with the steel centrifuge shell. Stationary brushes
 pick up the current from the steel centrifuge shell and are connected to the
DC power supply, as is the torch electrode.

2.9 How do you meet slag Acceptance Criteria?

See reference material for test methods and results (Appendix D).
Generally, slag leaching test methods are FED EPA Method 1311 TCLP
(RCRA protocols, 40 CFR, Appendix II, Part 26), and CAL EPA STLC and
TTLC (Title 22, CCR, Section 66261.24).

Slags tested thus far have successfully met disposal criteria according to
Federal and California State EPA toxicity requirements.

If for some unforeseen reason unsatisfactory slag is produced, it could be

reprocessed. Slag reprocessing has been demonstrated at the Retech
facility.

3.0 Maintenance Questions

3.1 How are critical components maintained?

Table 6 shows a routine maintenance activity list, by subsystems, for Retechs

PACT-8. Critical items are listed along with hours for maintenance activities. The
main critical area relates to the plasma torch and assemblies. Retech has over 25
years experience in maintaining plasma torch system for the global community.
The maintenance items listed are for a typical 240-hour test cycle.
 Table 6. Routine Maintenance Outline

Subsystem Maintenance Description Maintenance

Hours
Hydraulic Check reservoir level 0.16
Hydraulic p indicators of filters should be checked for filter 0.5
loading
Hydraulic Inspect hydraulic rams for o-ring leaks and cylinder 1.0
surfaces for degradation of finish that could cause
binding
Centrifuge Water Change bag filters if P indicator is > 2 Psig or if 1.0
filter have switched
Centrifuge Water Check pump mechanical seal and insure there is no 0.16
leaks
Torch Water Change or clean bag filter 1.0
Torch Water Check pump mechanical seal and insure there is no 0.16
leaks
Furnace Water Change bag filters if P indicator is > 2 Psig or if 1.0
filter have switched
Furnace Water Check pump mechanical seal and ensure there is 0.16
no leaks
Feeders Check level and add oil to seal oilers (if any) 0.5
Torch, Pylon, Inspect water and hydraulic fittings for leaks, hoses 8
Power Supply for mechanical integrity, electrical for hot spots and
(CRITICAL) general cleanliness around points of electrical
contact
Torch, Pylon, Electrical isolation tests should be performed to 2
Power Supply ensure proper isolation of nozzle and electrode from
(CRITICAL) ground potential
Primary Lubricate centrifuge bearing from external fitting 0.5
Chamber located in bearing support housing
Primary Lubricate drive gear and load adapter bearings 0.5
Chamber
Primary Inspect and adjust or replace ground brush 4.0
Chamber assembly; replace ground brush if greater than 50%
(CRITICAL) wear
Primary Inspect cooling water hoses and pipes for wear, 2.0
Chamber cracking, and leaks. Also inspect hydraulic fittings
and hoses for same
Primary Inspect electrical power connections for signs of hot 2.0
Chamber spots and general cleanliness around points
required for maintaining electrical isolation
GSC Inspect flanges, fittings, and hoses for leaks 1.0
STC Inspect flanges and fittings for leaks and hoses for 1.0
mechanical integrity
Slag Collection Lubricate gear boxes from external fitting 0.5
Total Per 240 hour Campaign 27.14
Maintenance
hours

Other critical components that are inspected are listed in Table 7. Where Retech
has limited critical component analysis, vendors are used to inspect and give
recommendations for those components.

Table 7. Other Critical Components, Retech PACT-8

Subsystem Component Maintenance Interval Performed by

(experience)

Control MCC Annual Retech OEM

Power Power Supply Annual Retech OEM

Slag Cooling Crane Quarterly Plant Personnel

Slag Collection Load Cells Quarterly Vendor

Temperature Thermal Couples Campaign, Quarterly Plant Personnel

Purge Rotometer Annual Calibration Vendor or Retech QA

Pressure Gauges Annual Calibration Vendor or Retech QA

Off-gas Bag-house Campaign, Annually Vendor, or Plant

Personnel

Off-gas HEPA Campaign, Annually Vendor, or Plant

Personnel

Off-gas Pack-bed scrubber Campaign, Annually Vendor

Off-gas ID Fan Campaign, Annually Vendor

Off-gas Re-heater Campaign, Annually Vendor or Retech OEM

3.2 Personnel Required for O & M?

 Table 8 outlines the answers to these questions. The Retech PACT-8 is a large
research and development-processing unit that carries out complex operations
and should be considered unique when compared to commercial equipment.

Table 8. O & M Personnel, Retech PACT-8 Integrated System

Item Description Comment

Operation staff 3 to 4 per shift Consistency can be specific to defined roles

such as torch operator, feeder operator, Off-
gas specialist, Test Engineer. Retech
operators are trained and perform all
operational roles

Record of yearly Nominal at 18,000 hours 12 operators (4 per shift, 24-hour cycle) x
man-hours for 1,500 hours = 18,000 total operational man
operation hours and nominal 24,000 paid hours

Number of 3 full time, 1 part time 3 full time people operate and maintain the
maintenance staff Retech PACT-8 during operational cycles. 1
part time electrical technician (OEM) who
usually is an operator.

Man-hours periodic Mean value for 1998- Periodic maintenance is based on campaign
maintenance 2000 = 425 hrs testing for the Retech PACT-8 including
quarterly and annual maintenance functions.

Man-hours Mean 1998-1999 = 235 Unpredicted maintenance is for the Retech

unpredicted hrs PACT-8 and is related to research and
maintenance development production scale testing.
Mean 2000-2001 = 86
hrs

Availability 1998-1999 = 82.0% 1998-1999: 3000 nominal hours operation +

periodic and unplanned maintenance = 3660
2000-2001 = 85.4% hours, availability = 3000/3660 x 100 =
82.0%. 2000-2001: (3000)/(3000+425+86) x
(Production scale R & D) 100 = 85.4%. These values are related to
research and development production scale
testing.

3.3 How long does it take to replace an electrode?

 On a PACT-8 system it takes two people about an hour to change an electrode
unless the furnace is operating with radioactive material. In the latter case, it
takes about six hours.

4.0 LICENSING QUESTIONS

4.1 What sort of documentation can Retech provide?

Licensing processes are conditioned by country specific procedures. Retechs

operation and maintenance manuals typically contain of the order of 1200 pages
of information. Records of documentation, personnel and man-hours involved in
previous licensing processes are available and can be collected if necessary as
reference data.

4.2 Can Retech assist in qualifying the process and the slag product?

Yes. The entire process has been qualified several times in the past as part of
the licensing process of our customers for their PACT systems.

The qualification of the final product could be done based on:

1. Records from test and development programs in the past

2. Available data from various test programs

3. Additional tests performed in PACT systems on predetermined waste mixes

using surrogate waste products

4. Analytical data on samples taken, and

5. Demonstration of product characteristics based on the broad set of available

data and scientific literature.