Current Status of PCB Treatment in Japan

Yukio Noma
Fukuoka Women’s University
1

1. Background and Progress of Measuresagainst PCB
2. Treatment for High Concentration PCB
Wastes by Japan Environmental Safety
Corporation (JESCO)
3. Scheme to Achieve Complete Treatment ofPCB Wastes
4. Basel Technical Guidelines on New POPs
2

1. Background and Progress of Measures against PCB
1954

Start of domestic production （Kanegabuchi Chemical、Mitsubishi Monsanto Chemical）

1968

Outbreak of Yusho incident

1972

Prohibition of production and new use of PCB by Administrative Direction.
The users were obliged to keep PCB or PCB-use devises .

1987

Kanebuchi Chemical disposed of 5,500 t liquid PCBs by high temperature incinerator (1400 ℃)
Electric Insulating Oil Foundation tried 39 times to construct PCB treatment
facilities by high temperature combustion method, but all failed in vain.
Around 11,000 PCB-use devises were lost for about 30-years storage period
and it raised concerns about pollution. (1998)
Addition of chemical decomposition methods, Setting of disposal standard ofPCB-oils (<0.5ppm). Wastes Disposal and Public Cleaning Law (1998)
2001: Japan ratified Stockholm Convention (Complete the treatment of PCB by 2028 )2001: Enactment of “Law concerning Special Measures for Promotion of Proper Treatment of PCB
Wastes”

Complete the treatment of PCB by 20162004: Construction of treatment facility by Japan Environment Safety Corporation (JESCO)
Start of treatment of high-concentration PCB wastes
2012: Amendment of “Law concerning Special Measures for Promotion of Proper Treatment ofPCB Wastes”

Complete the treatment of PCB by 2027

3

PCB Production, Usage per Application and Stockpiles in Japan
Domestic production
58,787t (up to 1972)

Export 5,318t

Import 1,048tDomestic usage 54,001t
Others 2,910t

For electrical appliances such astransformers, capacitors, etc.
37,156t
For heat conducting
medium 8,585t

For carbonless coated back paper
5,350tAmount of PCB wastes in storage and PCB-containing devises in use, March 2002
In storage
15077 units
242339 units
38121 units
1367724 units
1772563 units
4824973 pieces
171 t
163,632 t
662 t
239 t
19,005 t
233,524 t

In use2639 units
31653 units
453 units
33093 units
1952500 units
664947 pieces
79 t
3t
8,928 tClosed system

Type of waste or equipment
High-voltage transformers
High-voltage capacitors
Low-voltage transformers
Low-voltage capacitors
Pole-mounted transformers
Fluorescent ballasts
PCB
Waste oil containing PCB
Carbonless coated back paper
Waste cloth
SludgeOther appliances, etc.

4

2. Treatment for High Concentration PCB Wastes byJapan Environmental Safety Corporation (JESCO): Area assigned to eachfacility

Hokkaido Facility

Muroran City, Hokkaido
Operation to start: May 2008
Capacity: 1.8 t PCB/day
Method: Alkali metal reduction

Kitakyushu Facility

Kitakyushu City, Fukuoka
Operation started: Dec. 2004
Capacity: 1.5 t PCB/dayMethod: Alkali metal reduction

Osaka Facility

Osaka City, Osaka
Operation started: Oct. 2006
Capacity: 2 t PCB/day
Method: CHD method

Tokyo Facility

Koto-ku, Tokyo
Operation started: Nov. 2005
Capacity: 2 t PCB/day
Method: Subcritical water oxidation

Toyota Facility

Destruction methods adopted:
 Alkali metal reduction method by 3 facilities
 Catalytic hydrodechlorination (CHD) method by 1 facility
 Subcritical water oxidation by 1 facility

Toyota City, Aichi
Operation started: Sep. 2005
Capacity: 1.6 t PCB/day
Method: Alkali metal reduction

5Treatment Procedure for Typical High-voltage Transformer
Open the lid andextract PCB oil
Decomposing
treatment

PCB oilContainers of transformer, etc.
Metal container

Transformer

Main body

Filled with
PCB oil for
insulation

Cleansing Solvent

Iron core
Ceramics
Coils

Copperwire

Paper

Insulator

Wood
Terminal
Filled with
PCB oil for
insulation
Container

Separating
ShreddingCleansing

PCB liquidlevel
Iron-coreIron-core
coil
Typical high-voltage transformer

6Outline of dechlorination by Sodium Dispersion method
Dechlorination reaction

Completion of chemical reaction

Solid residueNa

Polymer ofbiphenyl

Insulation

Treated oil7

Line for Disassembly of Large
Transformers
Control Zone
Level 3

Disassembly ofTransformers

The workers operate the equipments by remote control on control
panel as far as possible.
When workers enter the room, they attach Respiratory protective
devices and Chemical protective clothes.

8Glove Box

Control Zone
Level 2

Disassembly ofCapacitors

9Treatment for Solid-type PCB-containing Wastes byPlasma Melting Decomposition
Hokkaido Facility
Muroran City, Hokkaido
Operation to start: September 2013
Method: Plasma melting decomposition
Capacity: 12.2t PCB-contaminated wastes/day

Kitakyushu Facility
Kitakyushu City, Fukuoka
Operation started: July. 2009
Method: Plasma melting decomposition
Capacity: 10.4t PCB-contaminated wastes/day
Fluorescent ballasts

Carbonless coated back paper
Waste cloth, Sludge, Other small electrical devices

10Plasma Melting Decomposition Method
On-line Monitoring

Exhaust gas
treatment
equipment

Plasma torch>15000 ℃

Ventilation
Maintained negative
pressure within equipment

CO2, H2O, HCl

Drums or Pails
Ballasts in pails

Moltingslag bath>1400 ℃

Slag

Plasma Melting
Decomposition Furnace

Melting state insideplasma melting
furnaceSlag11

Safety Design Concept
1. Safe design oftreatment process
2. Operation Monitoring
System
3. Fail-safe Functions
4. Safety Nets

・Cooperation with the location
area and related authorities
・Information disclosureManaging systemfor operations,maintenance andsecurity
Ensuring safetyof the workers
12Examples of Safety Nets
Multiple Measures toPrevent Underground
Infiltration

Negative
Pressure
Control

PCB Decomposition
Negative
Exhaust of Nitrogen,
Facilities
Pressureetc.

Leak-proof facilities
and piping↓
Oil Pan↓Oil Retraining Dikeand Impermeable
Floor（Or Shield Floor）

Air pressure of negative
pressure rooms arecontrolled according to
specified control levelof the rooms

Negative
Pressure
Cleansing
Facilities Exhaust of Nitrogen, etc

ShieldOil ExtractingandDisassembling
Facilities

Exhaust from
ShieldActivatedCarbon

ShieldFloor（Doublestructure）

Activated
CarbonNegative
Pressure

ShieldExhaust Treatment
Equipment

Oil PanExhaust Gas Treatment

Exhaust Gas
Exhaust gas is treated inexhaust treatment
equipment, andfurthermore, filteredthrough activated carbon
as a safety-net

PCB wastes are carried directly
inside the treatment building
Carrying in, Acceptance andInspection

Exhaust Gas Monitoring
Exhaust gas is monitoredonline and offline, andonly released if it meets
standards

13

Negative Pressure Control
NegativePressure
Control：Higher Negative Pressure Level (Air does not flow to lower level)-7mmAq-4mmAq-2mmAqShield（Stainlesssteel inner surface)Control Zone
Level 2Control Zone
Level 3At operations where PCB
is handled, a shield covers
the area, to protect theworkers from exposure toWindow PCB.

Control Panel

Control Zone
Level 1

BufferRoom

Buffer rooms protect
workers from effects fromsudden change of pressure
when entering different
control level zones

RemoteControl14Work environment in the extraction of PCB oilfrom transformer
JapanOverseas

Control Zone
Level 3Work with simple equipment in an
open space

・Work in the Shield room
・Negative Pressure Control:-7mmAq
・With Respiratory protective devices andChemical protective clothes
PCB≦0.01mg/m3
Dioxins≦2.5pg-TEQ/m3

15On-line Monitoring
Exhaust gas
PCB≦0.01mg/Nm3
Working atmosphere PCB≦0.01mg/m3

Exhaust gas and working atmosphere is monitored on-line.
Should any abnormal events occur, prompt action will be taken.
Exhaust gas
Workingatmosphere(Reference)

Constantmonitoringat central
control room

･Automatic sampling
・Automaticconcentration analysis(参考)(Reference)

1600

Standard reference
internal gas

5PCB
5Cl-PCB

Figures from onlinemonitoring andanalyzed figures fromofficial method(conducted offline)
show a strong
correlation

1200

signal strength



800

3PCB
3Cl-PCB
22Cl-PCB
PCB

400

025

Appearance of equipment

44Cl-PCB
PCB

28

31

66ClPCB
PCB
34

time-of-flight (μs)s3740

Output example of monitoring data
16

GPS System for Ensuring Safety ofPCB Transportation
Communications
CenterCommunication satellite

GPS satellite
System datacenter
Vehicle with GPS antennaTransportation company

PCB wasteholderJESCOThe Internet
Inquiry of a manifest slip

Transportation status list

Vehicular swept path

Daily report (Available fortransportation company only)

17

Loading of PCB wastes into a Vehicle
Loading of a Capacitor into Inner Tray

Loading of Inner tray into Leakproof Metal Container
One leakproof metal
container can hold up to4 inner trays.

Crane

Capacitor

Inner Tray

Inner Tray

Leakproof metal
container

GPS antenna

Waterproof Sheet

Leakproof metal
container18

Amount of PCB Wastes Treated at JESCO Facilities
FacilityType of waste
Unit FY2004 FY2005 FY2006 FY2007 FY2008 FY2009 FY2010 Total Target Progress
Kitakyushu Transformers
units
50239
241
214
178
258
303 1,483
3,023
49.1%
Capacitors
units
200
755
1,038
1,595
1,383
4,053
6,769 15,793 43,247
36.5%
drums
PCB oil
13
63
38
22675
116
333
PCB contaminents tons
10.4 144.283
155
PCB decomposition tons
9.5
55.8
67.7
78.6
65.2
143.9
249.3 669.9
ToyotaTransformers
units
4977
191
304
286
187 1,094
2,543
43.0%
Capacitors
units
1,185
1,605
2,289
3,836
4,753
3,770 17,438 47,775
36.5%
drums
PCB oil
33
11530
4966
194
PCB decomposition tons
31.5
63.7
115.8
185.6
198.5
159.9 754.9
TokyoTransformers
units
1190
82
238
268
357 1,064
4,231
25.1%
Capacitors
units
454
46
687
2,256
3,395
4,801 11,639 72,069
16.1%
drums
PCB oil
74
0
69
233
447
414 1,237
PCB decomposition tons
30.7
26.0
52.4
157.8
272.9
330.7 870.5
Osaka
Transformers
units
76
290
289
404
376 1,435
3,271
43.9%
Capacitors
units
1,941
4,875
5,136
5,692
6,557 24,201 65,109
37.2%
drums
PCB oil
5253878584361
PCB decomposition tons
33.9
165.7
181.9
236.5
205.3 823.3
Hokkaido
Transformers
units
19138
350
632 1,139
4,146
27.5%
Capacitors
units
224
1,822
4,803
6,630 13,479 53,809
25.0%
drums
PCB oil
47
23
2
34
106
PCB decomposition tons
11.6
65.0
194.9
261.8 533.3
Transformers
units
Total
50
407
394
796
1,147
1,566
1,855 6,215 17,214
36.1%
Capacitors
units
200
2,394
4,630
9,670 14,433 22,696 28,527 82,550 282,009
29.3%
drums
PCB oil
13
170
91
206
379
658
714 2,231
PCB contaminents tons
00000 10.441 144.283
155
PCB decomposition tons
9.5
117.9
191.3
424.0
655.4 1046.7 1207.0 3,651.9

193. Scheme to Achieve Complete Treatment of PCB Wastes
Intentionally used PCBcontaining devices

Intentionally used PCBcontaining devices

Transformer,
Capacitor

Fluorescent ballasts
Carbonless paper
Waste paint, coating

About 340,000 units
PCB conc.: ～Several ten %Fluorescent ballasts:
6 million units
PCB conc.: ～Several %About 40% of
PCB wastes weretreated

Secondary polluted waste
generated with manufacture ofPCB

Almost Stored.
Treatments have been
started since 2009

Waste recognized before Law establishment

SludgeWaste cloth
Waste Cloth: 339 tons
Sludge: 34,000 tons
PCB conc.: ～Several %Almost Stored

Operation waste
generated with PCB treatment

Unintentionally mixed trace amount of PCB-containing
devices

Activated carbon
Chemical protective implement
Waste paper, plastic, etc

Other electrical devices
except for pole-mounted
transformers

15,000 drums
10000 mg/kg～0.5mg/kg

1.6 million units
100 mg/kg～0.5mg/kg

Almost Stored

Almost Stored.
Treatments have been
started since 2009

Waste became clear after Law establishment

Pole-mountedtransformers
3.82 million units
100 mg/kg～0.5mg/kg

About 60% of
PCB wastes weretreated by thepower companies
themselves

Liquid PCB waste: Favorable.
High concentration PCB wastes : Behind. Disassembly and washing take much time.
Solid PCB wastes: Stored in many numbers. Start since 2009, Only 2 Plasma Melting Facilities.
Operation wastes : Generated by JESCO. Stored in large quantities.
Other electrical devices : Stored in many numbers. Start since 2009. Need much time for treatment.
High-concentration PCB wastes ( >5,000mg/kg) : JESCO
Low- contaminated PCB wastes ( ≦5,000mg/kg) : Private incinerators

New deadline of complete treatment (Amended Law, 2012.12) : 2027.3.31

20

Framework for PCB waste treatment and the method
PCB concentration～several ten %（ several 100,000mg/kg)

Intentionally used PCBcontaining devices

Intentionally used PCBcontaining devices

Secondary polluted
wasteTransformer,
Capacitor

Fluorescent ballasts

Sludge of amanufacturing
process

Fluorescent ballasts
Carbonless paper
Waste paint, coating

Cloth pieces
Other sludge～several %（ several 10,000mg/kg)～1%（ 10,000 mg/kg)

Operation waste

Chemical protective implement（ Demolition line）
Chemical protective glove
Activated carbon（ accident）

Activated carbon（ afterScrubber）
Chemical protectiveimplement
except for Demolition line
Waste paper
Waste plastic, etc
Activated carbon（ Ventilation）～1000 mg/kg～100 mg/kg～0.5mg/kg

・JESCO(5 Facilities)
・Non-combustion
methods

・JESCO(2Facilities)
・Plasma melting
methods

High-concentration PCB wastes ( >5,000mg/kg) :JESCO
Low-concentration PCB wastes ( ≦5,000mg/kg) : Private
incinerators authorized by Ministry of Environment

Unintentionally mixed trace amount of PCBcontaining devices

・JESCO(2Facilities)
・Plasma melting
methods

Other electricaldevices except f orpole-mounted
transformers

Pole-mountedtransformers

・Power companies
・Chemicaltreatment methods

・private company
・Combustion methods
・Low-concentration PCB wastes ( ≦5,000mg/kg)

21

Treatment for Low-contaminated PCB Wastes
Other electrical devices contaminated with trace amount of PCB
Operation wastes (generated with treatment ≦5000mg/kg)

Waste activated carbon

Chemical protective masks

Chemical protective clothing

Chemical protective shoes

Combustion methods・ Conduct verification tests by private incinerator
・ The facilities with the sufficient result of the test are Authorized by Ministryof Environment
・Only authorized incinerators can treat low-contaminated PCB wastes

22Incinerator with Stationary Furnace
Waste OilLow-concentration
PCB OilExhaust Gas
Treatment

DirectInstallation

Secondary
Combustion
Furnace

KilnDirect
Installation
Equipment

Stationary Furnace
23

4. Basel Technical Guidelines on New POPs
Existing Technical Guidelines for the Environmentally Sound
Management of POPs Wastes
The technical guidelines for the ESM of POPs wastes were developed by the Basel
Convention and adopted by its COP7 and COP8 in 2004 and 2006, respectively.

Guideline I

Updated general technical guidelines for the ESM of POPs wastes
Module a – Stockholm and Basel Convention mandates on POPs wastes
Module b – ESM of POPs wastes
Module c – Environmentally sound disposal of POPs wastes
Module d – POPs wastes: Remediation of contaminated sites, health andsafety, emergency response and public participation

Guideline II

Updated technical guidelines on PCBs, PCTs or PBBs

Guideline III Technical guidelines on DDT
Guideline IV Technical guidelines on unintentionally produced PCDDs, PCDFs,HCB or PCBs
Guideline V

Technical guidelines on POPs pesticides
All the guidelines are available from the website of the Basel Convention:
http://www.basel.int/meetings/sbc/workdoc/techdocs.html

24

New POPs
Pesticides:
Alpha hexachlorocyclohexane, Beta hexachlorocyclohexane,
Gamma hexachlorocyclohexane (Lindane), Chlordecone,
Endosulfan, Pentachlorobenzene
Brominated flame retardants:
Tetrabromodiphenyl ether, Pentabromodiphenyl ether,
Hexabromodiphenyl ether , Heptabromodiphenyl ether,
Hexabromocyclododecane
Hexabromobiphenyl
Surfactants, Firefighting foams :Perfluorooctane sulfonic acid (PFOS),
Perfluorooctane sulfonyl fluoride (PFOSF)

Unintentionally produced POPs:
Pentachlorobenzene

25

Development of new technical guidelines
Technical guidelines on PFOS; Canada
Preparation of Technical guidelines for the environmentally soundmanagement of wastes consisting of, containing or contaminated with
Perfluorooctane sulfonic acid (PFOS), its salts and perfluorooctane
sulfonyl fluoride (PFOSF)

Technical guidelines on PBDEs; China
Preparation of Technical guidelines for the environmentally soundmanagement of wastes consisting of, containing or contaminated with
Hexabromodiphenyl ether, heptabromodiphenyl ether,tetrabromodiphenyl ether, pentabromodiphenyl ether andHexabromocyclododecane
26

Update of existing technical guidelines
Technical Guidelines on Pesticides; FAO

Updating of the Technical guidelines for the environmentally sound management of wastes
consisting of, containing or contaminated with pesticides aldrin, chlordane, dieldrin, endrin,
heptachlor, hexachlorobenzene (HCB), mirex or toxaphene or with HCB as an industrial
chemical, Alpha hexachlorocyclohexane, Beta hexachlorocyclohexane, Lindane, Chlordecone,
Pentachlorobenzene and Endosulfan

Technical Guidelines on PCBs; Japan

Updating of the Technical guidelines for the environmentally sound management of wastes
consisting of, containing or contaminated with polychlorinated biphenyls (PCBs), polychlorinatedterphenyls (PCTs), polybrominated biphenyls (PBBs) or Hexabromobiphenyl

Technical Guidelines on Unintentionally produced POPs; UNEP Chemicals

Updating of the Technical guidelines for the environmentally sound management of wastes
consisting of, containing or contaminated with unintentionally produced dibenzo-p-dioxins(PCDDs), polychlorinated dibenzofurans (PCDFs), hexachlorobenzene (HCB) or polychlorinatedbiphenyls (PCBs) and pentachlorobenzeneGeneral technical guidelines on POPs; Canada

Updating of the General Technical Guidelines for the Environmentally Sound Management ofWastes Consisting of, Containing or Contaminated with Persistent Organic Pollutants (POPs)
Open-ended Working Group 9: Fall 2014, COP 12: May 2015
http://www.basel.int/meetings/sbc/workdoc/techdocs.html

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