The overall objective of this project is to demonstrate greater than 99.9999% destruction and removal of per- and polyfluoroalkyl substances (PFAS) in aqueous film-forming foam (AFFF) using the thermal plasma arc free radical gasification technology (FRG technology) designed by Responsible Energy. The FRG technology is proven to break carbon-fluorine (C–F) bonds in PFAS via thermolytic, photolytic, and free radical reactions, thereby achieving complete mineralization. This is facilitated through the continuous thermal plasma arc process of the FRG technology, the patented reactor chamber design, and the reactor metallurgy. Workup testing will be performed to establish steady-state reactor conditions and optimize reaction stoichiometry to achieve complete mineralization of the C–F bond in AFFF using FRG technology. This optimization/workup testing will ensure a consistent and uniform supply of feed to the reactor and maintain an appropriate residence time. The destruction and operations capabilities will be determined by evaluating PFAS mass removal efficiencies (destruction and removal efficiency [DRE], destruction efficiency [DE], and fluorine mass balance) to demonstrate the effectiveness of the FRG technology. The project will also include a comprehensive analysis of the energy and chemical consumption, providing clear estimates of both the capital expenditure and the operational expenditure needed for the destruction of AFFF at sites using this technology.

The FRG technology uses a thermal plasma arc process, where the liquid waste is forced into direct contact with a thermal plasma arc under high turbulence and ambient pressure while maintaining an ideal residence time of approximately (~) five seconds. The thermal plasma arc can generate bond decomposition energy greater than 1,000 kilojoule per mole via thermolytic, photolytic, and free radical reactions. This process converts organo-fluorine waste into hydrogen, and carbon dioxide, and fluorinated species into hydrogen fluoride (HF) in the reaction zone. The technology is designed to operate continuously to enable high throughput with high DRE. The reactor material is designed to be corrosion-resistant to the destruction byproducts of PFAS. Responsible Energy has successfully proven the performance of this technology for treating diverse waste streams of organo-fluorine, chlorine, sodium, and nitrogen-bound organic molecules at flow rates ranging from 30 gallon per hour (GPH) to 100 GPH. The downstream emission control process further removes the HF gas from the flue gas via an attached wet scrubber. In the scrubber, HF gas and small portions of other generated acidic compounds are sequestered as sodium fluoride and other respective salts, which are subsequently removed. 

This demonstration will help establish FRG technology as a cost effective, potentially modular (pre-engineered and prefabricated), and highly efficient thermal destruction technology that can mineralize PFAS and other organic components in AFFF concentrates. Unlike most other destructive technologies, the FRG technology operates at near-ambient pressures in an open-ended system, so potential pressure-induced operational risks are avoided. The FRG technology is unique because it can intake a broad range of wastes at the same time while still achieving the desired DREs and DEs. This project will help optimize the FRG technology for field-scale applications, with anticipated commercial availability. Successful implementation of this demonstration holds profound implications for improving the DoD's management of PFAS, directly addressing mission readiness by safeguarding the warfighter and communities. (Anticipated Project Completion - 2026)