ROTARY KILN INCINERATION SYSTEMS

Transcription

1 ROTARY KILN INCINERATION SYSTEMS GAS AND OIL FIRED SYSTEMS 12 Tons Per Day Rotary Kiln System Manual Feed Type Shown Hitemp Technology Corp Rotary Kilns, Thermal and Catalytic Oxidizer Systems P.O. Box 903, Flemington, NJ Fax:

2 Typical Rotary Kiln Solid Waste Incineration System The following information covers HTT RKS (Rotary Kiln Systems). The RKS units will easily handle the type of waste materials you described. HTT is a progressive company with many years of experience in fume and solid waste destruction. We have developed technology for meeting the worlds needs using readily available components, to both decrease delivery time and initial costs. We offer both rotary kilns and modular stepped hearth units that are very competitively priced. Because this system is designed for export and installation overseas, some of the items normally included in the package are not included in the price. These items are to be supplied by the customer onsite. Suggested pricing is shown. 1. Refractory lining of Rotary Kiln. $ US 2. Support columns for kiln and components. $ 10,000 US 3. Pollution control equipment $ 100,000 US 4. Monitoring equipment $ 10, Material feed System $ 50, ,000 US 2

3 ROTARY KILN INCINERATORS We offer both Stationary Hearth and Rotary Kiln Systems with models ranging from 200-4,000#/hr. The term Rotary means that the primary ignition chamber revolves and mixes the waste material. This increases the speed of the burning process by bringing unburned materials to the surface and into the flame. The Rotary action also moves the ash down the chamber into the drop out area and into a standard waste container that can be supplied by and picked up by your local hauler. For continuous service of solid waste we can offer the option of a screw feeder. With this feed device you can load continuously. A storage hopper attached to the feeder will allow you to operate continually for hours without attendance. The components are designed as modular units to allow for shipping by truck. The HTT-3000R2 series and larger utilize dual primary chambers to achieve the desired capacity yet still allow for shipping by truck or SEALAND container. The capacity of each unit is based on a heat value of the waste material averaging 6,000-7,000 BTU/lb. as in type 0-1 waste. For different materials such as those containing high percentages of plastics, the capacity value is adjusted. 3

4 HTT ROTARY KILN FURNACE PRICING AND TERMS The HTT Rotary Kiln Pyrolizing Furnace is the best method of handling sludge and heavy liquids. All components are modular and can be built using the structural frame of a standard SEALAND type trailer. This will ease component shipment and installation. The system as quoted will be equipped with the following components: 1.0 Storage Hopper and Screw Feed System (Optional) 2.0 Rotary Kiln Primary Chamber 3.0 Secondary Afterburner 4.0 High Pressure Drop Venturi w/ Packed Tower Scrubber (Optional) HTT lbs./hr R - (Diameter/Length) HTT 500R-48/240-G 500 #/hr 6 TPD $ 90, ($ US) HTT 1000R-72/240-G 1,000 #/hr 12 TPD $ 230, ($ US) HTT 2000R-96/360-G 2,000 #/hr 25 TPD $ 340, ($ US) Dual Rotary Kiln w/afterburner HTT 4000R2-96/360-G 4,000 #/hr 50 TPD $ 550, ($ US) HTT 8000R4-96/360-G 8,000 #/hr 100 TPD $1,100, ($ US) Note: Processing rates may be different than that of solid waste rates. Scrubbers and charging systems must be sized based on the application. The chambers are fabricated and shipped by common carrier. TERMS AND CONDITIONS OF SALE TERMS: 35% with order, 35% when fabrication period is 50% completed, 30% after customers inspection prior to shipment and delivery. Overseas projects will require an irrevocable letter of credit. Delivery: Export Freight not Included in price. Allow 2-4 weeks for approval drawings. Equipment will be ready for shipment weeks after the receipt of valid purchase order, progress payments, and all required approvals. Installation: HTT will assist during customers installation and startup at a per diem rate of $1, US. Not included are travel and living expenses. Warranty: HTT Guarantees that the unit will be free of defects in materials and workmanship for one (1) year from the time of delivery. Components purchased by HTT for use in making a complete package will be limited to the warrantee offered by those specific manufacturers. HTT shall assist in the applications for permits as required. Excluded Items: HTT shall supply only the items described above. Additional items required are to be supplied by the customer. Such items may consist of emission testing, building, modifications to support pad, electrical feeds, tipping floor, boiler feed system, ash container, overhead crane capability, etc. 4

5 HITEMP TECHNOLOGY CORP HTT ROTARY FURNACES TYPICAL SYSTEM DESCRIPTION 1.0 Screw Feed System - (Optional) Waste will be fed to the Ignition chamber by a variable speed screw feeder. Waste will be deposited into a large capacity feed hopper. This hopper will allow the unit to operate unattended for long periods of time. The screw will meter the material from the feed hopper to the pneumatic injector. Rotary action forces the waste sludge into the Ignition Chamber thereby maintaining proper flow and eliminating the possibility of ignition of the waste within the feeder. Thermocouples interlocked to the control panel and the feeder will prevent operation except at set temperatures on the control panel. Temperature interlocks on the feeder will detect heat or fires and spray water automatically should it occur. Temperature sensors will limit the feed system thus maintaining a constant burn rate. 2.0 Primary Ignition Chamber - The rotating chamber is proven to be one of the best units to handle waste materials. The Primary chamber shall be constructed of rolled carbon steel plate. The chamber shall be complete with the required structural supports, support channels, and flanged connections. Connected to the primary chamber shall be a stationary cylindrical mating section. This section contains the inspection door, blast gate peep sight, burner, and connecting duct to the secondary chamber. The chamber shall be lined with a combination of both insulating and hard faced refractory materials. The refractory shall be suitably supported with stainless steel anchors for long life. The chamber shall be complete with access doors for inspection and maintenance. 5

6 At the duct outlet connection shall be air nozzles connected to a high pressure blower with actuated damper. As the combustion rate of the material increases, the damper is opened thus maintaining a proper air ratio for complete combustion of the smoke and particulate. The materials to be consumed are charged into the rotating refractory lined cylindrical chamber which has been pre-heated to normal operating temperature. The burner ignites the material and the combustible components such as smoke and volatilized gases. The action of the burner and use of fuel is normally intermittent, but depends upon the materials to be consumed. The Primary Ignition Chambers consume the material thermally and as a result of the rotation action, continuously delivers the non-combustibles (including ash) to an exterior receptacle. The smoke (unconsumed particulate) and gases are drawn into a second, but stationary chamber for final thermal oxidation. The ash and unburned materials remain in the primary chamber and settle to the bottom. As the chamber rotates, the action transports the ash and other non- 6

7 combustibles to the opposite end where they exit through a slot at the edge of the kiln and into an ash receptacle. Rotating this chamber during the burning process exposes new surfaces to be burned while breaking up the insulating ash layer. The thick refractory lining retains the desired pre-set temperature and continually moves under the burning material while over-fire air supports the combustion from the other side. A controlled air condition is maintained and the reduction of the waste product is semi-pyrolytic. Non-combustible materials and ash are continuously discharged and collected from the system. During normal operation no ash will have to be handled, preventing a potential health hazard. 3.0 Afterburner Chamber - The afterburner chamber shall be constructed of rolled carbon steel plate. The chamber shall be complete with the required structural supports, and flanged connections. The chamber shall be lined with a combination of both insulating and hard faced refractory materials. The refractory shall be suitably supported with stainless steel anchors for long life. The chamber shall be complete with access door for inspection and maintenance. 7

8 The Secondary Combustion Chamber operates at a higher temperature than the Primary Chamber and consumes the gases, smoke, and particulate. The volatile products resulting from the thermal reduction process are drawn into the secondary combustion chamber to be further oxidized. The burner is positioned so that the incoming gases and particulate pass through the flame and are ignited. The direction of the flame assures a swirling, vortex action providing maximum turbulence and residence time to the burning mass. The Rotary Kiln System will be equipped with modulating Natural Gas Burners with flame safety. The burners will be mounted to the outer shells of both chambers and are directed to assure maximum turbulence. Also included will be complete gas valve trains. The system shall be monitored by the use of a computerized Programmable Logic Controller (PLC). The PLC shall monitor temperatures, feed rates and cycles, ram charger functions, external equipment conditions, and safeties. System modifications may require only simple program changes rather than extensive field modifications during system upgrades. The PLC is designed to permit the proper and safe operation of the unit and to provide the operator with various options to broaden the versatility of the unit. The control panel includes the various electrical controls to assure a safe start-up and pre-heat of the chambers and operation of the Kiln. Both under and over temperature limit set point circuits are interlocked with the feeding mechanism to assure control in feeding waste materials. The Rotary Chamber may be operated in a fixed mode, or rotated at various speeds, depending upon the materials being fed. The PLC is designed to interlock feeding of charges until the conditions of both chambers are brought up to pre-defined temperature levels. The feeding process will also stop if, during operation, conditions in any of the combustion chambers deviate from these pre-established conditions. Operating temperatures in both chambers are controlled by adjusting the fuel-to-air ratio according to temperature monitors in the designated flue gas flow areas. Temperature is sensed by Chromel Alumel Type K thermocouples which are connected to the system temperature controls which regulate the auxiliary fuel. Correct temperature setting is such that the fuel will preheat the Secondary Combustion Chamber to the required temperature level before feeding is allowed. When the feed rate satisfies the heat demand, the auxiliary fuel is cut off. The feed rate is further modulated to maintain required process temperatures. If the heating value of the waste material lowers, and feed alone cannot satisfy the heat 8

9 demand, auxiliary fuel is introduced automatically to make up for the deficiency. If proper fuel is not available for the system's operation, the system will shut down automatically. The Rotary Kiln Incinerator shall be equipped with a temperature controller which will shut off the feed when present operating conditions are not met. Feeding will not resume until conditions have been corrected. In cases of mixing various fuels, it should be remembered that feeds of a heat value below 5,000 BTU per pound may not be self-supporting in burning and may require auxiliary fuel assistance to maintain temperatures at the desired level. For the purpose of control consideration, the Rotary Kiln Incinerator is a "constant flow" system. The total flow of exhaust gases is preset by fan selection and adjustment of fan speed. The fuel is modulated to control excess air content and temperature of the resulting products of combustion. 9

10 There are limits to which the level of change of fuel supply can be made without adverse effect on the process. Not enough fuel will result in temperatures too low, too much fuel will result in unstable and incomplete combustion. The control of deficient feed is elementary and can be compensated for by auxiliary fuel. The maximum feed rate is preset and the system will control minimum and preset maximum rates. Fortunately, overcharge may seldom occur, even without preset limit. Before an overcharge can occur, overheating is detected and the equipment is shut off on an emergency basis. The ash shall drop out of the primary chamber once the proper burn time has elapsed. Directly below the opening shall be a collection container or optional ash conveyor to feed a container. The ash shall be cooled with water spray prior to removal for emptying. Customer is responsible for the furnishing of this container. As the container shall be located below the primary chamber, the kiln would be raised or the ash receiver placed in a pit, or a conveyor system may be used. The orientation is optional and the foundations shall be part of the customer supplied footings. 10

11 OPTIONAL COMPONENTS 4.0 High Pressure Drop Venturi w/ Packed Tower Scrubber and ID Blower One (1) HTT V-PTS -D/ L VOC system that will remove HCL vapors from the exhaust gas stream. The system shall include the fabricated 316L SS chamber lined with high temperature ceramic fiber. We also offer the only 5-Year Warranty in the business. The burner will heat the vapor stream to 1800F. These gases will then pass into the quencher and the scrubber units. The system shall be able to destroy the gases and remove the HCl with a high destruction efficiency. The stack connection will attach to a water spray cooling section for cooling the gases. The fresh water makeup is located in this section. The gases are cooled prior to entering the venturi and scrubber. A temperature sensor is located at the quencher exhaust and shall monitor effectiveness and temperature limits. A High Pressure Drop Venturi will entrain the particulate in the scrubber water for further processing. The scrubber water should be neutralized and the particulate filtered to collect the fines. The scrubber system will consist of the liquid storage/recirculation tank and the scubber tower. The scrubber will be designed to bolt directly to the recirculation tank flange connection. The unit will be designed with an upward flow. Access is with an 18" inlet plenum, a 36-48" packing area, a spray plenum section, spray nozzles with blind flanged access, a 10-12" demister pad, a 12" outlet plenum and flange connection sized for customers ducting. The outlet duct connection will be on the side or top of the outlet plenum. Material of construction will be 316L shell. This approach will allow us to have strength, heat resistance, and acid resistance. Connections for access to the unit are, matching inlet and outlet flanges, supports for packing plate, packing fill and removal flanges, blind flanges for nozzle insertion and all nozzles and internal piping, demister pad and supports, and access cover on the top of the scrubber. System components shall include, recirculation pump, pump pressure switch, reservoir tank, interconnecting CPVC piping, spray nozzles in top of the chamber, and demister pad. And connection for the induced draft blower and exhaust stack. 11

12 TYPICAL HTT SOURCES OF SUPPLY 1. Refractory Materials - AP GREEN - CARBORUNDUM 2. System Controls PLC - Allen-Bradley SWITCHES - Square D, Allen-Bradley RELAYS - Square D, 3PDT W\Neon indication PANELS - Hoffman, NEMA 4 CONTROLLERS - Honeywell, UDC Heat Exchanger - DES CHAMPS LABORATORIES, INC Catalyst Bed - METPRO CORP Fabrication - Rose Corporation Dyna Steel Warranty: HTT shall warrant that the system described shall meet all pertinent emissions codes per the submitted documentation. HTT shall warrant that the equipment furnished shall be free of defects in materials and workmanship. This warranty shall cover parts manufactured by HTT for a period of FIVE YEARS. HTT shall limit warranties for parts not manufactured by HTT to those offered by the respective manufacturer. Defective components shall be repaired or replaced per the manufacturer's warranty to be installed by customers personnel. Documentation: HTT shall provide operating and maintenance manuals that include operating instructions, component data, and drawings. *SPECIAL NOTE 1. Customer shall be responsible for all emission testing, and site modifications, field ducting, piping and wiring, mounting and wiring of remote panels, monitoring equipment, and all starters, VFD, and 3 phase electrical work. No platform is provided for stack gas sampling. 2. HTT shall assist in the design and layout and also provide the time of an on site technician as required during system installation at no charge. 3. Unit is shipped Freight Allowed. 4. Customer shall be responsible for providing, duct and final connections, electric and the gas to the burner train, and plant air regulated as required. Remote panel will be provided for installation by others. 12