危险废物回转式流化冷渣多段焚烧系统焚烧特性研究

危险废物的处理和处置是摆在我国各级市政府面前的紧迫任务。然而我国已经运行的危险废物焚烧装置普遍存在回转窑挂壁结渣、热灼减率偏高和污染排放超标等问题,作者通过将回转窑和流化床特点相结合的方法提出了一种新型危险废物回转式流化冷渣多段焚烧处置装置。该装置采用回转窑(一燃室)、二燃室和流化床结合的热解-流化焚烧工艺,特别是采用控制窑头温度避免了回转窑挂壁结渣;采用流化冷渣装置延长未燃烬渣的焚烧时间,解决了热灼减率偏高问题;水冷式烟气急冷装置可以将烟气温度从1 100℃降到200℃,防止了二恶英的尾部低温再生成。该系统运行稳定可靠,可以处理医疗垃圾和大多数的固态和液态危险废物,实现了烟气污染物尤其是二恶英排放达到国家标准的目标。同时对该系统运行时窑头温度分布、二燃室炉膛出口氧量变化、回转窑和炉膛升温特性、燃烧室外壁温度分布等几方面运行数据都进行了详细的介绍,为危险废物焚烧炉的运行提供了宝贵的经验数据。     

Combustion modeling and performance evaluation in a full-scale rotary kiln incinerator.

This work summarizes the results of numerical investigations and in situ measurements for turbulent combustion in a full-scale rotary kiln incinerator (RKI). The three-dimensional (3D) governing equations for mass, momentum, energy, and species, together with the kappa - epsilon turbulence model, are formulated and solved using a finite volume method. Volatile gases from solid waste were simulated by gaseous CH4 distributed nonuniformly along the kiln bed. The combustion process was considered to be a two-step stoichiometric reaction for primary air mixed with CH4 gas in the combustion chamber. The mixing-controlled eddy-dissipation model (EDM) was employed to predict the conversion rates of CH4, O2, CO2, and CO. The results of the prediction show that reverse flows occur near the entrance of the first combustion chamber (FCC) and the turning point at the entrance to the second combustion chamber (SCC). Temperature and species are nonuniform and are vertically stratified. Meanwhile, additional mixing in the SCC enhances postflame oxidation. A combustion efficiency of up to 99.96% can be achieved at approximately 150% excess air and 20-30% secondary air. Reasonable agreement is achieved between numerical predictions and in situ measurements.     

Emissions of Trace Products of Incomplete Combustion from a Pilot-Scale Incinerator Secondary Combustion Chamber

Abstract

Experiments were performed on a 73 kW rotary kiln incinerator simulator equipped with a 73 kW secondary combustion chamber (SCC) to examine emissions of products of incomplete combustion (PICs) resulting from incineration of carbon tetrachloride (CC14) and dichloromethane (CH2C12). Species were measured using an on-line gas chromatograph (GC) system capable of measuring concentrations of eight species of volatile organic compounds (VOCs) in a near-realtime fashion. Samples were taken at several points within the SCC, to generate species profiles with respect to system residence time. For the experiments, the afterburner on the SCC was operated at conditions ranging from fuel-rich to fuellean, while the kiln was operated at a constant set of conditions. Results indicate that combustion of CH2C12 produces higher levels of measured PICs than combustion of CC14, particularly 1, 2 dichlorobenzene, and to a lesser extent, monochlorobenzene. Benzene emissions were predominantly affected by the afterburner air/fuel ratio regardless of whether or not a surrogate waste was being fed.     

Combined simulation of combustion and gas flow in a grate-type incinerator

Computational fluid dynamic (CFD) analysis of the thermal flow in the combustion chamber of a solid waste incinerator provides crucial insight into the incinerator's performance. However, the interrelation of the gas flow with the burning waste has not been adequately treated in many CFD models. A strategy for a combined simulation of the waste combustion and the gas flow in the furnace is introduced here. When coupled with CFD, a model of the waste combustion in the bed provides the inlet conditions for the gas flow field and receives the radiative heat flux onto the bed from the furnace wall and gaseous species. An unsteady one-dimensional bed model was used for the test simulation, in which the moving bed was treated as a packed bed of homogeneous fuel particles. The simulation results show the physical processes of the waste combustion and its interaction with the gas flow for various operational parameters.     

垃圾焚烧炉二次配风优化数值模拟

针对城市生活垃圾焚烧发电的排放问题，以重庆市某垃圾焚烧炉为原始模型，在炉膛两侧炉壁的适当位置设置二次配风口，并采用CFD（计算流体动力学）方法对炉膛内气体的二次燃烧过程进行数值模拟。通过观察对比有无二次配风以及二次配风口位置不同时炉膛内气体的温度场、气体在炉膛内的停留时间分布以及炉膛内气体的混合程度和湍动能等，重点分析了二次风在气体燃烧过程中所起的作用，并对2种不同二次配风口位置时抑制二恶英产生的效果进行了评价。通过对垃圾焚烧炉二次风的优化数值模拟，获得了适合本焚烧炉的比较合理的二次配风条件，可为焚烧炉的设计和改进提供一些有价值的参考。     

Air Pollution Acronyms

Abstract

Computational fluid dynamic (CFD) analysis of the thermal flow in the combustion chamber of a solid waste incinerator provides crucial insight into the incinerator’s performance. However, the interrelation of the gas flow with the burning waste has not been adequately treated in many CFD models. A strategy for a combined simulation of the waste combustion and the gas flow in the furnace is introduced here. When coupled with CFD, a model of the waste combustion in the bed provides the inlet conditions for the gas flow field and receives the radiative heat flux onto the bed from the furnace wall and gaseous species. An unsteady one-dimensional bed model was used for the test simulation, in which the moving bed was treated as a packed bed of homogeneous fuel particles. The simulation results show the physical processes of the waste combustion and its interaction with the gas flow for various operational parameters.     

Design of a compact dilution sampler for stationary combustion sources

The dilution sampling method simulates the rapid cooling and dilution processes after hot flue gas have left the stack. This allows gases or vapors to nucleate both homogeneously and heterogeneously, and to condense on preexisting particles in processes analogous to those that occur in the ambient environment. Using this method the authors can collect filterable particulate matter (PM) and condensible PM, that is, primary PM, simultaneously. In order to make this method more suitable for field investigation, a compact dilution sampler was developed. The sampler enhances mixing of dilution air with the stack gas, and thus shortens the length of the mixing section. The design decreases the nominal flow rate through the aging section, and accordingly reduces the size of the residence chamber. The decreased size of the sampler is suitable for field test. Sampling gas is pressured into the residence chamber, and air pressure in the chamber is micro-positive. Uncollected redundant gas is automatically discharged through unused sampling ports, which keeps the unit stable. Performance evaluation tests demonstrate that the design is reasonable. The sampler has been applied to characterize PM emissions from various combustion sources in China.     

PCDD/PCDF reduction by the co-combustion process

A novel process, termed the co-combustion process, has been developed and designed to utilise the thermal treatment of municipal solid waste (MSW) in cement clinker production and reduce PCDD/PCDF emissions. To test the conceptual design; detailed engineering design of the process and equipment was performed and a pilot plant was constructed to treat up to 40 tonnes MSW per day. The novel process features included several units external to the main traditional cement rotary kiln: an external calcinations unit in which the hot gas calcined the limestone thus making significant energy savings for this chemical reaction; the lime generated was used in a second chamber to act as a giant acid gas scrubber to remove SOx and particularly HCl (a source of chloride); an external rotary kiln and secondary combustion unit capable of producing a hot gas at 1200 degrees C; a gas cooler to simulate a boiler turbogenerator set for electricity generation; the incorporation of some of the bottom ash, calcined lime and dust collector solids into the cement clinker. A PCDD/PCDF inventory has been completed for the entire process and measured PCDD/PCDF emissions were 0.001 ng I-TEQ/Nm(3) on average which is 1% of the best practical means [Hong Kong Environmental Protection Department, 2001. A guidance note on the best practicable means for incinerators (municipal waste incineration), BPM12/1] MSW incineration emission limit values.     

Behavior of PCNs, PCDDs, PCDFs, and dioxin-like PCBs in the thermal destruction of wastes containing PCNs

In the first known study to characterize the emissions of polychlorinated naphthalenes (PCNs), polychlorinated dibenzo-p-dioxins (PCDDs), polychlorinated dibenzofurans (PCDFs), and dioxin-like polychlorinated biphenyls (dl-PCBs) from the thermal treatment of wastes containing PCNs, the formation and decomposition behavior of these pollutants was investigated both at laboratory scale and at plant scale. Exhaust gas measurements from laboratory-scale combustion of rubber belts containing PCNs (FB belts) were used as the basis for calculations predicting that the incremental dioxin toxic equivalency (TEQ) emissions from municipal solid waste (MSW) incinerators would be less than 0.1 ng/m3 N. In order to directly examine co-incineration of FB belts with MSW and to address potential differences between the laboratory experiment and full-scale MSW incinerators, experiments were conducted using a larger scale thermal treatment test facility with sampling and analysis at several points in the thermal treatment process. Congener specific analysis of PCNs clearly showed that both destruction and synthesis simultaneously occurred during combustion in the kiln. Most of the PCNs were destroyed by secondary combustion, and almost all PCNs were removed after flue gas treatment. Almost all PCDDs/DFs were synthesized as by-products of kiln combustion, most of them were destroyed by the secondary combustion, and almost all dioxins (PCDDs/DFs and dl-PCBs) were removed after flue gas treatment. The TEQ emission levels were less than 0.1 ng/m3 N for all plant-scale tests, and differences in TEQ emission levels were very small. Adding wastes containing PCNs to MSW will not influence thermal treatment emissions to the environment from modern solid waste incinerators.     

Formation of PCDDs and PCDFs during the combustion of polyvinylidene chloride

In laboratory-scale combustion of polyvinylidene chloride (PVDC) with a quartz tubular furnace designed and fabricated to provide the desired combustion temperature and mixing state of combustion gas with air, it was found that at 800 degrees C or higher the level of polychlorinated dibenzo-p-dioxins/polychlorinated dibenzofurans [corrected] (PCDDs/PCDFs) resulting from PVDC combustion was no higher than that from heating air alone, and thus far below the levels which resulted from PVDC combustion at 750 degrees C or lower. The results provide the first laboratory confirmation of the relation between PVDC incineration temperature and PCDD/PCDF formation, and of the primary importance of high temperature, turbulence for mixing between air and combustion gas, and sufficient residence time, as governing factors for the minimization of PCDD/PCDF formation in municipal solid waste incinerators.     

Rotary Kiln Incineration of Dichloromethane and Xylene: A Comparison of Incinerability Characteristics Under Various Operating Conditions

Comparisons are made, for the first time, between the combustion characteristics of dichloromethane and xylene in an industrial rotary kiln incinerator. The comparisons are made under different operating conditions, including variable kiln rotation rate and operation both with and without turbulence air. Continuous gas composition and temperature measurements and batch gas composition measurements were obtained from two vertical locations hear the exit region of the rotary kiln. The measurements show that there is significant vertical stratification at the exit of the kiln. Addition of turbulence air enhanced combustion conditions throughout the kiln during xylene processing. During dichloromethane processing, however, the addition of turbulence air had minimal effect and only promoted greater bulk mixing; chlorinated compounds transported from the lower kiln during operation with turbulence air were not efficiently processed in the upper kiln. Evolution of test liquids from the bed was not constant but rather was characterized by intermittent peaks. The field-scale data of this work suggest that the evolution rate of the test liquid was increased as kiln rotation rate increased. Many of the differences between xylene and dichloromethane processing during these experiments are explained by a simple stoichiometric analysis.     

Prediction of Flue Gas Composition of an Incinerator Based on a Nonequilibrium-Reaction Approach

A nonequilibrium-reaetion model is developed to predict the flue gas composition of an incinerator for solid waste combustion and gasification. The model may also be effectively utilized to predict the composition of exit gas from the primary chamber of an incinerator where invariably substoichiometrie combustion conditions exist The model assumes that the drying and pyrolysis of waste occurs in sequence followed by combustion of devolatilized gas and residue separately. The model is applied to the combustion of pine wood, and the flue gas compositions are computed as a function of operating parameters such as temperature (1100 to 1500 K), initial moisture content (0 to 40 percent), and percentage excess air (up to 100 percent). The model is extended to include substoichiometric combustion (to simulate the gasification process without steam injection) to compare its predictions with the available experimental data. The general agreement of theory and experiment is good.     

Spray-dry desulfurization of flue gas from heavy oil combustion

An experimental investigation on sulfur dioxide removal in a pilot-scale spray dryer from the flue gas generated by combustion of low-sulfur (S) heavy oil is reported. A limewater slurry was sprayed through an ultrasonic two-fluid atomizer in the spray-dry chamber, and the spent sorbent was collected downstream in a pulse-jet baghouse together with fly ash. Flue gas was sampled at different points to measure the desulfurization efficiency after both the spray-dry chamber and the baghouse. Parametric tests were performed to study the effect of the following variables: gas inlet temperature, difference between gas outlet temperature and adiabatic saturation temperature, lime-to-S ratio, and average size of lime particles in the slurry. Results indicated that spray drying is an effective technology for the desulfurization of low-S fuel oil flue gas, provided operating conditions are chosen carefully. In particular, the lowest gas inlet and outlet temperatures compatible with baghouse operation should be selected, as should a sufficiently high lime-to-S ratio. The attainment of a small lime particle size in the slurry is critical for obtaining a high desulfurization efficiency. A previously presented spray-dry flue gas desulfurization model was used to simulate the pilot-scale desulfurization tests, to check the ability of the model to predict the S capture data and its usefulness as a design tool, minimizing the need for pilot-scale experimentation. Comparison between model and experimental results was fairly good for the whole range of calcium/S ratios considered.     

On the Occurrence of Transient Puffs in a Rotary Kiln Incinerator Simulator II. Contained Liquid Wastes on Sorbent

The generation of transient puffs resulting from the batch introduction of liquid waste into a 73 kW (250,000 Btu/h) rotary kiln incinerator simulator was investigated. The liquid was added onto a sorbent, enclosed in cylindrical cardboard containers that were introduced into the combustion chamber one at a time. A statistically designed parametric investigation determined the effects of liquid mass, liquid composition, kiln temperature, and kiln rotation speed on the total magnitude and instantaneous intensity of the pollutant puff leaving the kiln. Liquid "wastes" investigated included toluene, methylene chloride, carbon tetrachloride, and No. 5 fuel oil. Transient puffs from these wastes were monitored using on-line measurements for FID-measurable hydrocarbons, CO, and integrated particulate filter loadings, although the suitability of any one of these indicators depended on the chemical nature of the waste involved.

Results demonstrate that puffs formed during transient conditions are generated easily, even with small quantities of wastes and with the kiln operating at 100 percent excess air. High kiln temperatures and increased kiln rotation speeds exacerbated the generation of puffs, due to increased liquid evaporation rates. Transient puffs may contain hazardous products of incomplete combustion (PICs) even though adequate destruction and removal efficiencies are achieved. Mixtures of chlorinated and nonchlorinated principal organic hazardous constituents (POHCs) in the waste can lead to the formation of more diverse chlorinated compounds than are formed from a single chlorinated POHC such as carbon tetrachloride alone.

This paper is the second of a series. Its companion paper, Part I, which has been published previously,¹ is concerned with solid plastic wastes.     

回转窑式纯氧熔融焚烧垃圾技术研究

生活垃圾安全无害化处理是目前迫切需要解决的问题,直接气化熔融焚烧垃圾技术以降低二恶英排放方面巨大优势得到广泛关注,在此基础上提出纯氧熔融焚烧垃圾技术,几乎可以实现所有二次污染物近零排放。以350 t/d回转窑垃圾焚烧炉为例,对纯氧代替空气应用在回转窑上熔融焚烧垃圾系统进行了详细热力计算及分析。结果表明,纯氧熔融焚烧垃圾系统的锅炉效率可达90.56%,回转窑熔融焚烧系统还可以在垃圾焚烧后灰渣达到熔融温度的条件下,保持该系统热量平衡,稳定燃烧。并参考回转窑设计标准对该纯氧熔融焚烧城市生活垃圾的回转窑参数进行确定。     

Field Testing and Computer Modeling of an Oxygen Combustion System at the EPA Mobile Incinerator

The LINDE® Oxygen Combustion System has been demonstrated successfully at the EPA Denney Farm site as part of the modified EPA mobile incinerator. This paper describes the field testing results and computer modeling of the LINDE system. The oxygen system enables the EPA unit to incinerate dioxin and PCB contaminated soil at a consistent rate of 4000 lb/h—200 percent of the original maximum capacity. The pure oxygen combustion system improved the thermal efficiency of the incinerator by over 60 percent and reduced the flue gas volume dramatically. Therefore, the dust carryover problem was mitigated. The destruction and removal efficiencies of hazardous wastes exceeded EPA requirements.

The design of the proprietary burner allows the use of up to 100 percent oxygen in place of air for incineration with improvements over conventional oxy-fuel burners. As a result, the temperature distributions in the rotary kiln are uniform and NO_x emissions are low.

The oxygen combustion system, controlled by a programmable controller, provided much better response and flexibility than conventional air based systems. The system generated a stable flame and responsed well to the transient conditions of the rotary kiln. Kiln puff occurrence was virtually eliminated in the operation of the mobile incinerator.

A computer model of the incinerator was developed and used for the process design of the LINDE system. The model predicted the test results reasonably well. This model can be a useful tool in the design and operation of rotary kiln incineration systems.     

Waste burning and heat recovery characteristics of a mass burn incineration system

An experimental investigation on waste combustion characteristics of a mass burn incinerator is conducted in this study. Three different charging modes, including operator manipulation, periodic feeding, and temperature control, are taken into consideration. The results indicate that the burning characteristics in the combustion chambers are closely related to the operating modes. For the operator manipulation where the wastes are sent into the incinerator in two short periods, the entire temperature distribution of the primary combustion chamber can be partitioned into two parts, thereby yielding waste group combustion. Temperature oscillations in both the primary and secondary combustion chambers are characterized for the periodic feeding. However, because of the shorter charging period and smaller amount of waste, the burning interaction between the two chambers is initially weak and becomes notable in the final stage. When temperature control is performed, the burning oscillation of the primary combustion chamber is further amplified so the combustion interaction is drastic. These exhibitions are mainly caused by the competition between endothermic and exothermic reactions. The instantaneous heat exchange efficiency of the cyclone heat recovery system (CHRS) installed in the incineration system is also evaluated to obtain details of energy recovery behaviors. As a result, the efficiency tends to decrease linearly with increasing temperature of hot flue gas. This arises from the fact that heat loss from the gas to the environment is increased when the temperature of the former is higher, even though the temperature gradient across the cyclone is enlarged.     

Low NOx,High Efficiency Multistaged Burner: Fuel Oil Results

A multistaged combustion burner designed for in-furnace NO_x control and high combustion efficiency is being evaluated for high nitrogen content fuel and waste incineration application in a 0.6 MW package boiler simulator. A low NO_x precombustion chamber burner has been reduced in size by approximately a factor of two (from 600 to 250 ms first-stage residence time) and coupled with (1) air staging, resulting in a three-stage configuration, and (2) natural gas fuel staging, yielding up to four stolchlometric zones. Natural gas, doped with ammonia to yield a 5.8 percent fuel nitrogen content, and distillate fuel oil, doped with pyridine to yield a 2 percent fuel nitrogen content, were used to simulate high nitrogen content fuel/waste mixtures. The multistaged burner reduced NO emissions by 85 percent from emission levels from a conventional unstaged burner mounted on a commercial package bollerTA minimum NO emission level of 110 ppm was achieved in the fuel oil tests, from a level of 765 ppm for conventional firing. This is compared with a 160 ppm minimum NO level achieved in gaseous fuel tests, from an uncontrolled level of 1000 ppm. Boiler fuel staging, or reburnlng, appears to be superior to air staging for high combustion efficiency due to its minimal fuel-rich core and second flame front in the boiler.     

PCB decomposition and formation in thermal treatment plant equipment

In this study we investigated both the decomposition and unintentional formation of polychlorinated biphenyl congeners during combustion experiments of refuse-derived fuel (RDF) and automobile shredder residue (ASR) at several stages in thermal treatment plant equipment composed of a primary combustion chamber, a secondary combustion chamber, and other equipments for flue gas treatment. In both experiments, the unintentional formation of PCB occurred in the primary combustion chamber at the same time as the decomposition of PCB in input samples. By combusting RDF, non-ortho-PCB predominantly formed, whereas ortho-PCB and symmetric chlorinated biphenyls (e.g., #52/69, #87/108, and #151) tended to be decomposed. ASR formed the higher chlorinated biphenyls more than RDF. These by-products from ASR had no structural relation with ortho-chlorine. Lower chlorinated biphenyls appeared as predominant homologues at the final exit site, while all congeners from lower to higher chlorinated PCB were unintentionally formed as by-products in the primary combustion chamber. This result showed that the flue gas treatment equipments effectively removed higher chlorinated PCB. Input marker congeners of RDF were #11, #39, and #68, while those for ASR were #11, #101, #110/120, and #118. Otherwise, combustion marker congeners of RDF were #13/12, #35, #77, and #126, while those for ASR were #170, #194, #206, and #209. While the concentration of PCB increased significantly in the primary combustion chamber, the value of toxicity equivalency quantity for dioxin-like PCB decreased in the secondary combustion chamber and the flue gas treatment equipments.