Rotary Kiln Incineration IV. An Indepth Study— Kiln Exit,Transition and Afterburner Sampling During Liquid CCl4 Processing

Detailed temperature and stable species concentration data are presented from the kiln exit, transition section and afterburner of a full-scale incinerator facility firing natural gas/carbon tetrachloride/air. The data are collected as part of a cooperative program involving university, industry and government participation. The overall goal of the program is to develop an understanding and predictive capability for rotary kiln and afterburner performance as influenced by basic design and operational parameters. The data demonstrate that nonuniformities in stable species and temperature exist, under certain operating conditions, at the kiln exit in the vertical direction only. Measurements from the transition section indicate that non-uniformities may exist within this region under certain operating conditions. Flow perturbations from within the kiln can persist into the afterburner, although the degree of nonuniformity is substantially reduced compared to either the kiln or transition sections. High destruction and removal efficiencies were achieved under all operating conditions of these tests through a combination of kiln and secondary combustion processing.     

Rotary Kiln Incineration III. An Indepth Study—Kiln Exit/Afterburner/Stack Train and Kiln Exit Pattern Factor Measurements During Liquid CCl4 Processing

Temperature and stable species concentration data are presented from various locations within a full-scale rotary kiln incinerator firing natural gas/carbon tetrachloride/air. The data are being collected as part of a cooperative program involving university, industry and government participation. The overall goal of the program is to develop a more sophisticated understanding of and a predictive capability for rotary kiln and afterburner performance as influenced by basic design and operational parameters. Non-uniformities in stable species and temperature exist for this particular kiln, at the kiln exit, under certain operating conditions. Flow perturbations from within the kiln were found to persist into the afterburner, but not into the stack. High destruction and removal efficiencies (DRE’s) were achieved under the operating conditions of these tests through adequate secondary combustion processing.     

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.     

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.     

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.     

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.     

回转窑在医废焚烧工程应用中的参数优化

以规模3 t/h的某医疗废物焚烧生产线为依托,优化分析了回转窑焚烧装置核心控制参数(窑头温度、供风量及窑转速),考察了不同负荷、回转窑转动模式及进料方式对焚烧效果的影响,结果表明:窑头温度升高,有利于提高焚烧效果,是影响焚烧效果最重要的工艺参数;75%负荷时最佳工况是窑头温度850℃、窑转速0.09 r/min、供风量7 000 Nm3/h;连续反转的回转窑转动模式和恒流量的连续进料技术,有助于保持良好焚烧工况,炉渣热灼减率分别达到2.6%和2.3%。     

In Situ Velocity Measurements from an Industrial Rotary Kiln Incinerator

Abstract

For the first time, velocities were measured inside a fieldscale rotary kiln incinerator. Combustion gas velocities and temperatures were measured at multiple points across a quadrant of the kiln near its exit using a bidirectional pressure probe and suction pyrometer. To accommodate the new bidirectional probe and gain access to the upper portion of the kiln, a lighter and stiffer positioning boom was designed. The kiln was directly fired using natural gas in a steady state mode. Results indicate strong vertical stratification of both velocity and temperature, with the highest values corresponding to the top of the kiln. Access restraints prevented the lower region of the kiln from being mapped. Horizontal variations in both temperature and velocity were insignificant. Operating conditions were varied by adjusting the amount of ambient air added to the front of the kiln. Increasing the flow of ambient air into the front of the kiln reduced the measured temperatures as expected, but did hot have as significant an effect on measured velocities. The quality of the results is examined by performing mass balances across the incinerator and by comparison to an existing numerical model. Both methods indicate that the experimental results are reasonable.     

3-D Flow Modeling of a Hazardous Waste Incinerator

A three-dimensional flow model of a hazardous waste incinerator kiln and vertical secondary combustion chamber arrangement was constructed to evaluate critical system parameters. The chamber wall configuration, location and arrangement of burners, and the positioning of the outlet duct were examined to determine the critical secondary combustion chamber gas residence time and mixing of the combustion flows. The scale model consisted of the rotary kiln as a primary combustion chamber, the secondary combustion chamber, two burners, and the exhaust ducting. Flue gas velocities in the model inlets and outlet were maintained to provide a Reynolds numbers equal to the full size unit. Patterns of smoke which were injected into the model inlets were viewed to evaluate flow mixing. Slow motion playback of video tape was used to determine the minimum residence time of flow in the high temperature combustion zone. The results of the model study were used to complete the engineering of a waste incineration system.     

Composition of Exhaust from a Regenerative Turbine System

Particulate and hydrocarbon content of gases in a regenerative gas turbine was analyzed at several points. Particle samples were measured with a condensation nuclei counter, a light scattering single particle counter and an impactor. Hydrocarbon analyses were made using gas chromatography. The effects of operation with JP-4 and No. 2 fuel oil were noted. It was concluded that a regenerative gas turbine will not add appreciably to the burden of air pollution. In fact, particulate contamination levels in the exhaust less than those in the inlet air indicates that the high rotation rate may result in some air cleaning. Low hyd rocarbon contents in the exhaust gas were ascribed to efficient combustion under the operating conditions used in this work. In general, it was concluded that hydrocarbon levels significantly lower than those seen from gasoline or diesel engines could be expected from a well maintained and operated regenerative gas turbine.     

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。     

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。     

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.     

Performance of High-temperature Slagging Rotary Kiln Incinerator

A high-temperature, slagging rotary kiln hazardous waste incineration system with modern combustion, heat recovery and air pollution control equipment was put in operation at PPG Coating and Resin Plant in Circleville, Ohio in the latter part of 1987. New design solutions contributed to the overall high performance of the system. The system employs European and American feed, combustion, heat recovery and stack emission control technologies. Performance of the system is analyzed in detail covering topics such as feed methods, equipment selection, destruction and removal efficiencies, fate of the metals, and financial information.     

Continuous emissions monitoring using spark-induced breakdown spectroscopy

A new technology for monitoring airborne heavy metals on aerosols and particulates based on spark-induced breakdown spectroscopy (SIBS) was evaluated at a joint U.S. Environmental Protection Agency (EPA)/U.S. Department of Energy test at the rotary kiln incinerator simulator (RKIS) facility at EPA/Research Triangle Park, NC, in September 1997. The instrument was configured to measure lead and chromium in a simulated combustion flue gas in real time and in situ at target levels of 15 and 75 micrograms/dry standard cubic meters. Actual metal concentrations were measured during the tests using EPA Reference Method (RM) 29. The SIBS technology detected both lead and chromium at the low- and high-level concentrations. Additionally, the hardware performed without failure for more than 100 hr of operation and acquired data for 100% of the RM tests. The chromium data were well correlated with concentration increases resulting from duct operations and pressure fluctuations that are known to entrain dust.     

Nitric oxide formation in an iron oxide pellet rotary kiln furnace

A one-dimensional numerical model was developed to simulate the effects of heat and mass transfer on the formation of oxides of nitrogen (NOx) in a rotary kiln furnace for iron oxide pellet induration. The modeled kiln has a length-to-diameter ratio of approximately seven. The principal mechanism of heat transfer is radiation from the flame, which was described by the net radiation method. The well known Zeldovich mechanism was used to predict thermal NOx generation. Temperature fluctuations in the vicinity of the flame were estimated with a clipped Gaussian probability density function. The thermal energy and mass balance model equations were solved numerically. The model is capable of predicting temperature profiles and NOx production rates in agreement with observed plant performance. The model was used to explore the effects of process changes on the total NOx formation in the kiln. It was concluded that the gas temperature as well as the partial pressure of oxygen in the process gases controls the rate of NOx formation. Lowering the temperature of the kiln gases by increasing the secondary air flow rates requires simultaneously decreasing the pellet production rate in order to maintain the pellet temperatures needed for blast furnace conditions.     

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.     

Speciated non-methane organic compounds emissions from food cooking in Mexico

Non-methane organic compound (NMOC) emissions from different sorts of food preparation sites, were quantified for the first time in Mexico, in order to develop emission profiles for further application in the chemical mass balance receptor model (CMB). Restaurants using charcoal grills and LP gas stoves, “tortillerı́as”, food frying places and rotisseries were sampled using SUMMA^® stainless-steel canisters to analyse NMOC by high-resolution gas chromatography. The results obtained show that profiles determined from food cooking processes have similarities to those found in LP gas combustion, which is the most common fuel in Mexico used for this purpose, although there were differences in the relative composition of propane and butane in both cases. This suggests that, the rates of combustion of propane and butane are different. It has also been detected that propene, a reactive olefin is produced during the combustion process. The obtained profiles of restaurants, rotisseries and fried food show an important contribution of two carbon compounds (ethane, ethylene and acetylene) that can be attributed to the complex process of grease and meat cooking. The presence of these compounds cannot be attributed to vehicular sources since the concentrations are higher than in ambient air. These were also determined from aromatic compounds such as benzene, toluene and xylene in the combustion of vegetal charcoal. The measured concentrations indicate that NMOC emissions from cooking may become an important indoor source of NMOC under crowded conditions in closed places.     

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.     

Changes in PCDD/PCDF formation processes during instationary phases of combustor operation--exemplified by the use of Cl4DD isomer patterns

In this paper results of various measurement campaigns at different municipal waste incineration (MWI) plants concerning the change of the PCDD/PCDF isomer distribution in the crude gas during transiently impaired combustion conditions are presented. The focus is on the Cl4DD isomer distributions exemplarily for all other homologue groups to demonstrate the change in PCDD/PCDF formation mechanism at transient combustion conditions. Additionally to crude gas samples, at one plant filter and boiler ash were investigated simultaneously to determine if there is any difference in the isomer distribution between the matrices. For the ash from an electrostatic precipitator (ESP ash), the boiler ash and the corresponding crude gas sample, nearly identical changes in the Cl4DD isomer distribution under transient combustion conditions in relation to the normal operation process could be detected. By comparing the Cl4DD isomer distributions from different incineration plants (two municipal waste incinerators and one little incinerator burning wood chips for heating domestic household) under transient combustion conditions, in all cases the 1,3,6,8- and 1,3,7,9-Cl4DD were dominating the isomer distribution, whereas under normal operation other isomers were predominant. Obviously PCDD/PCDF formation mechanisms under transient combustion conditions are independent from the type of incinerator and of the burned fuel, respectively. Data sets were analyzed with respect to the possible reaction mechanism via chlorophenols and a good correlation of 2,4,6-trichlorophenol during the second phase of a start-up process and during a CO experiment was found. To get more detailed information about possible formation mechanisms, at one plant the dependence of the PCDD/PCDF isomer distribution on the different matrices was studied. Separate analysis of fly ash collected at the boiler exit, subsequent gas phase, ESP ash and boiler ash under normal operation conditions showed that, apart from the fly ash, the Cl4DD isomer distributions are nearly the same in the different matrices. Surprisingly, the Cl4DD isomer distribution of the fly ash was more similar to the distributions found under transient combustion conditions.