Modeling of Solid Particle Flow and Heat Transfer in Rotary Kiln Calciners

Abstract

Contaminated solid wastes exist in many industrial sites, gas plants, and oil refineries. One method of decontaminating the soil is to subject it to high temperatures in a rotary calciner in an anaerobic environment. Preliminary results from a computational model are presented in this paper for the flow and heat transfer from granular solid particles under treatment in a rotary kiln calciner. A fluidization model using kinetic theory of granular flow has been employed to solve the particle flow and heat transfer problem. While a two-dimensional model is used to predict the rotation induced flow of the solid particles, a pseudo three-dimensional model for heat transfer is developed where the axial bulk temperature gradient is obtained from a one-dimensional energy balance model. The model predictions indicate interesting features of the flow and temperature fields in the bed material. Future tasks include the development of a devolatilization model to study the decontamination of waste soil in the rotary calciner.     

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.     

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.     

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.     

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.     

A Comparison of In situ Vitrification and Rotary Kiln Incineration for Soils Treatment

In the hazardous waste community, the term “thermal destruction” is a catchallphrase that broadly refers to high temperature destruction of hazardous contaminants. Included in the thermal destruction category are treatment technologies such as rotary kiln incineration, fiuidized bed incineration, infrared thermal treatment, wet air oxidation, pyrolytic incineration, and vitrification. Among them, conventional rotary kiln incineration, a disposal method for many years, is the most well established, and often serves as a barometer to gauge the relative success of similar technologies. Public sentiment on environmental issues and increasingly stringent environmental regulations has, over time, spurred design and development of innovative thermal treatment processes directed toward reducing harmful emissions and residuals that may require further treatment or disposal. In situ vitrification (ISV), a technology that combines heat and immobiliztion, is one such innovative and relatively new technology.

This paper presents a comparison of ISV and rotary kiln incineration for soils treatment in the areas of process performance, process residuals, process limitations, applicable or relevant and appropriate (ARAJRs) regulations, criteria and limitations, and costs.     

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.     

Destruction of Chlorofluorocarbons in a Cement Kiln

Abstract

One of the thermal oxidation technologies recommended by the United Nations Environment Programme (UNEP) is destruction of chlorofluorocarbons (CFCs) in a cement kiln. The destruction of CFC12, CFC11 and CFC113 was studied in a cement kiln plant in actual commercial operation. CFCs were completely destroyed in the kiln under normal operating conditions. Hydrogen fluoride and hydrogen chloride generated by CFC decomposition were absorbed by cement materials. No formation of toxic ha-logenated organic compounds, such as polychlorinated dibenzo-p-dioxins or dibenzofurans (PCDDs/PCDFs), was observed in the CFC incineration.     

Performance of Dry Flue Gas Desulfurization on a Petroleum Coke Kiln Application

The information contained in this paper is directed to engineering, production, and management individuals who will be concerned with the application of dry flue gas desulfurization technology to process and combustion sources. This paper describes such a system which is operating successfully on a petroleum coke calcining kiln. Acceptance tests and continuous data logging demonstrate sulfur dioxide removal efficiencies in excess of 90%, and participate emissions less than 0.005 gr/acf. The system consists of a spray dryer, fabric filter and auxiliaries which are designed to process up to 205,000 acfm gas flow. Continuing development work on system components has resulted in system availability exceeding 90%, while requiring an average of 4 man-hours per shift of operator supervision. A preventive maintenance program which includes routine operator inspections and data acquisition has served to reduce forced outages and maximize production.     

Development of cleaner-burning brick kilns in Ciudad Juarez, Chihuahua, Mexico

The following results provide a comparison between net airborne contamination produced by the traditional form of kiln used in Northern Mexico and by those modified according to a design by Dr. Robert Marquez. What has become known as the MK style kiln was intended to significantly reduce contaminant emissions. The concept involves covering the kiln with a dome and channeling the output of an active kiln through a second, identical loaded kiln for its additional filtration of the effluents. Kilns of a pair are connected via clay brick channels. The roles are reversed after the initial kiln is refilled. Significant reductions in the particulate and gaseous emissions were achieved in the prototype system, but a connectional problem with recent kiln pairs has also limited the degree of operational success. The problem did not mask the potential of the MK kiln, as will be shown. Additional anticipated benefits to the owners of MK kilns, such as reduced operating cycles and decreased quantities of fuel, also have been verified. Key measurements made during all of the burns were of aerosol densities and buoyancies in the flues, kiln temperatures, and, on a number of occasions, chemical analyses of both aerosol and gaseous effluents. Continuous time histories of aerosol densities for most burns (of a total of -40) provide a basis for examining features and the effects of differing styles of operation with respect to burn efficiency and net contaminant masses. Covering the active kiln with a dome produces a net reduction in dry aerosol effluent mass of a factor between 5 and 10, whereas the addition of a filter kiln produces a net reduction of about a factor of 2. The use of used motor oil as a fuel further reduced aerosol contamination by -1 order of magnitude.     

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.     

Effects of inert dust on olive (<Emphasis Type="Italic">Olea europaea</Emphasis> L.) leaf physiological parameters

BACKGROUND: Cement factories are major pollutants for the surrounding areas. Inert dust deposition has been found to affect photosynthesis, stomatal functioning and productivity. Very few studies have been conducted on the effects of cement kiln dust on the physiology of perennial fruit crops. Our goal was to study some cement dust effects on olive leaf physiology.effects on olive leaf physiology. On METHODS: Cement kiln dust has been applied periodically since April 2003 onto olive leaves. Cement dust accumulation and various leaf physiological parameters were evaluated early in July 2003. Measurements were also taken on olive trees close to the cement factory. RESULTS: Leaf dry matter content and specific leaf weight increased with leaf age and dust content. Cement dust decreased leaf total chlorophyll content and chlorophyll a/chlorophyll b ratio. As a result, photosynthetic rate and quantum yield decreased. In addition, transpiration rate slightly decreased, stomatal conductance to H2O and CO2 movement decreased, internal CO2 concentration remained constant and leaf temperature increased. DISCUSSION: The changes in chlorophyll are possibly due to shading and/or photosystem damage. The changes in stomatal functioning were possibly due to dust accumulation between the peltates or othe effects on stomata. CONCLUSIONS: Dust (in this case from a cement kiln) seems to cause substantial changes to leaf physiology, possibly leading to reduced olive productivity. RECOMMENDATIONS: Avoidance of air contamination from cement factories by using available technology should be examined together with any possible methodologies to reduce plant tissue contamination from cement dust. PERSPECTIVES: Longterm effects of dust (from cement kiln or other sources) on olive leaf, plant productivity and nutritional quality of edible parts could be studied for conclusive results on dust contamination effects to perennial crops.     

N2O emissions: modeling the effect of process configuration and diurnal loading patterns

The objective of this research was to develop a mechanistic model for quantifying N2O emissions from activated sludge plants and demonstrate how this may be used to evaluate the effects of process configuration and diurnal loading patterns. The model describes the mechanistic link between the factors recognized to correlate positively with N2O emissions. The primary factors are the presence of ammonia and nitrite accumulation. Low dissolved oxygen concentrations also may be implicated through differential impacts on ammonia-oxidizing bacteria (AOB) versus nitrite-oxidizing bacteria (NOB) activity. Factors promoting N2O emissions at treatment plants are discussed below. The model was applied to data from laboratory and pilot-scale systems. From a practical standpoint, plant configuration (e.g., plug-flow versus complete-mix), influent loading patterns (and peak load), and certain operating strategies (e.g., handling of return streams) are all important in determining N2O emissions.     

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。     

石煤渣生产工业窑炉保温材料的工艺研究

以石煤渣为主要原料研制的工业窑炉保温材料，具有较高的耐压强度和较低的导热率。分析研究了保温材料在烧成工艺过程中的物理化学变化，同时通过试验确定了干燥和烧成过程的工艺参数，为石煤渣治理和综合利用开辟了一种新的途径。     

Adsorption study for the removal of a basic dye: experimental and modeling

An effective adsorbent is developed from saw dust and its various adsorption characteristics are studied for removing a basic dye (crystal violet) from its aqueous solution. Equilibrium data are fitted to various adsorption isotherms. It is seen that about 341 mg of crystal violet can be removed using 1g of the adsorbent at 298 K. Kinetic study is also carried out to observe the effects of various process parameters viz. particle size of the adsorbent, initial concentration of the dye, temperature and adsorbent amount. A generalized two-resistance mass transfer model, which includes a film mass transfer coefficient (k(f)) and an internal effective diffusivity (Dp), is used to interpret the adsorption kinetic data. The model parameters (k(f) and Dp) are estimated by fitting the experimental data to the model. The evaluated parameters are used to predict the concentration profiles at various other operating conditions. The average deviation of the predicted values lies within 10% in all the cases. Sensitivity analysis is performed to observe the sensitivity of the model to the variations in the model parameters.     

Bio-oxidation of airborne volatile organic compounds in an activated sludge aeration tank

An activated sludge aeration tank (40 x 40 x 300 cm, width x length x height) with a set of 2-mm orifice air spargers was used to treat gas-borne volatile organic compounds (VOCs; toluene, p-xylene, and dichloromethane) in air streams. The effects of liquid depth (Z), aeration intensity (G/A), the overall mass-transfer rate of oxygen in clean water (KLaO2), the Henry's law constant of the tested VOC (H), and the influent gaseous VOC concentration (C0) on the efficiency of removal of VOCs were examined and compared with a literature-cited model. Results show that the measured VOC removal efficiencies and those predicted by the model were comparable at a G/A of 3.75-11.25 m3/m2 hr and C0 of approximately 1000-6000 mg/m3. Experimental data also indicated that the designed gas treatment reactor with KLaO2 = 5-15 hr(-l) could achieve > 85% removal of VOCs with H = 0.24-0.25 at an aerated liquid depth of 1 m and > 95% removal of dichloromethane with H = 0.13 at a 1-m liquid depth.     

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.     

Enhanced experimental flexibility and control in ecotoxicological mesocosm experiments--a new outdoor and indoor pond and stream system

Scope The German Federal Environmental Agency has put into operation a new modular mesocosm system consisting of eight outdoor and eight indoor ponds and streams in order to investigate fate and effects of chemicals and municipal wastewater in aquatic ecosystems. General design and special characteristics are given to demonstrate the wide range of possibilities for experimental research. - General design. Each of the 16 streams with riffle and pool sections can be varied in length up to 106 m. The streams can be run as circular or flow-through systems at a flow velocity of 0.02 to 0.6 m/s. Physico-chemical standard parameters are measured on-line. The 16 ponds, which can be connected to the stream systems, are equipped with drainage and pore water-sampling devices for simulating processes in the littoral zone including influent and effluent ground water flow. Perspectives Since the highly flexible and controllable construction also allows treating a wide range of hydrological and ecological experiments external institutions are invited to submit proposals.