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.     

城市生活垃圾在机械炉排炉内焚烧过程研究及数值模拟

研究城市生活垃圾在机械炉排炉内焚烧过程,建立了垃圾在炉排炉移动床内燃烧过程中垃圾体积变化、水分蒸发、挥发分析出及燃烧、垃圾颗粒的移动、气-固两相热传递、焦炭燃烧等各个反应阶段的热化学模型,采用一维非稳态模型分别建立了床层内气固两相介质控制方程。通过对炉排上垃圾焚烧过程的数值模拟研究,获得料层中温度分布、料层高度、炉床机械负荷、气相中反应物组分和污染物浓度分布。利用建立的模型对某大型垃圾焚烧炉的燃烧过程进行数值仿真,对燃烧过程、烟气成分进行预测,为垃圾焚烧炉排炉的设计和燃烧控制提供理论依据。     

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。     

Basic Research on the Emission of Polycyclic Aromatic Hydrocarbons caused by Waste Incineration

The emission of polycyclic aromatic hydrocarbons (PAH) caused by municipal waste incineration varies according to waste composition and operating parameters such as furnace temperature and excess air. However, to obtain a sample sufficient to measure the emission of PAH at trace levels, it is necessary to operate the incinerator for many hours. Since during these lengthy periods it has not always been possible to maintain stable conditions, it is very difficult to determine the relationship between the emission and waste composition.

In our basic research, therefore, we used municipal waste with an artificially regulated composition for our combustion experiments, and by using an experimental Incinerator we examined the emission behavior of PAH with respect to changes in waste composition and combustion conditions. The following facts were revealed by the results: ? The PAH found in the flue gas were predominantly the more volatile compounds.

? When municipal waste was incinerated at over 850 °C, the concentration of PAH in the flue gas increased rapidly as the proportion of plastics in the waste increased from 0 to 24 percent.

? The elimination of plastics from municipal waste by separate collection and the improvement of combustion conditions can effectively diminish the emission of PAH.

     

Combustion Characteristics of Spent Catalyst and Paper Sludge in an Internally Circulating Fluidized-Bed Combustor

Abstract

Combustion of spent vacuum residue hydrodesulfurization catalyst and incineration of paper sludge were carried out in thermo-gravimetric analyzer and an internally circulating fluidized-bed (ICFB) reactor. From the thermogravimetric analyzer-differential thermo-gravimetric curves, the pre-exponential factors and activation energies are determined at the divided temperature regions, and the thermo-gravimetric analysis patterns can be predicted by the kinetic equations. The effects of bed temperature, gas velocity in the draft tube and annulus, solid circulation rate, and waste feed rate on combustion efficiency of the wastes have been determined in an ICFB from the experiments and the model studies. The ICFB combustor exhibits uniform temperature distribution along the bed height with high combustion efficiency (>90%). The combustion efficiency increases with increasing reaction temperature, gas velocity in the annulus region, and solid circulation rate and decreases with increasing waste feed rate and gas velocity in the draft tube. The simulated data from the kinetic equation and the hydrodynamic models predict the experimental data reasonably well.     

Urea as a PCDD/F Inhibitor in Municipal Waste Incineration

ABSTRACT

Emissions of polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) from municipal waste incineration have been widely studied because of their extensive toxicity, and many efforts have been made to restrict their emissions. Although a number of chemical compounds have been shown in laboratory-scale tests to inhibit the formation of PCDD/Fs, few have been tested in pilot- or full-scale plants. This work evaluates the effect of urea as a PCDD/F inhibitor in a pilot-scale incinerator that uses refuse-derived fuel (RDF). The decomposition of urea under the test conditions was also studied using detailed kinetic modeling. An aqueous solution of urea was injected into the flue gas stream after the furnace at ~730 °C, with varied urea concentrations and flue gas residence times used between the furnace and the sampling point. The results demonstrate that urea can successfully inhibit PCDD/F formation in waste incineration if concentrations and injection points are properly adjusted. The kinetic model showed that urea can be rapidly decomposed under appropriate flue gas conditions, indicating that in addition to the urea molecule itself, decomposition products of urea can also be responsible for the reduction of PCDD/F production during incineration.     

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.     

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.     

Dioxins and their fingerprint in size-classified fly ash fractions from municipal solid waste incinerators in China—Mechanical grate and fluidized bed units

The distribution of polychlorinated dibenzo-p-dioxins/dibenzofurans (PCDD/Fs), in brief dioxins, has seldom been addressed systematically in fly ash from municipal solid waste incinerators (MSWIs). This study shows the amount and fingerprint of PCDD/Fs in fly ash from four different Chinese MSWIs, that is, three mechanical grate units and one circulating fluidized bed unit. In these fly ash samples, dioxins-related parameters (international toxic equivalent quantity, total amount of PCDD/Fs, individual isomer classes, and 17 toxic 2,3,7,8-substituted congeners) all tend to increase with decreasing particle size for mechanical grate incinerators, yet only for the finest fraction for fluidized bed units. Moreover, the fluidized bed incinerator seems superior to grate incineration in controlling dioxins, yet a comparison is hampered by internal differences in the sample, for example, the fluidized bed fly ash has much lower carbon and chlorine contents. In addition, the presence of sulfur from mixing coal as supplemental fuel to the MSW may poison the catalytic steps in dioxins formation and thus suppress the formation of dioxins. With more residual carbon and chlorine in the fly ash, it is easier to form dioxins during cooling. Nevertheless, there is no apparent relation between Fe, Cu, and Zn contents and that of dioxins in fly ash.

Implications This paper is of interest because it presents the amounts and distribution of PCDD/Fs in fly ash samples from some typical waste incineration plants in China, featuring distinct incinerator types, combustion conditions, fuel composition, or residual carbon, chloride, and heavy metal contents in fly ash.     

Identification of Sources Contributing to Mid-Atlantic Regional Aerosol

Abstract

Source types or source regions contributing to the concentration of atmospheric fine particles measured at Brigantine National Wildlife Refuge, NJ, were identified using a factor analysis model called Positive Matrix Factorization (PMF). Cluster analysis of backward air trajectories on days of high- and low-factor concentrations was used to link factors to potential source regions. Brigantine is a Class I visibility area with few local sources in the center of the eastern urban corridor and is therefore a good location to study Mid-Atlantic regional aerosol. Sulfate (expressed as ammonium sulfate) was the most abundant species, accounting for 49% of annual average fine mass. Organic compounds (22%; expressed as 1.4 × organic carbon) and ammonium nitrate (10%) were the next abundant species. Some evidence herein suggests that secondary organic aerosol formation is an important contributor to summertime regional aerosol.

Nine factors were identified that contributed to PM_2.5 mass concentrations: coal combustion factors (66%, summer and winter), sea salt factors (9%, fresh and aged), motor vehicle/mixed combustion (8%), diesel/Zn-Pb (6%), incinerator/industrial (5%), oil combustion (4%), and soil (2%). The aged sea salt concentrations were highest in springtime, when the land breeze-sea breeze cycle is strongest. Comparison of backward air trajectories of high- and low-concentration days suggests that Brigantine is surrounded by sources of oil combustion, motor vehicle/mixed combustion, and waste incinerator/industrial emissions that together account for 17% of PM_2.5 mass. The diesel/Zn-Pb factor was associated with sources north and west of Brigantine. Coal combustion factors were associated with coal-fired power plants west and southwest of the site. Particulate carbon was associated not only with oil combustion, motor vehicle/mixed combustion, waste incinerator/industrial, and diesel/Pb-Zn, but also with the coal combustion factors, perhaps through common transport.     

垃圾炉一次风量对炉床燃烧影响的仿真研究

针对垃圾焚烧炉床层内垃圾燃烧过程复杂性及影响垃圾燃烧效率因素多的问题,运用数值仿真方法对某垃圾焚烧炉床层垃圾燃烧进行了模拟,获得了垃圾质量流失速率、水分蒸发速率、挥发分释放速率、焦炭燃烧速率和烟气的温度;并在50~1 000 Nm3/min范围内改变一次风流量,获得了床层质量流失比值、过剩空气系数和烟气中各组分的质量百分比含量。仿真结果显示,一次风流量取值517.47~6`32.09 Nm3/min时燃烧效率较高;炉排两端区域的一次风流量在50~75 Nm3/min时,可以使垃圾床表面平均温度明显提高,而且还可以提高燃烧效率,同时减少供风总量,节约能源与动力资源。本研究对优化设计垃圾焚烧炉,提高床层内垃圾的燃烧效率有一定参考价值。     

Waste Incineration and Pulmonary Function: An Epidemiologic Study of Six Communities

ABSTRACT

This study investigated the chronic effects of emissions from three different waste incinerators on pulmonary function of both healthy and sensitive subjects with chronic respiratory symptoms. Participants were 8-80 years old, not currently smoking, and living in one of three communities each with an incinerator or one of three matched comparison communities. In total, 1018 subjects underwent a spirometric test once a year during 1992-1994. Exposure was assessed by three methods: living in an incinerator community; distance from the incinerator; and an incinerator exposure index, a function of the distance and direction of each subject's residence to the incinerator, days downwind, and average time spent outdoors. The results generally showed no statistically significant association between pulmonary function and these three incinerators, adjustment for gas oven/range use at home, length of residency, and smoking history in the mixed linear models. Two significant associations were that exposure to the hazardous waste incinerator in 1994 and to the municipal waste incinerator in 1993 were related to poor forced vital capacity. Sensitive subjects were not more adversely affected by incineration emissions than were hay fever or normal subjects. Possible explanations for the negative findings are low exposure levels and bias due to nondifferential misclassification of exposures.     

The Relationship between the Quantity of Heavy Metal and PAHs in Fly Ash

ABSTRACT

Heavy metal and polycyclic aromatic hydrocarbons (PAHs) in flue gas have received considerable attention in recent years due to their mutagenic or carcinogenic properties. The present study is carried out to investigate the influence of the quantity of heavy metals on PAHs formation in fly ash.

A fluidized bed incinerator was used in this experiment to obtain fly ash of chemical similarity by incinerating various compositions of waste. The obtained fly ash, both with and without heavy metal, were used to adsorb the PAHs in the flue gas and to investigate the formation of PAHs in fly ash. The results indicate that carbon and heavy metals most greatly influence the formation of PAHs in the fly ash. Carbon is absorptive; heavy metals encourage not only absorption of PAHs but also catalyze PAHs formation.     

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.     

Particulate PAHs observed in the surrounding of a municipal incinerator

An intensive sampling campaign was undertaken in the surroundings of a municipal waste incinerator located in a French great urban centre in order to evaluate the impact of particles emissions on the ambient air and to estimate the exposure levels to toxic or carcinogenic compounds for a population living in the neighbourhood of this incinerator. To minimise the effect of industrial and road activities, sampling was performed during the 2 days of a weekend and on Monday morning. Different operating modes of the incinerator were investigated: (i) normal incinerator functioning and (ii) maintenance activity of the combustion chamber corresponding to the stop and cooling furnace periods. Particulate polycyclic aromatic hydrocarbons (PAHs) and total particulate carbon concentrations were determined in three sites situated, respectively, close to the incinerator, 2 km downwind and 1 km upwind of the plant. In normal operating mode similar concentrations were observed in the three sites. During the furnace stop an increase of total PAH concentrations was observed in the sampling site close to the incinerator. The concentration was 3 times higher than those measured in the other two sampling sites. But this increase was limited in time and in space since this phenomenon is only observed in the vicinity of the incinerator. The study of PAH profiles indicated that Pyrene and Retene showed the highest enhancement of their relative concentrations. The influence of incinerator functioning parameters on the PAHs concentrations is discussed. The furnace temperature and the mode of exhaust fumes seem to be deciding parameters to explain the increase of PAH level in the incinerator site. However, the incinerator emissions remained a minor part of the atmospheric pollution in the urban area.     

Comparison of CaO’s effect on the fate of heavy metals during thermal treatment of two typical types of MSWI fly ashes in China

Both grate and fluidized bed incinerators are widely used for MSW incineration in China. CaO addition for removing hazardous emissions from MSWI flue gas changes the characteristics of fly ash and affects the thermal behavior of heavy metals when the ash is reheated. In the present work, two types of MSWI fly ashes, sampled from both grate and fluidized bed incinerators respectively, were thermal treated at 1023–1323 K and the fate of heavy metals was observed. The results show that both of the fly ashes were rich in Ca and Ca-compounds were the main alkaline matter which strongly affected the leaching behavior of heavy metals. Ca was mostly in the forms of Ca(OH)₂ and CaCO₃ in the fly ash from grate incinerator in which nascent fly ash particles were covered by Ca-compounds. In contrast, the content of Ca was lower in the fly ash from fluidized bed incinerator and Ca was mostly in the form of CaSO₄. Chemical reactions among Ca-compounds caused particle agglomeration in thermal treated fly ash from grate incinerator, restraining the heavy metals volatilization. In thermal treated fly ash from fluidized bed incinerator, Ca was converted into aluminosilicates especially at 1323 K which enhanced heavy metals immobilization, decreasing their volatile fractions as well as leaching concentrations. Particle agglomeration hardly affected the leaching behavior of heavy metals. However, it suppressed the leachable-CaCrO₄ formation and lowered Cr leaching concentration.     

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.     

Fate of polycyclic aromatic hydrocarbons during vitrification of incinerator ash in a coke bed furnace

Fate of polycyclic aromatic hydrocarbons (PAHs) during the vitrification of fly ash and bottom ash from the municipal waste incinerator in a coke bed furnace was investigated. In this system, both coke and lime were added to enhance the melting reaction. The major PAH sources in this system were ash and coke, which respectively contributed 97% and 3% of PAHs in the input-mass. During vitrification process, low molecular PAHs (LM-PAH, 2-3-ring), median molecular PAHs (MM-PAH, 4-ring) and high molecular PAHs (HM-PAH, 5-7-ring) mass respectively accounted for >99%, >99% and 84% of the output-mass emitted as the stack flue gas; while those discharged from the slag were <1%, <1% and 16%, respectively. The O/I (output-mass/input-mass) ratio of LM-, MM- and HM-PAHs were 0.063, 0.002 and <0.001, respectively. The high distribution in flue gas and O/I ratio of LM-PAHs is reasonable since they are more easily evaporated, hence difficult to be removed by air pollution control devices. On the contrary, the HM-PAHs, having lower vapor pressure, primarily stays mainly in slag. Based on the 21 total PAH content in feeding ash and slag, the reduction efficiency of the coke bed furnace was >99.9%. To minimize the risk of secondary pollution, the efficiency of coke bed furnace should be improved to reduce the PAH emission into ambient air.     

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.     

Computational fluid dynamics modeling of laboratory flames and an industrial flare

A computational fluid dynamics (CFD) methodology for simulating the combustion process has been validated with experimental results. Three different types of experimental setups were used to validate the CFD model. These setups include an industrial-scale flare setups and two lab-scale flames. The CFD study also involved three different fuels: C₃H₆/CH₄/Air/N₂, C₂H₄/O₂/Ar, and CH₄/Air. In the first setup, flare efficiency data from the Texas Commission on Environmental Quality (TCEQ) 2010 field tests were used to validate the CFD model. In the second setup, a McKenna burner with flat flames was simulated. Temperature and mass fractions of important species were compared with the experimental data. Finally, results of an experimental study done at Sandia National Laboratories to generate a lifted jet flame were used for the purpose of validation. The reduced 50 species mechanism, LU 1.1, the realizable k-? turbulence model, and the EDC turbulence–chemistry interaction model were used for this work. Flare efficiency, axial profiles of temperature, and mass fractions of various intermediate species obtained in the simulation were compared with experimental data and a good agreement between the profiles was clearly observed. In particular, the simulation match with the TCEQ 2010 flare tests has been significantly improved (within 5% of the data) compared to the results reported by Singh et al. in 2012. Validation of the speciated flat flame data supports the view that flares can be a primary source of formaldehyde emission.

ImplicationsValidated computational fluid dynamics (CFD) models can be a useful tool to predict destruction and removal efficiency (DRE) and combustion efficiency (CE) under steam/air assist conditions in the face of many other flare operating variables such as fuel composition, exit jet velocity, and crosswind. Augmented with rigorous combustion chemistry, CFD is also a powerful tool to predict flare emissions such as formaldehyde. In fact, this study implicates flares emissions as a primary source of formaldehyde emissions. The rigorous CFD simulations, together with available controlled flare test data, can be fitted into simple response surface models for quick engineering use.