Académique Documents
Professionnel Documents
Culture Documents
1, 2007
25
Markus A. Reuter
Faculty of Engineering, Department of Chemical and Biomolecular Engineering,
University of Melbourne, Melbourne, Australia
E-mail: mreuter@unimelb.edu.au
Joep Verwoerd
AVR, P.O. Box 59144, 3008 PC Rotterdam, The Netherlands
E-mail: Joep.Verwoerd@avr.nl
Abstract: Processing of hazardous waste in a rotary kiln incinerator is a complex process.
Since hazardous waste has often very complicated chemical compositions and physical forms, the
transport phenomena within the incinerator are not well understood, and the incineration process
expects large uncertainties in process chemistry and is difficult for emission control. For better
understanding of the incineration process, various transport phenomena taking place in the rotary
kiln were discussed and analysed in this paper. To get more quantitative understanding, process
simulation was conducted by using Computational Fluid-Dynamics (CFD) to characterise gas
and solid flow and mixing, temperature and species distribution in the incinerator. To include all
the waste streams in a single CFD model is a difficult task, and how to define the different
waste streams with different calorific values and chemical compositions is a challenge to the
CFD modelling. In this study, hazardous waste in various forms is firstly converted to a
hydrocarbon-based virtual fuel mixture based on an overall mass and energy balance.
The combustion of the simplified waste was then simulated with a combustion model.
The distribution of temperature and chemical species is broadly investigated under various
conditions. The predicted temperature distribution has been validated with available
measurement data from an operating rotary kiln waste incinerator, and reasonable agreement
between the predicted and measured data has been reached.
Keywords: hazardous waste incineration; rotary kiln; transport phenomena; Computational
Fluid-Dynamics (CFD); combustion model.
Reference to this paper should be made as follows: Yang, Y., Pijnenborg, M.J.A., Reuter, M.A.
and Verwoerd, J. (2007) Analysis of transport phenomena in a rotary-kiln hazardous waste
incinerator, Progress in Computational Fluid Dynamics, Vol. 7, No. 1, pp.2539.
Biographical notes: Yongxiang Yang received his BSc and MSc Degrees at Northeastern
University in Extractive Metallurgy (China, 1982 and 1988), and the degrees of Licentiate and
Dr. of Tech. at Helsinki University of Technology in Materials Processing (Finland, 1992 and
1996). He has worked as design engineer, researcher and lecturer in metallurgical engineering.
Since 1998 he has been working at Delft University Technology (The Netherlands) as an
Assistant Professor in Process Metallurgy. His main interests include metallurgical and materials
processing, transport phenomena, and applications of CFD in process simulation. He is a
co-author of the book Metrics of Material and Metal Ecology.
Marc J.A. Pijnenborg got his MSc Degree in Resource Engineering in 2003, Delft University of
Technology (TU Delft). He has made his MSc Thesis in modelling combustion and flow
behaviour in hazardous waste incineration process. He is now working outside TU Delft as
Process Engineer.
Markus A. Reuter: Chief Executive Technologist Ausmelt Ltd. Australia. Degrees: B.Eng.
(Chemical Engineering 1981), M.Eng. (1985), PhD (1991), D.Eng. (2006) all University of
Stellenbosch (South Africa) and Dr.Habil. (1995) Aachen University of Technology (Germany).
26
Introduction
Figure 2
27
Transport phenomena
28
CFD simulation
(1)
where
29
Table 1
Item
Model information
Waste processing
rate
Turbulence
Radiation
Wall boundary
conditions
(2)
(3)
30
24.0
0.42
(1.0 + 0.15 Re0.687 ) +
.
Re
1.0 + 4.25 104 Re 1.16
(4)
Vslip D p
(5)
lies in the areas near the burner zones where gas velocity is
very high.
Both steady and transient situations of solid waste flow
were simulated. For transient studies, the time interval of
0.11 second was used with 28 time steps to catch the
smooth change of the particle flow, especially in the first
second of the transient flow. In total 15 seconds was
simulated in most of the transient models, which could
approach roughly (if not completely) the steady flow of the
solid. In these studies, the steady gas phase flow was firstly
solved for the single gas-phase flow. Afterwards, the
particles were added into the system from the solid waste
burner. The variation of the particle volume fraction was
followed to see the development of the solid flowing
process and the statistical particle trajectories, especially the
dispersion extent of the solid waste in the system.
31
(7)
2H 2 + O 2 = 2H 2 O.
(8)
(6)
Streams
C3H4
Fuel rich
21.64 15.64
Fuel lean
0.28 20.97
O2
CO
CO2 H2O
N2
Total
Stream distribution, the mass and thermal input for all inlet streams
Compositions (wt. %)
Input data
Streams Load chute Main burner Sludge burner Solid burner1 SCC burner Air lances Ash sump Total
0.00
34.45
40.00
37.77
13.10
0.0
0.0
Fuel lean
100.0
65.55
60.00
62.23
86.90
100.0
100.0
27,000
11,250
3,900
8,193
6,620
9,030
4,000
69,993
Practice
0.00
11.67
4.33
11.67
2.84
0.00
0.00
30.51
Model
1.00
11.39
4.56
10.67
2.70
0.33
0.15
30.80
In definition of solid waste burner, 15.04% was assumed as inert materials reported to slag. The total mass flow rate and the
stream distribution are based on the mass flow rate to the gases phase only.
2
The mass flow rate reported here includes the wastes, oxidation air and water content. The waste processing rate is estimated at
7,200 kg/h, based on the operational data in practice.
32
Table 3 shows the mass and energy input for all the
incoming waste streams as well as additional air supply.
For heat of combustion and energy input from each
incoming stream, the difference of the model data from the
real operation conditions in practice is illustrated, and the
deviation is relatively small.
Simulation results
Gas flow pattern inside the rotary kiln and SCC during combustion process
Figure 7
the solid bed for part of the solid waste could be clearly
seen. However, in the 3-gas model, all the solid waste was
fed through the load chute, and the combustion was
assumed to take place completely on a solid bed at the
bottom of the rotary kiln.
It is important to notice the distribution of the main
combustion air, coming from the load-chute. Due to the
physical arrangement, the air enters the kiln front from the
load-chute at an angle of 50 downward. This causes a poor
mixing of the air with waste vapours. From the temperature
distribution maps, one can see the colder zone at the lower
part of the kiln from both Figures 8 and 9. In addition, rather
high temperature gradients of the combustion system can be
observed. The hotter zones in the kiln lie in the upper-half,
and very long flames were formed with a maximum
temperature above 2000C. Combustion from the solid-bed
waste takes place somewhat downstream away from the
bed, due to the cooling effect of the load-chute air.
However, the maximum temperature from the flames is
highly dependent on the rate constant (CEBU) of the EBU
model. In the model shown here, the CEBU constant from
both the primary and secondary reactions was set at 2.0.
The constant at various levels have been tested, the
fine-tuning of the constant needs to be conducted carefully
in the next stage. The cooling effect by the cold air from
injection lances seems to be significant, and this effect could
extend up to the outlet region.
Figure 8
33
34
Figure 9
35
36
37
Figure 14 Illustration of the accumulation of the shredded solid waste (dp = 20 mm): solid volume fraction across the solid burner plane:
transient model after 15 seconds solid injection (a) low injection velocity (5.5 m/s) and (b) high injection velocity (55 m/s)
Model validation
38
Summary
Acknowledgements
The authors wish to thank the financial support from
AVR-Chemie in the Netherlands and its permission to
publish the work. The authors are also grateful to the
engineering staff of AVR-Chemie for their interests and
support to this work.
References
Cham (2004) Phoenics: Parabolic Hyperbolic or Elliptic
Numerical Integration Code Series, http://www.cham.co.uk,
accessed in September 2004.
Chen, K.S. and Lee, M. (1995) Visualization studies of
three dimensional flow and solid motion in rotary kiln,
Hazardous Waste and Hazardous Materials, Vol. 12, No. 4,
pp.395409.
Clift, R., Grace, J.R. and Webber, M.E. (1978) Bubbles, Drops and
Particles, Academic Press, New York.
39