DESIGN AND CONSTRUCTION OF

SMOKELESS INCINERATOR
BY

AJIDE OLUWAMAYOWA OLUWATOBI

12/30GD017

A PROJECT REPORT SUBMITTED TO THE DEPARTMENT OF

MECHANICAL ENGINEERING, FACULTY OF ENGINEERING

AND TECHNOLOGY, UNIVERSITY OF ILORIN, ILORIN,

NIGERIA

IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE

AWARD OF A BACHELLOR OF ENGINEERING (B.ENG) DEGREE

IN MECHANICAL ENGINEERING.

AUGUST 2017
 APPROVAL PAGE

This project has been read and approved as meeting the requirement of the

Department of Mechanical Engineering, Faculty of Engineering and Technology,

University of Ilorin; for the award of Bachelor of Engineering (B.ENG) Degree in

Mechanical Engineering.

…………………………….. ……………………
PROF. O.A LASODE DATE
(SUPERVISOR)

…………………………...... …………………….
DR ABDULKAREEM DATE
(HEAD OF DEPARTMENT)

…………………………...... ……………………
(EXTERNAL EXAMINER) DATE

2
 DEDICATION

I dedicate this project to Almighty God who has guided, guarded and protected

my life to this present moment.

I also dedicate it to my parents who contributed a lot towards the successful

completion of this project and also my family, friends and well-wishers may God

continue to bless you all.

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 ACKNOWLEDGEMENT

All praise and adorations belong to the Father of my lord Jesus Christ for enabling

my successful completion of this work. I am also grateful to my parents (Mr. and

Mrs. Ajide) and siblings (Muyiwa, Bukunmi and Femi Ajide) who have shown

me great care, love and concern throughout my life.

I acknowledge my amiable supervisor Prof O.A Lasode who through his

graciousness and generosity supervised me through my project and triggered

more confidence in me (about Mechanical Engineering) with his applicative and

innovative level of thinking, till the very end of the work. In like terms, I thank

Mr Ola Dipo, Mr Adewuyi Sanmi for helping me through the design concept and

construction of my project.

I also express my gratitude to my father in the Lord Pastor Moji Adeyemi who

encouraged me when I was down psychologically. I also appreciate the support of

Apostle Ikumapayi Tomi and the final year brethren in my fellowship.

My appreciation goes to my great friends; Akande George, Adelekan olalekan,

Ogundile Phebe, Adeniyi Tunde, Omokayode Victor, Balogun Olabomi and many

more.

Finally, I wish to express my gratitude to my closest friend; the Holy Spirit who

has been my strengthener and also my fellowship on campus Foursquare Student

4
Fellowship (FSF) for their spiritual and moral blessing imparted to my life. I pray

God enrich you in all sides in Jesus name.

ABSTRACT

Waste management is defined as a disposal measure of waste produced by human

activities i.e. reducing the effect of municipal waste on human health. It is also the

reduction of waste to a significant amount without any consequential effect to the

environment. There are three major waste management option which are landfills,

recycling and incineration systems. Out of all the three options incineration

system puts into consideration the health state of the people living in the

community. Smokeless incinerator is an engineered apparatus capable of safely

withstanding heat and designed to break down chemical bonds of waste to give

less harmful substance. The primary chamber of the smokeless incinerator is

designed to burn the waste. Incomplete combustion occurs in the primary

chamber, therefore the secondary chamber is constructed in such a way that

complete combustion is achieved by the supply of excess air. The chimney serves

as the exit for the gases emitted during the combustion process. The incinerator is

a closed system in which an insulating material (fiberglass) is used to prevent heat

loss to the environment. Factors that were considered in the design of the

incinerator are materials, types of waste, cost and availability of materials. A well

designed incineration system can reduce waste into ash which amounts to about

5
5% of the original weight of the waste. The system is odourless, smokeless and

releases no poisonous substance to the atmosphere; therefore, it is eco-friendly.

TABLE OF CONTENTS

Content Page

TITLE PAGE i

APPROVAL PAGE ii

DEDICATION iii

ACKNWOLEDGMENT iv

ABSTRACT v

Table of Contents vi

LIST OF TABLES x

CHAPTER ONE

1.0 INTRODUCTION 1

1.1INCINERATION OF WASTE 2

1.2 THE NEED OF AN INCINERATOR 4

1.3. INCINEATORS 5

1.3.1ADVANTAGES OF INCINERATION 6

1.3.2 DISADVANTAGES OF INCINERATION 7

1.3.3 APPLICATION OF INCINERATION 7

1.4 PROBLEM STATEMENT 8

6
1.5 AIM AND OBJECTIVES OF A SMOKELESS INCINERATOR 10

7
CHAPTER TWO

2.0 LITERATURE REVIEW 11

2.1 BRIEF HISTORY OF INCINERATION 11

2.2 TYPES OF INCINERATORS 12

2.2.1 Simple Incinerator 13

2.2.2 Fluidized Bed Incinerator 13

2.2.3 Two chambered Incinerator 15

2.2.4 Multiple Hearth 15

2.2.5 Ocean Incinerator 16

2.2.6 Rotary Kiln Incinerator 16

2.2.7 Liquid Injection 18

2.3 INCINERATION PROCESS 19

2.4 CHOICE OF ALTERNATIVE 20

CHAPTER THREE

3.1 GENERAL DESCRIPTION OF THE INCINERATION 21

3.1.2 KEY FEATURES 22

3.2 COMPONENTS OF A SMOKELESS INCINERATOR 23

3.2.1 PRIMARY CHAMBER 23

3.2.2 SECONDARY CHAMBER 24

3.2.3 CHIMNEY 25

3.2.4 BURNER 26

8
 3.2.5 BLOWER 26

3.2.6 FIBERGLASS 26

3.3 DESIGN CONSIDERATION 27

3.3.1 MATERIAL SELECTION 27

3.3.2 PROPERTY ANALYSIS 28

3.3.3 WASTE ANALYSIS 29

3.4 WASTE 29

3.4.1 TYPES OF WASTE 29

3.4.2 CLASSIFICTION OF WASTE 30

3.4.3 LOADING CAPACITY 31

3.5 DESIGN ANALYSIS 31

3.5.1 APPLICATION 31

3.5.2 CONSTRUCTION DETAILS 31

3.6 DESIGN CALCULATION 32

3.6.1 PRIMARY CHAMBER 32

3.6.2 PRIMARY CHAMBER DIMENSION 32

3.6.3 SECONDARY CHAMBER 33

3.6.4 COMBUSTION CALCULATIONS 39

3.6.5 MATERIAL BALANCE 42

3.6.6 HEAT BALANCE 44

3.6.7 PRODUCT OF COMBUSTION FROM AUXILARY FUEL 46

9
 3.6.8 SECONDARY CHAMBER DIMENSION 48

3.7 OPERATION, PROCEDURES AND TOOLS INVOLVED 49

3.8 CONSTRUCTION OF INCINERATOR 51

3.9 DESIGN DRAWING 52

3.10 COST ANALYSIS 58

CHAPTER FOUR

4.1 RESULTS AND DISCUSSION 59

4.2 TEST AND PERFORMANCE EVALUATION 59

4.2.1 FOAM TEST 60

CHAPTER FIVE

5.1 CONCLUSION 69

5.2 RECOMMENDATIONS 70

REFERENCES 71

APPENDIX 77

10
 LIST OF TABLES

PAGE

TABLE 3.1: Typical Data on Ultimate Analysis of the Combustible

Components in Municipal Solid Wastes (dry basis) 34

TABLE 3.2: Typical Data on Ultimate Analysis of the Combustible

Components in Municipal Solid Wastes 35

TABLE 3.3: General Composition of Solid Waste 37

TABLE 3.4: Components and their percentage wet weight 38

TABLE 3.5: Operations, procedures and tools involved 49

TABLE 3.6: Bill of engineering material and evaluation 58

TABLE 4.1 60

TABLE 4:2 63

TABLE 4:3 64

TABLE4.4 66

11
 LIST OF FIGURES

FIGURE 2.2 17

FIGURE 3.1: 52

FIGURE 3.2 53

FIGURE 3.3 54

FIGURE 3.4 55

FIGURE 3.5 56

FIGURE 3.6 57

FIGURE 4.1 65

FIGURE4.2A 67

FIGURE 4.2B 68

FIGURE4.2C 68

12
 CHAPTER ONE

1.0 INTRODUCTION

Wastes are unwanted or unusable materials [1] which need to be properly

disposed so as not to cause health hazards to human lives. The manner by

which waste products are to be disposed need to be critically considered.

There are traditional ways by which waste products have been disposed in the

past such as: open burning, dumping into the sea, fermentation and biological

digestion, composting, and so on. [2] These have several implications which

people do not consider such as:

i. Water pollution by dumping into sea;

ii. Land pollution by land filling;

iii. Air pollution caused by burning of waste

iv. Greenhouse effect which affect the climate due to increased levels of

carbon monoxide, nitrous oxide, chloroflurocarbons (CFCs) and so

on which depletes the ozone layers.

v. Harm to human health through engagement in the method mentioned

above.

1
Therefore, the need to devise an environmental friendly way of disposing waste

will not be harmful to man and his environment was imminent and this can be

achieved through the design of smokeless incinerator.

1.1 INCINERATION OF WASTE

Incineration is a waste treatment technology that involves the combustion of

waste at high temperature [3]. Incineration is a thermal treatment process in

which hazardous wastes are converted into gases in the form of flue gases and

essentially incombustible solid residue. Incineration reduce the solid mass of the

original waste by 80–85% and the volume (already compressed somewhat in

garbage trucks) by 95–96%, depending on the composition and degree of

recovery of materials such as metals from the ash for recycling [4]. High level

technical competence is needed in designing, operating and maintaining an

Incineration facility. It is an integrated activity involving a number of process

operations (feed reception, control and preparation - actual combustion stage -

treatment of combustion products, waste gases and residues). The options

available within these process operations can be combined in various ways to

meet the technical needs of a wide range of circumstances. Incineration's main

advantage is that it permanently destroys many of the hazardous characteristics of

the waste. This process is accompanied by a substantial reduction in the weight

and volume of industrial wastes being incinerated. For municipal wastes there is

2
typically a weight reduction of up to 2/3 and volume reduction of up to 90%.

Increasingly, incinerators also are being designed or modified to recover the

energy potential in hazardous wastes [5]. Incineration is an environmentally and

technically superior method of waste disposal offering reliability, safety, and

efficiency.

Despite its advantages, it is highly controversial and expensive. In previous

decades, landfills were primarily used for waste disposal, allowing nature to take

its courses, eventually reducing the end volume toxicity of the wastes. However,

because of increasingly stringent environmental regulations concerning air

quality, landfills, and ground water contamination, along with the decreasing

availability of land for the encapsulation of wastes, incineration has become the

desired disposal methods for municipalities and industries [6].

Also, uncontrolled dumping is frequently used for the disposal of solid wastes.

These dumps are frequently allowed to burn - either deliberately, as a means of

volume reduction, or accidentally. The emissions from this type of uncontrolled

burning can be noxious and harmful. Properly controlled incineration is an

effective means of reducing waste volume. It ensures cleaner and more complete

combustion of waste and lends itself well to waste disposal in areas where

population density is relatively high and availability of sites for landfill is low.

Potential pollutants can be contained within the resulting residue which, if

3
disposed carefully, reduces the risk of contamination of local groundwater.

Consequently, whilst recycling has an important part to play, incineration

frequently forms part of an overall strategy for the management of municipal

waste.

1.2. THE NEED FOR INCINERATOR

The demand for an Incinerator came in as a result of improper waste or refuse

disposal which has led to various air-borne diseases and pollution. Due to the

globalization and advancement of technology, the design of a compactible

machine good enough to provide a solution to the problem of waste disposal came

into existence [7].

In Nigeria, the Federal Ministry of Environment (FME), acting through the

Federal Environmental Protection Agency Act (FEPA), has revealed that untreated

industrial and domestic wastes can be detrimental to public health or the

environment if not properly managed. Hazardous wastes can be generated from

virtually every industrial wastes, for example industries that are involved in the

production of cosmetics, pharmaceuticals, detergents, household paints, cleaning

products, light bulbs, telephones, televisions, newspapers, garden pesticides,

computers, chemicals, gasoline and even automotive safety devices such as air

bags produce wastes that are very dangerous to the ecosystem [8].

4
Majority of the companies are making considerable strides to reduce or recycle

hazardous waste from their production processes. They have been encouraged to

do so by public policies like the

 Environmental Impact Assessment Act of 1992 (EIA Act),

 Federal Environmental Protection Agency Act of 1988 (FEPA Act)

 Harmful Wastes (Special Criminal Provisions etc.) Act of 1988 (Harmful

Wastes Act) [9]

Through these policies, there has been a reduction in the cost of waste disposal.

Hence, high temperature incineration will continue to play an important role in

the future for safe and effective treatment of much of the organic hazardous

wastes that will continue to be generated by Nigeria industries [10].

1.3. INCINERATORS

An incinerator is an engineered apparatus capable of withstanding heat and

designed to efficiently reduce solid, semi-solid, liquid, or gaseous waste at

specified rates, and from which the residues contain little or no combustible

material [11].

A good Incinerator is the one that has the capability of attaining a high standard of

combustion efficiency regularly when burning a specific class of waste. In

5
achieving this standard harmoniously, the design and construction must ensure

that:

i. Air and fuel are mixed in correct theoretical proportion

ii. Air and fuel, especially the combustible classes are thoroughly mixed

together

iii. Internal temperatures must be enough for the spontaneous ignition of

both the waste produce and it’s gaseous components, (e.g. smoke and

fumes)

iv. The furnace volume must be wide enough to provide the necessary

retention time needed to achieve complete combustion.

v. Furnace proportion and the type of refractory materials must be chosen

to ensure that ignition temperature is maintained and ‘fly-ash’

emission is completely minimized.

1.3.1 Advantages of an Incineration

The following are the advantages of incineration:

i. Reduction in the weight and volume of the waste. This process results

in a less hazardous amount of waste. The gas and residue that

incineration produces, such as slag and ash, is odorless.

6
 ii. Waste incineration requires less land area as compared to waste-

disposal sites [12].

iii. Incineration can be used as a source for the generation of electricity.

iv. Incineration can also serve to stabilize and sanitize certain form of

medical and hazardous waste, and effectively destroy all biological

contaminants.

1.3.2 Disadvantages of an Incinerator

A disadvantage of waste incineration is that flue gases produced during this

process contain residues that can pollute the environment. Also, the amount of

energy produced by incineration can only serve a small town. Incinerated waste

produces ash that contains toxins. If not handled properly, these toxins can lead to

environmental problems when toxicity levels become high [12].

1.3.3 Applications of Incineration

Incinerators are used to burn various forms of hazardous solids and liquid waste

from the following sources:

 Hospitals

 Blood banks

7
  Pathological laboratory

 Hotels

 Food processing industries

 Municipal corporations

 Bulk drug units

 Tanneries

 Animal/slaughter houses

 Pharmaceutical industries

 Chemical/dyeing industries

1.4 PROBLEM STATEMENT

Incinerators discharge products such as ash and gases that are dangerous to health.

So, the combustion product gases exhausted by incineration are a source of

concern. The major pollutant in the exhaust gases include acid gases such as

hydrogen, chloride, sulphur dioxide, nitrogen oxides (referred to as NO2) and

carbon dioxide. The most publicized concern from environmentalists about the

incineration of Municipal Solid Wastes (MSW) involves the fear that it produces

significant amounts of dioxin and furan emissions to the atmosphere. Dioxins and

furans are considered by many to be serious health hazard [13].

8
Also, incineration produces fly ash and bottom ash just as is the case when coal is

combusted. The total amount of ash produced by municipal solid waste

incineration ranges from 15% to 25% by weight of the original quantity of waste,

and the fly ash amounts to about 10% to 20% of the total ash. The fly ash,

constitutes more of the potential health hazard than those of the bottom ash

because the fly ash contains toxic metals such as lead, cadmium, copper and zinc

as well as small amounts of dioxins and furans [14].

For instance, a number of methods are available to prepare old cars for resale as

scrap metals. The easiest and most popular method is by incineration. However,

most cars contain a variety of combustible materials such as plastic, foam, rubber,

under coating and grease. Due to the expenses and time involved in removing

such materials prior to incineration, the cars are commonly left intact. This results

in visible, irritating pollution and smokes as these materials burn-off the car

during incineration. Such discharges often do not meet local environmental

standards. The demand for a non-polluting and smokeless incinerator capable of

burning is therefore apparent.

9
1.5 AIM AND OBJECTIVES

The aim of the project is to design and construct an incinerator for the efficient

burning of waste without adverse effect or pollution to the environment.

The objectives include the following:

i. To design a smokeless incinerator which induces substantial flow of

air through the incinerator facilitating complete combustion of waste

materials.

ii. To construct various part of the incinerator such as the primary and

secondary chamber.

iii. To analyze the gas effluents of the incinerator

10
 CHAPTER TWO

2.0 LITERATURE REVIEW

2.1 BRIEF HISTORY OF INCINERATION

The history of municipal solid waste (MSW) incineration is linked intimately to

the history of landfills and other waste treatment technology. The first UK

incinerators for waste disposal were built in Nottingham by Manlove, Alliott &

Co. Ltd. in 1874 to a design patented by Albert Fryer. They were originally

known as destructors [15]. The first US incinerator was built in 1885

on Governors Island in New York, NY [16]. The first facility in the Czech

Republic was built in 1905 in Brno [17]. The first full-scale, municipally operated

incineration facility in the U.S. was the Arnold O. Chantland Resource Recovery

Plant, built in 1975 and located in Ames, Iowa. This plant is still functional and

produces refuse-derived fuel that is sent to local power plants for fuel [18]. The

first commercially successful incineration plant in the U.S. was built in Saugus,

Massachusetts in October 1975 by Wheelabrator Technologies, and is still in

operation today.

In Nigeria, Adedoyin et al [19] designed a smokeless incinerator. Alternatives to

incineration, its benefits and the components were analyzed. Buhari Abimbola et

al [20] also constructed a smokeless incinerator. The incinerator that was

11
constructed was made in such a way that the suction fan was just to aid the

emission of gases easily out of the chimney. The combustion was incomplete

because that was inadequate supply of air to support combustion. This resulted to

emission of pollutants such as carbon monoxide. There were some deficiencies

such as the body part was not insulated which made it hot during operation. Some

of the waste also were not burnt due to the design of the primary chamber. The

gas effluents

2.2 TYPES OF INCINERATORS

An incinerator is a forge for burning refuse. Recent incinerators include pollution

mitigation device such as gas cleaning which provide secondary treatment for

environmentally unsafe compounds so that they can be released to the atmosphere

at suitable concentration level. Several types of incinerators are currently being

manufactured. The choice of an incinerator depends on types of wastes (such as

liquid, solid and gas) and combustibility level of the waste and usage location.

The waste combustibility such as: ignitability, corrosivity, reactivity, toxicity,

flammability and flash point determines the necessary operating temperature.

The following are types of Incinerators:

 Simple Incinerators

 Fluidized bed

12
  Two-chambered incinerators

 Multiple hearth

 Ocean Incinerators

 Rotary-Kiln

 Liquid injection

 Thermal Oxidizers

2.2.1 Simple Incinerator

This type of incinerator are being built with bricks which has a metallic cover.

The opening is situated at the top or the side for loading the wastes and another

side for disposing incombustible solid called clinkers. Many of these incinerators

are small in size which are now being replaced by waste compactors.

2.2.2 Fluidized Bed Incinerator

In the fluidized-bed incinerator, wastes are quickly and uniformly incinerated

utilizing thermal capacity of hot fluidizing sand [21]. To achieve a stabled

fluidized-bed at a high temperature, the silica sand is filled in the incinerator

furnace with maximum quantity.

When the fluidizing air heated with waste heat exchanger is blown from the

13
bottom of the furnace, the fluidized-bed is actively formed in the sand layer. The

product to be incinerated is supplied on the sand fluidized-bed and mixed with the

sand while the sand particles are actively moving. The water is instantly

evaporated from the product and the product temperature is increased by the

contact with hot air. The product is incinerated through these processes. The ash

produced by incineration is crushed into small pieces and discharged out of the

system which is accompanied by the exhaust gas. Finally, the ash is collected with

dust collecting system.

14
 Figure 2.1

Characteristics of Fluidized Bed Incinerator

i. Sludge or screen residues with high moisture content can be

completely incinerated due to high thermal capacitance of sand and

excellent thermal conductance of fluidized-bed.

ii. Small consumption of auxiliary fuel

iii. Extremely low ignition loss of ash

iv. Operating temperature from 760°C - 980°C

v. Little fear for breakdown and durable construction

vi. Small site requirement and waste pass out through nozzle [22].

2.2.3 Two-chambered incinerators

It consist of mainly two chambers which is the primary and secondary chambers.

The first level of incineration happens/occurs in the primary chamber where the

smoke passes into the secondary chamber due to air-draft where it is super-heated

to produce hot air. The hot air flows through the chimney into the atmosphere. It

operates from the range of 500oC-800oC

2.2.4 Multiple Hearth Incinerator

15
A multiple hearth incinerator is also known as a vertical calciner. It consists of

vertically shaped hearth and are majorly used for sewage sludge. The material can

go through separate stages, such as drying, devolatilizing, calcining, reduction,

oxidization and so on. With careful control and proper internal combustion, each

zone can be closely monitored and the proper atmosphere can be maintained in

each zone. It operates from the temperature range of 760°C - 985°C.

2.2.5 Ocean Incinerators

This form of incineration is controversial and is presently banned in the Unites

States but still functional in Europe. In here, two forms of incinerators are

mounted on a very large ship that carries the waste out to the middle of the sea

and burns them out there. The ideal wastes for this kind of disposals are toxic and

hazardous wastes such as chlorinated matter, polychlorobi-phenyl (PCBs) and

organo-metallic wastes.

Neutralization of the waste which is acidic occurs due to the huge buffering

capacity of the ocean. It eliminates the need for secondary treatment of the waste

thereby making it more environmentally acceptable and cheap.

2.2.6 Rotary Kiln Incinerators

Its design is one of the major incinerators used by municipalities and by large

industrial plants. The rotary kiln allows the disposal of almost all types of waste

16
safely and efficiently. In the first section, the refuse is dried. The drum consist of a

rotary body which is refractory lined using a highly resistant type of refractory

adapted to requirements of the waste. It is slightly inclined (approx. 1°) in order to

move the product towards the post combustion chamber by the revolution of the

drum. Drum revolution can be adjusted and usually is in the range of 0.5 to 1 rpm.

This leads to a residence time of approximately 1 hour within the drum, assuring

good burn out of the solid residue (bottom ash).

17
18
 Figure 2.2

Characteristics of Rotary Kiln Incinerator

 Its operating temperature is from 815°C - 1650°C.

 Has greatest resistance to high temperature.

 Provision of mobility for on-site treatment.

 Its unique feature is that it can accept drums of waste.

 Large capacity to handle solid, liquid sludge and gases.

 It allows thorough mixing with air due to the rotation of the cylindrical

waste container.

2.2.7 Liquid Injection

This type of incinerators are generally selected for waste which can be atomized

and sprayed into small droplets to allow for the greatest possible mixing in the air.

Solid wastes can be incinerated if they can be melted and burnt. The viscosity of

the liquid has to be low to ensure it can be pumped and it should have sufficient

heat value. It completely combusts non-flammable materials leaving out any form

of hazardous waste like contaminated water along with kitchen wastes (sewage)

[23]

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2.3 INCINERATION PROCESS

The following are the processes a typical incinerator undergoes:

WASTE STORAGE AND FEED PREPARATION: The waste is being

delivered to the plant and discharged to a refuse storage pit. Various wastes such

as wood, polythene bags, plastics, and papers and so on are brought together and

separated based on their sizes. Sometimes, sun-drying which is one of the

cheapest form of drying waste product is used. [24]

COMBUSTION IN A PRIMARY CHAMBER: After the drying process, the

waste is subjected to a high level of heat where combustion takes place. The dry

refuse is combusted and there is a reduction in volume [25]

COMPLETE COMBUSTION IN THE SECONDARY CHAMBER: Since the

refuse fed comprises of a heterogeneous mixture, excess air is supplied which

facilitate the complete combustion in the secondary chamber.

DISPERSION OF TREATED GAS: the flue gas is being treated. The ash that

remain is termed bottom ash. This a residue of burnt material like metals, glass,

ceramics and unburnt organic materials. The cleaned flue gas is discharged into

the environment.

20
21
2.4. CHOICE OF ALTERNATIVE

A suitable incinerator is selected based on a proper analysis of waste to be

destroyed and the selection of adequate equipment to destroy the particular waste

efficiently. A two-chambered incinerator is preferred to other incinerator based on

the following reason:

i. It frequently reaches high standard of combustion efficiency when

burning any class of wastes.

ii. Internal temperatures is adequate for the spontaneous ignition of both

the waste material and its gaseous component for instance smoke and

fumes

iii. Its maintenance can be simply accomplished by the renewal of all

parts when required.

iv. Due to simplicity of designs, it doesn’t require skilled-technical

knowhow for its operation

v. It is very easy to install.

vi. The furnace volume is large enough to provide necessary retention

time needed to achieve complete combustion.

22
 CHAPTER THREE

3.0 DESIGN CONSIDERATION AND METHODOLOGY

3.1 GENERAL DESCRIPTION OF THE INCINERATOR AND ITS

WORKING PRINCIPLE

This type of incinerator consists of two major chambers which are primary and

secondary chambers. The basic principles of operation of a two-stage incinerator

are as follows:

Raw waste is fed into the primary chamber, which is a large refractory lined shell.

The waste is being reduced in the primary chamber. A fraction of the waste,

generally the fixed carbon, is oxidized releasing heat. The gases leave the primary

chamber into the secondary chambers. The air flow rate into the first stage is

carefully metered and is less than the stoichiometric rate required for complete

combustion of the waste-hence the term ‘starved-air.’ In the secondary chamber,

there is complete oxidation of the smoke. The process can be written chemically

as:

Primary combustion

23
 1 O
C+ (¿¿ 2 ) CO --------
2
¿

(3.1)

Secondary Combustion

C + O2 C O2 ----------- (3.2)

[26]

These chambers are lined to prevent heat transfer to the surrounding and heat loss.

For the ignition process, a burner is incorporated to burn the waste. Smokeless

incinerator is a compact machine of about 99% destruction efficiency reducing

the waste to ash [27].

3.1.2 Key features

 Less installation space required.

 Easy maintenance

 High combustion efficiency

 High heat and temperature resistant material

24
 No smoke or flame

 Low fuel consumption

 Very low running cost

 Suitable for solid/liquid/ semi-solid waste

 Capacity range of about 2kg/hr to 50kg/hr

25
3.2 COMPONENTS OF A SMOKELESS INCINERATOR

The following are the component of a smokeless incinerator

1. Primary chamber

2. Secondary chamber

3. Chimney

4. Burner

5. Blower

6. Fiber glass

3.2.1 Primary chamber

Primary chamber is the main combustion chamber where reduction of waste take

place at a controlled temperature. This chamber is designed to incinerate wide

range of hazardous solid, liquid and semi-liquid waste.

During the incineration of wastes, the heating value is moderately high. Waste

loading takes place at the primary chamber. This main chamber is maintained at

sub stoichiometric oxygen level. The destruction of waste by the equipment is

achieved by subjecting the waste to a high temperature above 400oC; ideally the

26
temperature is 600oC (or more) in the primary chamber and higher at the

secondary. Due to such high temperature, the chambers are lined with high

temperature resistant insulator. Each chamber (primary and secondary) has its

own respective burner. An electrical units ignites this burner. At a point, the

burner becomes red hot thereby increasing the temperature in the chamber. This

enables the waste to burn to ash. The ash door helps to dispose the ash generated

after incineration since it is in form of a tray.

Procedure

First, waste preparation and feeding takes place i.e. loading of waste, through

the loading door on the primary chamber. The burner is ignited to a temperature

of 500oC. Due to the inclined loading door on both sides, waste tends to be

centered to the burner for effective decomposition. The waste is being reduced to

white ash, which is formed on the ash door in form of a tray. The ash generated is

about 3% of the original volume. The refractory lining prevent heat to be

transferred to the surrounding, thus making it home friendly.

After the completion of burning, gases leave this chamber. Gases (smoke) exiting

the primary chamber contains carbon monoxide, un burnt hydrocarbons, water

vapour and compounds related to the reduction of waste. They are drawn up or

over into the secondary chamber [28].

27
3.2.2 Secondary chamber

Secondary chamber is the chamber where complete oxidation/ reduction

of all related compound leaving the primary chamber such as carbon monoxide,

water vapour and so on. Complete combustion takes place to make it odourless

and smokeless.

The secondary and primary chamber has similar features such as the

insulator, mild steel and burner among others. The temperature at which the

secondary chamber operates is 800OC but ideally it is about 1050oC (or more).

The temperature is higher than that of the primary so as to reheat the flue gas

from the primary chamber.

Procedure

Gases from the primary chamber are drawn up into the secondary

chamber. The burner maintains the temperature of this chamber at 800 oC. The

design of this unit ensure sufficient residence time of all secondary chamber gases

suitable for complete oxidation/ reduction of all volatile compounds. The gases

leaving this chamber thus, exit through the chimney [29].

28
3.2.3 Chimney

This is the exhaust unit for the final emission of the gaseous product of

incineration. Since the chimney does not perform any other task aside this, there

is no need for lagging. Like that of a furnace, it is located at the top mast part of

the assembly to prevent air pollution.

3.2.4 Burner

They are used to generate the heat needed to burn the waste fed into the first

chamber and to superheat the exhaust gasses in the secondary chamber.

3.2.5 Blower

This is used to supply air needed in the secondary chamber to complete the

combustion of gases from the primary combustion chamber. The blower is been

powered by an electric motor. The type of blower to use depends on the

operational temperature of the secondary chamber.

3.2.6 Fiberglass

Fiber glass (also called fiberglass and glass fiber) is a material made from

extremely fine fibers of glass. It is used as a reinforcing agent for many polymer

products; the resulting composite material, properly known as fiber-reinforced

29
polymer (FRP) or glass-reinforced plastic (GRP), is called “fiber glass” in popular

usage.

Glass makers throughout history have experimented with glass fibers, but mass

manufacture of fiber glass was only made possible with the advent of ginner

machine tools [30].

3.3 DESIGN CONSIDERATION

3.3.1 Material selection

Certain measures must be put into consideration during the design of any

machine. One important thing to consider is material selection. For the durability

and effective working of a device, the material component is very essential [31].

1. Material properties

In terms of physical properties, thermal properties, strength, temperature

resistance, corrosion resistance and so on.

2. Availability

In selecting the materials for construction, the availability of the materials were

put into consideration. For example the mild steel were easily acquired

3. Cost

30
The most important factor is the cost of the materials. A good material with an

ambiguous cost may lead to failure during the design of the machine.

31
4. Merit rating

Here, you balance the characteristics of the materials by selecting the material

with a reasonable low cost that is readily available and able to satisfy the design

condition.

3.3.2 PROPERTY ANALYSIS

1. Physical properties

With respect to smokeless incinerator, some of the physical properties taken into

consideration are the thermal conductivity and temperature resistance. Since the

material component must be able to resist transfer of heat from the chamber to the

surrounding and as a result of high temperature being generated, the thermal

conductivity is considered.

2. Wear resistance

In relation to incinerator, due to the opening and closing of the load door and ash

door and / or as a result of fluid on the surface of the material, the material can

wear. Wear is as a result of contact of two surfaces by sliding or rolling or flow of

fluid on surface leading to deterioration of the material surface thereby reducing

the strength.

32
3. Corrosion resistance

With reference to metal or other hard material needed for composition of an

incinerator, corrosion is the process of gradual weakening or deterioration of a

material by a chemical action. Since an incinerator is exposed to the atmosphere,

it is necessary to alloy the material (low and mild carbon steel) with chromium to

prevent condensation of moisture by the climatic condition because of its

(chromium) resistance to atmosphere.

3.3.3 WASTE ANALYSIS

During the design of smokeless incinerator there are certain conditions that

govern the compactness and work efficiency of the machine. They are the

type/class of waste and the capacity of the machine.

3.4 Waste: Wastes are unwanted or unusable materials.

3.4.1 Types of waste

The destruction of energetic upgrading of industrial waste made of plastic, tar,

resin, paints, textiles, fabrics, etc. can be classified as:

33
  Solid waste such as plastic (including PVC), sawdust, rubber, boards,

wood, paint and all kinds of organic material.

 Liquid waste such as phenolic waste water, hydrocarbon base, organic

solvent, contaminated oil sludge at a station or filter press outlet and

all bitumen waste.

 Gaseous waste such as volatile organic compounds at baking oven

outlets [32].

3.4.2 Classification of waste

Type A: A mixture of highly combustible waste such as paper, cardboard,

combustible floor sweeping, and trash from commercial and industrial activities,

domestic wastes.

Type B: Refuse, consisting of an approximately even mixture of rubbish and

garbage by weight. This type of waste is common to apartment and residential

occupancy.

Type C: Garbage consisting of animal and vegetable wastes from restaurants,

cafeterias, hotels, hospitals, market and so on.

Type D: Human and animal remains, consisting of carcasses, organs and solid

organic waste from hospital, laboratories and abattoirs.

34
Type 4 E: By-product waste, gaseous liquid and semi-liquid, such as tar, paints

fumes and so on from industrial operations.

Type F: Solid by-product waste such as rubber, wood plastic and so on from

industrial operations [33].

3.4.3 Loading capacity

The burning rate is of great importance when designing an incinerator because

this governs certain technicalities such as the loading door (in terms of the area)

and the weight (the capacity of the waste to be incinerated).

3.5 DESIGN ANALYSIS

3.5.1 Application:

Wastes that are been disposed are gotten from the following: Floor sweepings,

empty sachet water, cotton rags, dry leaves, waste paper and nylon, residential

colonies for disposal of gunny bags, kitchen trash / rubbish, old newspaper, food

wastes, yard wastes and so on.

3.5.2 Construction details

1. It should be sited on a level concrete hard standing.

2. Detachable material components in case of repair.

35
 3. Good lining throughout the chambers.

4. Ash tray door for the disposal of white ash produce after incineration

process.

5. Long chimney pipe to prevent high temperature of the immediate

environment.

6. It should be ruggedly built with welded and reinforced steel sheet.

7. Fiberglass to provide high insulation between the chamber and the outer

case, thereby increasing the incinerator internal protection against high

operating temperature.

8. Compactable secondary chamber with respect to its weight.

3.6 DESIGN CALCULATION

The primary chamber is designed to have the following as its dimension:

Length = 698.5 mm

Breadth = 558.8 mm

Height = 584.2 mm

36
Therefore the volume of the incinerator is the product of length, breadth and

height.

Volume = 698.5 x 558.8 x584.2 = 228025995.6 mm3

A mass of 20kg of waste is dumped as heap. The average density of the solid

waste can therefore be calculated.

Density = Volume/mass = 228025995.6/20 = 0.114x108 kg/mm3

WASTE CHEMICAL COMPOSTION ANALYSIS

For the design of the incinerator, the waste chemical composition need to be

known for maximum combustion. Waste are considered to be semi-moist and

non-combustible materials. The waste consist of various elements such as carbon,

hydrogen, nitrogen, sulphur, and other minor element such as chromium.

Therefore the ultimate analysis of a waste component is needed for appropriate

combustion. [34]

37
Table 3.1: Typical Data on Ultimate Analysis of the Combustible
Components in Municipal Solid Wastes ( Percent by weight ( dry basis)[35]

COMPONENT CARBO HYDROGE OXYGEN NITROGE OXYGE ASH

N N N N

FOOD 48.0 6.4 37.6 2.6 0.4 5.0

WASTES

PAPER 43.5 6.0 44.0 0.3 0.2 6.0

CARDBOAR 44.0 5.9 44.6 0.3 0.2 5.0

D

PLASTIC 60.0 7.2 22.8 -- - 10.0

TEXTILES 55.0 6.6 31.2 4.2 0.15 2.5

RUBBER 78.0 10.0 ---- 2.0 -- 10.0

LEATHER 60.0 8.0 11.6 10.0 0.4 10.0

YARD 47.8 6.0 38.0 3.4 0.3 4.5

WASTES

WOOD 49.5 6.0 42.7 0.2 0.1 1.5

DIRT,ASH 26.3 3.0 2.0 0.5 0.2 68.0

The table above provides information on the ultimate analysis of various

waste components when dried. The carbon content of the waste has the

38
highest percentage which is one of the element required for the generation of

carbon-monoxide. Therefore excess supply of air is needed to get a rich

mixture during the combustion state.

Table 3.2: Typical data on the ultimate analysis of the combustible

components in residential solid waste [36]

Component % wet % of Moisture Heating Energy

By weight(kg Content Values contribution
Mass ) kJ/kg
Food wastes 9 1.8 70 4652 418.68
Paper 34 6.8 6 16747.2 5694.048
Cardboard 6 1.2 5 16282 976.92
Plastic 7 1.4 1 3256.4 228.242
Textiles 2 0.4 10 17445 348.9
Rubber 0.5 0.1 0 23260 116.3
Leather 0.5 0.1 20 17445 87.225
yard waste 18.5 3.7 65 6512.8 1204.668
Wood 2 0.4 20 18608 372.16
Inorganic 20.5 4.1 3 6978 1430.49
Total 10877.539

39
 Total energy contribution = 10877.539 kJ/kg

= 10877.539 kJ/kg (1055.056 J/0.4536 kg)

= 25299479.96 J/kg

= 25299479.96 J/kg (20/1000) = 505989.5995 kJ/kg

The table gives

Using data from table 3.1 and 3.2, the weight of Carbon, Hydrogen, Oxygen,

Nitrogen, and Sulphur in each component is calculated

Food waste

Moisture Content = 70%

Wet weight in kg =1.8

Dry weight = wet weight- wet weight (moisture content in percentage)

=1.8 – 1.8(0.70) = 0.54 kg

The weight of various element = the dry weight (percent by Table 3.1)

Carbon = 0.54(0.48) = 0.26 kg

Hydrogen = 0.54(0.064) = 0.034 kg

Oxygen = 0.54(0.376) = 0.2

Nitrogen = 0.54(0.026) = 0.014 kg

Sulphur = 0.54(0.004) = 0.0021 kg

Ash = 0.54(0.05) = 0.027 kg

40
Table 3.3: General Composition of Solid Waste [36]

Component Wet Dry Composition

Weight Weight
Kg Kg C H O N S Ash Moisture Content
Food wastes 1.8 0.54 0.26 0.034 0.2 0.014 0.0021 0.027 1.26
Paper 6.8 6.392 2.78 0.38 2.81 0.019 0.013 0.38 0.408
Cardboard 1.2 1.14 0.5 0.067 0.508 0.0034 0.0023 0.057 0.06
Plastic 1.4 1.386 0.819 0.0998 0.316 0 0 0.1386 0.014
Textiles 0.4 0.36 0.198 0.024 0.112 0.017 0.0005 0.009 0.04
Rubber 0.1 0.1 0.078 0.01 0 0.002 0 0.01 0
Leather 0.1 0.08 0.048 0.0064 0.0093 0.008 0.00032 0.008 0.02
Yard waste 3.7 1.295 0.62 0.078 0.4921 0.044 0.0039 0.058 2.405
Wood 0.4 0.32 0.16 0.019 0.0137 0.0064 0.0032 0.0048 0.08
Non- 4.1 3.977 1.046 0.11931 0.07954 0.019885 0.008 3.38 0.123
Combustible
TOTAL 20 15.59 6.249 0.80351 4.34064 0.119685 0.03122 4.0454 4.41

41
The charging rate is assumed at 20 kg per hr of refuse consisting of;

element
Percentage wet weight composition = weight of ∗100
total

TABLE 3.4: Components and percentage content

COMPONENTS PERCENTAGE (WET WEIGHT)

MOISTURE 22.05
CARBON 31.25
HYDROGEN 4.02
OXYGEN 21.7
NITROGEN 0.6
SULFUR 0.16
ASH 20.23

Hydrogen and Oxygen are present in water molecules in the ratio 2:16 by weight,

which can be simplified to 1:8 [37].

Therefore, the net hydrogen available for combustion is 4.02-(21.7/8) = 1.31

percent.

The bound water in the above refuse, which is released during combustion, is

21.7(9/8) = 24.4 percent

3.6.4 Combustion Calculations

For the combustion purposes the residue may be restated in the following forms;

Carbon: (0.3125) (20) = 6.25 kg/hr

42
Less C in residue: Quantity of the carbon residue in the non-combustible x

Quantity of ash in the residue x (Charging rate/ Quantity of residue left in the

non-combustible)

Less C in residue: (1.046/20)x(0.2023)x(20/1-(1.046/20)) = 0.223 kg/hr

Available Hydrogen: (0.0131) (20) =0.262 kg/hr

Moisture, initial: (0.2205) (20) =4.41 kg/hr

Bound water: (0.244) (20) =4.88 kg/hr

Residue

Ash: (0.2023) (20) =4.046 kg/hr

Carbon = 0.223 kg/hr [38]

In analyzing the combustion process, the theoretical or stoichiometric air required

in burning the carbon and available hydrogen is determined.

By weight,

[26]

43
For 1kg of Carbon the above equation becomes;

There are 23.3% of Oxygen and 76.7% of Nitrogen in 100% weight of air [39].

1kg of oxygen is contained in (100/23.3)x2.667 = 11.56 kg of air

1kg of nitrogen is contained in (76.7/23.3)(32/12) =8.81 kg of air [38]

1 kg of Carbon requires 11.56kg of air to produce 3.667 kg of carbon dioxide and

8.81 kg of nitrogen.

Similarly,

[40]

By weight,

For 1kg of Hydrogen the above equation becomes;

44
Also, there are 23.3% of Oxygen and 76.7% of Nitrogen in 100% weight of air

[39]

1kg of oxygen is contained in (100/23.3) x8 =34.33kg of air

1kg of nitrogen is contained in (76.7/23.3) (8) =26.33 kg of air

1 kg of Hydrogen requires 34.33kg of air to produce 9 kg of water vapour and

26.33 kg of nitrogen.

The dry air theoretically required for the combustion of the waste burned is;

For the carbon; (6.027) (11.56) =69.67 kg/hr

For the available hydrogen; (0.262) (34.33) =9 kg/hr

Theoretical dry air, hourly =78.67 kg/hr

Excess air = (1.30) (78.67) =102.27 kg/hr

Total dry air per hr =Theoretical dry air + Excess air

Total dry air per hr = 78.67+102.27 =180.94 kg/hr [38]

Calculation of moisture in air

45
The ambient temperature of air is assumed to be 23oC [41].

The relative humidity of air, is assumed to be 60%

Constant atmospheric pressure is 101.325 kPa [42].

From the steam table the saturated pressure at 23 oC is read as, =2.8104

kPa.

Therefore, specific humidity (w) can be calculated as:

[43]

/kg of dry air

3.6.5 MATERIAL BALANCE

Total Mass of Waste = 20 kg/hr

Dry air supplied = 180.94 kg/hr

Moisture in air = (180.94 x 0.0105) = 1.9 kg/hr

46
Total Mass Input = (20 + 180.94 + 1.9) = 202.84 kg/hr

Output

Dry flue gas

= (6.25-0.223) (3.667) = 22.101 kg/hr

= 180.94(102.27/ 180.94) (0.233) = 23.83 kg/hr

= (180.94) (0.767) = 138.78 kg/hr

Total dry flue gas = 184.711 kg/hr

Water vapour

From refuse = (4.88+4.41) = 9.29 kg/hr

From air = (180.94) (0.0119) = 2.15 kg/hr

From combustion of hydrogen = (0.262) (9) = 2.358 kg/hr

Total water vapour = 13.798 kg/hr

Residue = 4.287 kg/hr

Therefore, total mass output = (184.711 + 13.798 + 4.287) = 202.84 kg/hr [38]

47
3.6.6 HEAT BALANCE

Total heat from waste =10877357.55j/kg(20/1000) = 217,547.15 kJ/hr

Total output heat based on secondary chamber temperature of C

Radiation heat loss = 5% of total heat available [44].

= (0.05)(217,547.15) = 10877.36 kJ/hr

Heat to ash =

Where m = weight of ash = 4.0454 kg/hr

Cp = mean heat capacity of ash = 0.831 kJ/kg. °C (assumed average value) [44].

dT = Temperature difference = (800-15) = C

Therefore, Heat to ash = (4.0454)(0.831)(777)

=2638.96 kJ/hr

Heat to dry combustion; Products =mCpdT

Where m = weight of combustion products

= 184.71 kg/hr

48
Cp = mean heat capacity of dry products

= 1.086 kJ/kg°C (assumed average value) [44].

dT = (800-15) °C = 777°C

Therefore, Heat to dry combustion = (184.71) (1.086)(777)= 157,467.12 kJ/hr

Heat to moisture = (mCpdT) + (mHv) [44].

Where m = weight of water = 13.798 kg/hr

Cp = mean heat capacity of water

= 2.347 kJ/kg. °C [33]

dT = (800-23)°C = 777°C

Hv = latent heat of vaporizations of water

= 2460.3 kJ/kg

(mCpdT)+ (mHv) = (13.798 x 2.347 x 777) +

(13.798 x 2460.3)

= 25,162.3 + 33,947.22

= 59,109.51 kJ/hr

49
Total heat out = 10,877.36 + 2,638.96 + 157,467.12 + 59,109.51

= 230,352.03 kJ/hr

Net heat balance = Total heat input – Total heat output

= 217,547.15 kJ/hr – 230,352.03

= -12,804.88 kJ/hr

Auxiliary fuel must be supplied to achieve design temperature of 800°C.

Required auxiliary fuel to achieve a temperature of 800°C

Total heat required from fuel = 12,804.88 kJ/hr + 5% radiation loss

= 23,682.24 kJ/hr

Available heat (net) from Propane =46390.9 kJ/hr

Natural gas required = 23, 682 kJ/hr /46390.9 kJ/hr

=0.5105 kg/hr

3.6.7Products of Combustion from Auxiliary Fuel

Dry Products from Fuel at 30% Excess Air = 0.504 kg [Mass of Propane per litre]

x0.5105 kg/hr= 0.257 kg/hr

50
Moisture From Fuel = 0 (Moisture content of Propane) x 0.5105 = 0 kg/hr

Secondary chamber volume to achieve one second retention time at 800°C

Total Dry Products

From waste + fuel = 184.71 kg/hr + 0.257 kg/hr =184.967 kg/hr

Assuming dry products have the properties of air and using the ideal gas law, the

volumetric flow rate of dry products (dp) at 800°C (Vp) can be calculated as

follows:

Vp = 184.967 kg/hr x (22.4 m3)/29 kg) x (1073 K /273K) x (1 h/3600s) = 0.1163

m /s

Total Moisture

From waste + fuel = 13.798 kg/hr +0 kg/hr = 13.798 kg/hr

Using the ideal gas law, the volumetric flow rate of Moisture at 800°C can be

calculated as follows:

Vm = (13.807 kg H2O/hr) x (22.4 m3/18kg H2O) x (1073K/273k) x (lhr/3600s) =

0.0187 m3/s [45].

Total Volumetric Flow Rate = sum of (i, ii)

51
Total Volumetric Flow Rate = 0.1163 + 0.0187 = 0.135 m3/s = 135,000,000 mm3/s

Assuming the depth of the secondary chamber = 558.8 mm

Area of secondary chamber = 135,000,000/558.8 = 241589.1195 mm2

Breadth of secondary chamber = Breadth of primary chamber = 558.8 mm

Therefore, the length of the secondary chamber =241589.1195mm2/558.8 = 431.8

mm

3.6.8 Secondary Chamber Dimension

Height= 558.8 mm

Length = 431.8 mm

Breadth = 558.8 mm

52
3.7 OPERATION PROCEDURES AND TOOLS INVOLVED

TABLE3.5: OPERATION PROCEDURES AND TOOLS INVOLVED

COMPONENT PROCEDURE TOOLS

Base frame 1170mmx 1130.5mm Cutting machine, scriber,
mild steel made from tri square and welding
25.4mm x 25.4mmm machine.
hollow square pipe was
cut. After the cutting it
was welded together
Primary chamber 558.8mm x 698.5mm File, hacksaw, scriber,
base frame was welded welding machine and
together. 0.9 inches sheet grounding machine.
plate was cut and then
welded to the inner and
the outer surface of the
primary chamber. The
fiber glass was placed in
between both plate. After
the welding the surface
was grounded to ensure a
very smooth surface.
Secondary chamber Mild steel hollow square Hacksaw, scriber,
bar was cut into a size of welding machine and
432mm x 1170mm. This grounding machine.
serves as the base frame.
Mild steel flat plate of
1.5mm thickness was
placed at the inner and
the outer part of the
secondary chamber.
Fiber glass was also
placed in between the
plate. It was then welded
together. Grounding
machine was used to
ensure a smooth surface
finish.

53
Chimney A hollow cylinder of Vice, hack saw, cutting
89mm diameter of length machine.
200mm was cut for the
fabrication of the
chimney. It was placed at
top centre of the
secondary chamber. The
chimney was then welded
together to the secondary
chamber.
Blower The blower was placed at Plier, welding machine.
the lower side of the
secondary chamber. Two
hinges was welded to it.
This ensures the easy
removal of the blower for
repair.
Burner The burner was welded to Welding machine
the primary chamber. It
was placed at the left
lower part of the primary
chamber.
Front door 1.5 mm mild steel hollow Welding machine.
square bar was welded to Grounding machine.
form the base frame. In
between the inner and
outer part fiber glass was
placed to avoid heat loss.
It was then attached to the
front part of the primary
chamber using hinges.

54
3.8 CONSTRUCTION OF THE INCINERATOR

The base frame of 1170 mm×1130.5 mm made from 25.4 mm×25.4 mm hollow

pipe was welded to form a square base. Mild steel plate of low carbon steel (0.3-

0.4C %), Nigerian gauge 0.9 inches was used to construct an inner and outer

part of the primary chamber respectively around the base frame of 558.8

mm×698.5 mm. It was doubled-laid with fiber glass as filler/lagging material for

the space between the two plates to serve as insulator. The secondary chamber

was double laid with fiber glass which functions as the heat insulator around the

base frame of 432 mm x 1170 mm. A hollow cylinder of diameter 89 mm was

used in the fabrication of the chimney. This serves as the exit for the exhaust

gases after it has been sucked in by the extractor blower attached to the lower end

of the secondary chamber. The extractor blower that was attached (using hinges)

to the secondary chamber was made detachable to make it accessible anytime in

case of repair. 8mm rod was welded together in the construction of hearth (where

the waste seat on). This was used so that it can withstand heat compared to a wire

gauze. It was designed to have hole spacing so that ash and other residue could

fall to the ash collector. The ash collector is 1.5 mm galvanized plate placed

directly under the hearth. A garbage loading door was constructed to feed the

incinerator at the primary chamber. The front door was riveted to the main frame.

The ash collector passes through the front door for disposal. An industrial burner

55
was connected to the primary chamber. The burner is round which makes the fire

that it is ignited to spread quickly and equally to every part in the primary

chamber. Provision was made for a cooking gas cylinder to be connected with

hose to the burner at the primary chamber which is effective for the primary and

secondary combustion chambers. The primary element was used to start the

garbage burning until the combustion has stabilized.

3.9 DESIGN DRAWING

FIGURE 3.1

56
FIGURE 3.2

57
FIGURE 3.3

58
FIGURE 3.4

59
FIGURE 3.5

60
FIGURE 3.6

61
3.10 COST ANALYSIS

TABLE 3.6 Bill of engineering material and evaluation

S/ Material Unit Quantity Total

N Cost Required Cost
(Naira) (Naira)
1. Mild steel Hollow square bar 600 5 3,000
2. Mild steel flat plate[0.9mm] 6,000 3 18,000
3. Mild steel flat plate [1.5mm] 7,500 2.5 18,750
4. Fiberglass 12000 12000
5. Suction fan 4000 1 4,000
6. Bolt and Nut (13mm) 50 3 150
7. Hinges 200 4 400
8. Paint (2 litres) 500 2 1,000
9. Socket 250 1 250
10 Wire (1.5mm) 70 1 yard 750
11. Electrode 1,000 1 1,000
12. Cutting disc 500 2 1,000
13. Labour cost 10,000
14. Galvanized Sheet 2000
15. Miscellaneous 3,000
16 Burner 7500 1 7500
17 Lightener 1500 1 1500
TOTAL 84000

CHAPTER FOUR

4.1 RESULTS AND DISCUSSION

In the design of the incinerator, relatively cheap locally made materials were used.

The material selected to be incorporated into the design is able to withstand heat.
62
Fiberglass was overlaid n between the outer and inner sheet having a thickness of

0.005m. This ensures that heat is not lost during the combustion process and also

makes it durable over with time. The materials satisfy the performance

requirement of incineration.

4.2 Test and Performance evaluation. Experiment was carried out to evaluate

the efficiency of the incinerator. A dried sorghum plant was used in carrying out

the experiment. There are basic operating conditions that affect the rate of

incineration and the residual weight of waste incinerated. Weight, time and size

were the basic parameters considered. These three parameters were varied with

each other. The table 4.1 below shows the response under different operating

condition.

63
Table 4.1: The actual residual weight for various combination of Weight,

Time and Size.

Run Factor1 Factor 2 Factor 3 Response 1

A:Weight B:Time C:Size Residue

Weight
Kg Min cm
kg

1 0.64 10.00 2.00 0.000076

2 2.00 5.00 1.00 0.04567

3 2.00 5.00 1.00 0.04567

4 2.00 15.00 3.00 0.01965

5 2.00 15.00 3.00 0.01965

6 4.00 1.59 2.00 3.05

7 4.00 10.00 0.32 0.02047

8 4.00 10.00 2.00 0.09138

9 4.00 10.00 2.00 0.09138

10 4.00 10.00 2.00 0.09138

11 4.00 10.00 2.00 0.09138

12 4.00 10.00 2.00 0.09138

13 4.00 10.00 2.00 0.09138

14 4.00 10.00 2.00 0.09138

64
15 4.00 18.41 2.00 0.04089

16 6.00 5.00 1.00 0.13879

17 6.00 5.00 3.00 0.13989

18 6.00 15.00 1.00 0.04523

19 6.00 15.00 3.00 0.05012

20 7.36 10.00 2.00 0.10126

In determining the regression model for the process design expert software

was used to generate the equation. The regression model for the process for the

selected combinations of process parameter is as given in Equation (4.1):

Residual weight= 0.09170772+0.0115092A+0.00142765B+0.0050414C-

0.015522A2-0.0208402B2-0.0209625C2+0.01671637AB-0.0010814AC-9.862*10-
5
BC … (4.1)

Where: A= weight; B= time and C= size.

The predicted residual weight calculated using Equation (4.1) the various

combination of weight, time and size is shown in Table 4.2

65
 Table 4.2: The predicted residual weight for various combinations of weight,

time and size.

A B C A2 B2 C2 AB AC BC Predicted

Residual

Weight
7.3 10.0 2.0 54.169 100 4.00 73.6 14.7 20.0

6 0 0 6 0 2 0 0.031929
4.0 1.59 2.0 16.00 2.5281 4.00 6.36 8.00 3.18

0 0 0.023677
4.0 18.4 2.0 16.00 338.928 4.00 73.6 8.00 36.8

0 1 0 1 4 2 0.001548
2.0 5.00 3.0 4.00 25.00 9.00 10.0 6.00 15.0

0 0 0 0 0.060162
4.0 10.0 2.0 8.00 100.00 4.00 40.0 8.00 20.0

0 0 0 0 0 0.044397
6.0 15.0 3.0 36.00 225 9.00 90.0 9.00 45.0

0 0 0 0 0 0.03182
4.0 10.0 2.0 8.00 100.00 4.00 40.0 8.00 20.0

0 0 0 0 0 0.013622
2.0 15.0 3.0 4.00 225 9.00 30.0 6.00 45.0

0 0 0 0 0 0.06791
4.0 10.0 2.0 8.00 100.00 4.00 40.0 8.00 20.0

0 0 0 0 0 0.028449
4.0 10.0 2.0 8.00 100.00 4.00 40.0 8.00 20.0

0 0 0 0 0 0.067161
2.0 15.0 1.0 4.00 225 1 30.0 2.00 15.0 0.035164

66
0 0 0 0 0
2.0 5.00 1.0 4.00 25.00 1.00 10.0 2.00 5.00

0 0 0 0.023917
4.0 10.0 3.6 16.00 100.00 13.542 40.0 14.7 36.8

0 0 8 4 0 2 0.040917
6.0 5.00 3.0 36.00 25.00 9.00 30.0 18.0 15.0

0 0 0 0 0 0.091708

TABLE 4.3: ANALYSIS OF VARIANCE TABLE

SOURCE Sum of Degree of Mean F- Prob>F

MODEL Squares Freedom Square Value(fisher
(DF) Snedecor
distribution)
0.017391 9 0.001932 4.845268 0.0139
A 0.017391 1 0.001809 4.536102 0.0620
B 1.8*10-5 1 1.82*10-5 0.045696 0.8355
C 0.000349 1 0.000349 0.874757 0.3741
A2 0.003303 1 0.003303 8.283377 0.0182
B2 0.003653 1 0.003652 9.157295 0.0143
C2 0.006025 1 0.003652 15.10767 0.0037
AB 0.002235 1 0.002235 5.605518 0.0421
AC 9.35*10-6 1 9.35*10-6 0.023458 0.8817
BC 7.78*10-8 1 7.78*10-8 0.000195 0.9892
Residual 0.003589 9 0.000399
Lack of Fit 0.003589 4 0.000897
Pure Error 0 5 0
Cor Total 0.02098 18

For the ANOVA result shown in Table 4.3, a confidence interval of 95% is used.

Variables with P-Value (probability value) less than 0.05 are significant while

those with P-value (probability value) greater than 0.05 are insignificant. In this

67
case A,A2,B2,C2 and AB are significant model terms. This thus implies that the

regression model approximates a quadratic model as it is a combination of square

interaction ( A2.B2, C2), 2-way interaction (AB) and a linear term (A). Cutting

off the insignificant terms the resulting model is given by Equation (4.2):

Residual Weight = 0.09170772+0.0115092A-0.015522A2-0.0208402B2-

0.0209625C2+0.01671637AB. … (4.2)

The graphical regression analysis presented in Figure 4.1 shows a perfect

correlation between the predicted residual weight and the actual residual weight.

This is evident because R2 value of the plot is 0.8289 which is very close to 1.

This implies that the predicted model can adequately represent the actual model.

68
 Figure 4.1

The difference between the actual and predicted efficiency gives the residual and

the standard deviation (SD) of the residual shown in Table 4.4:

Table 4.4: Diagnostics for all observations

Standar Actual Predicted Residual SD of Residual

Value Value
d Order
1 0.04567 0.031929 0.013741 0.76533
2 0.0136 0.023677 -0.01008 0.76533
3 0.01533 0.001548 0.013782 0.676806
4 0.04523 0.060162 -0.01493 0.676806
5 0.05528 0.044397 0.010883 0.76533
6 0.013989 0.03182 -0.01783 0.76533
7 0.01965 0.013622 0.006028 0.676806
8 0.05012 0.06791 -0.01779 0.676806
9 0.000076 0.028449 -0.02837 0.632668
10 0.10126 0.067161 0.034099 0.632668
12 0.04089 0.035164 0.005726 0.702244
13 0.02047 0.023917 -0.00345 0.632668
14 0.05009 0.040917 0.009173 0.632668
15 0.091544 0.091708 -0.00016 0.166423
16 0.091544 0.091708 -0.00016 0.166423
17 0.091544 0.091708 -0.00016 0.166423
18 0.091544 0.091708 -0.00016 0.166423
19 0.091544 0.091708 -0.00016 0.166423
20 0.091544 0.091708 -0.00016 0.166423

The low value of the residuals is an indication that the linear regression is

appropriate to describe the behavior of the model. The interaction graph of the

residual weight has shown in Figure 4.2 shows the relationship between the two

way interactions and the residual weight of the waste in the incinerator. In the

69
Figure 4.2a, as size decreases and weight decreases, residual weight reduces. In

Figure 4.2b, an increase in time with a decrease in weight leads to an increase in

residual weight. In Figure 4.2c, an increase size and time leads to an increase in

residual weight. .

E SI G
D N - EXP ERT Plot
e s i due W
R ei ght

X= A: W e ig ht
Y= C: S iz e

D esi gn P
o in ts
C - 1.0 00
C +3. 000
c t ual Factor
A
:B Ti m
e = 10. 00

Interaction Graph
C: Size
0 .1 0 126

0 .0 75 9 64
Residue Weight

0 .0 50 6 68

0 .0 25 3 72

7.6 E-0 0 5

2.0 0 3 .00 4 .00 5 .0 0 6.0 0

A: Weight

Figure 4.2a

70
DESIG N-EXPERTPlot
Res idue Weight
X =A: Weight
Y =B: Time
Des ignPoint s
B- 5.000
ActuB+ 15c. to00
al Fa r0
C: Siz e =2. 00

Interaction Graph
B: Time
0.105425

0.0790876

Residue Weight
0.0527504

0.0264132

7.6E-005

2.00 3.00 4.00 5.00 6.00

A: Weight

Figure 4.2b

DESIG N-EXPERTPlot
Res idue Weight
X =B: Time
Y =C: Siz e
Des ignPoint s

C- 1.000
ActuC+ 3.c000
al Fa tor
A: Wei ght =4.00

Interaction Graph
C: Size
0.10126

0.075964
Residue Weight

0.050668

0.025372

7.6E-005

5.00 7.50 10.00 12.50 15.00

B: Time

Figure 4.2c

71
 CHAPTER FIVE

5.0 CONCLUSION AND RECOMMENDATION

Environmental hazards caused by the incessant disposal of solid waste on

landfills have been one of the major problems faced by the government. Proper

measures and standards must be taken by the federal, state and the local

government to curb this problem. Solid waste management inevitably deals with

the option of landfills, incineration systems and recycling. Ultimate choices are

traded against the available landfill space and also the cost of building new

landfills.

5.1 CONCLUSION\

Incinerator can be said to be the most effective means of waste disposal, because

it completely decomposes trash/ rubbish to white ash with a minimal side effect.

With the existence of smokeless incinerator, the problem of creating or building

space for dumping refuse which will lead to increase in bacteria and micro-

organism or burning of waste that can result to air pollution, which would

eventually jeopardize one’s health, can be taken care of. Therefore, the aim and

objectives of this project has largely been achieved.

72
5.2 RECOMMENDATION

Having completed the design and construction of a smokeless incinerator, the

following suggestions are recommended for further improvement:

i. The construction of an automatic feed machine.

ii. The conversion of the flue gas to power a boiler.

iii. The conversion of the flue gas to generate electricity.

iv. High pressure gas should be employed to enable effective supply of

gas for faster burning

73
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APPENDIX

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