HiTemp manufactures Rotary Kiln Systems that will operate at 12 to 100 tons per day. All system components are factory-built and tested. By using a 309 stainless steel liner and ceramic fiber insulation, we can shop assemble the largest systems without exceeding the weight and size restrictions of standard freight. Shop fabrication and on-site time is minimized. Complete systems can be designed, built, installed and operational in 3 months. System components are shipped as a standard Sealand type trailers. Locally available cranes and rigging equipment can assemble the system in just a few days. Electrical and piping installed in one week. The unit shown in the attached pictures was delivered on Monday and in operation on Thursday morning the same week. The system is 12 Tons Per Day Rotary Kiln Incineration system for solid waste. The unit was installed by a private company with contracts with the US Customs, DEA, and FBI, for disposal of confiscated drugs.
The HiTemp rotary system is sized based on operating with materials that require constant mixing, drying, and agitation. Larger systems are designed with dual rotating chambers. The exhaust from each chamber is connected to a single afterburner. The rotary chambers require an afterburner for control of particulate and vapor emissions. Depending on the operating period (8 to 24 hours), your plant will be able to handle amounts depending on the heat content.
Due to the various options for material feeding, the price does not include the feed mechanism. We suggest customers purchase a feed system such as those manufactured by Komar Industries.
TYPICAL SYSTEM DESCRIPTION OF ROTARY FURNACES
1.1 Feed System- Waste will be fed to the Ignition chamber through a round access door. Temperature sensors will limit the feed system thus maintaining a constant burn rate. Thermocouples interlocked to the control panel and the feeder will prevent operation except at set temperatures on the control panel.
1.2 Primary Ignition Chamber - The rotating chamber is proven to be one of the best units to materials for combustion. Contaminated materials can be heated to drive off the chemicals and the vapors produced are destroyed in the afterburner chamber.
The system is designed with special alloys and refractory materials to minimize weight. To accomplish this, we have designed the system using a high temperature 309 stainless steel liner, with a 304 stainless frame assembly, and lightweight ceramic fiber installation. The hard refractory typically used in a Rotary Kiln would have to be field installed and would not be suitable for the system design parameters. The weight of hard refractory is 160 pounds per cubic foot. The weight of typical ceramic fiber is 8 pounds per cubic. The weight alone would greatly exceed the design requirements.
Connected to the primary chamber shall be a stationary mating section. This section contains the inspection door, blast gate peep sight, burner, and connecting duct to the secondary chamber. Both the burning chamber and a stationary chamber shall be mounted on a single trailer.
At the chamber to the outlet connection shall be air nozzles connected to a high-pressure blower with actuated damper. As the combustion rate of the material increases, the damper is opened thus maintaining a proper air ratio for complete combustion of the smoke and particulate.
The materials to be consumed are charged into the rotating refractory lined cylindrical chamber, which has been pre-heated to normal operating temperature. The burner ignites the material and the combustible components such as smoke and volatilized gases. The action of the burner and use of fuel is normally intermittent, but depends upon the materials to be consumed.
The Primary Ignition Chambers consume the material thermally and as a result of the rotation action, continuously delivers the non-combustibles (including ash) to an exterior receptacle. The smoke (unconsumed particulate) and gases are drawn into a second, but stationary chamber for final thermal oxidation.
The ash remains in the primary chamber and settles to the bottom. As the chamber rotates, the rotary action transports the ash and other non-combustibles to the opposite end where they exit through a slot at the edge of the kiln and into an ash receptacle. A man sized access door is provided.
Rotating this chamber during the burning process exposes new surfaces to be burned while breaking up the insulating ash layer. The thick refractory lining retains the desired pre-set temperature and continually moves under the burning material while over-fire air supports the combustion from the other side.
A controlled air condition is maintained and the reduction of the waste product is semi-pyrolytic. Non-combustible materials and ash are continuously discharged and collected from the system. During normal operation no ash will have to be handled, preventing a potential health hazard.
1.3 Secondary Combustion Chamber - The secondary chamber or afterburner will be mounted on a second trailer. A suitable refractory lined transition section shall be provided. The Secondary combustion chamber shall be constructed of rolled carbon steel plate. The chamber shall be complete with the required structural supports, and flanged connections. The chamber shall be lined with a combination of both insulating and hard faced refractory materials. The refractory shall be suitably supported with stainless steel anchors for long life. The chamber shall be complete with access doors for inspection and maintenance.
The Secondary Combustion Chamber operates at a higher temperature (1400-1800 F) than the Primary Chamber and consumes the gases, smoke, and particulate. The volatile products resulting from the thermal reduction process are drawn into the secondary combustion chamber to be further oxidized. The burner is positioned below HiTemp time still air so that the incoming gases and particulate pass through the flame and are ignited. The direction of the flame assures a swirling, vortex action providing maximum turbulence and residence time to the burning mass.
A 304 stainless steel air dilution type stack shall be mounted to the discharge connection of the secondary chamber. The stack shall be designed intersections for ease of assembly and storage during equipment transport.
2.4 Burners - The Rotary Kiln System will be equipped with modulating Natural Gas or light oil burners with flame safety. The burners will be mounted to the outer shells of both chambers and are directed to assure maximum turbulence. Also included will be complete fuel trains.
2.5 Controls - The system shall monitor and record temperatures temperatures, feed rates and cycles, external equipment conditions, and safeties. System modifications may require only simple program changes rather than extensive field modifications during system upgrades.
The controls are designed to permit the proper and safe operation of the unit and to provide the operator with various options to broaden the versatility of the unit. The control panel includes the various electrical controls to assure a safe start-up and pre-heat of the chambers and operation of the Kiln.
Both under and over temperature limit set point circuits are interlocked with the feeding mechanism to assure control in feeding waste materials. The Rotary Chamber may be operated in a fixed mode, or rotated at various speeds, depending upon the materials being fed.
The controls are designed to interlock feeding of charges until the conditions of both chambers are brought up to pre-defined temperature levels. The feeding process will also stop if, during operation, conditions in the combustion chambers deviate from these pre-established conditions.
Operating temperatures controlled by adjusting the fuel-to-air ratio according to temperature monitors in the designated flue gas flow areas. Temperature is sensed by Chromel Alumel Type K thermocouples, which are connected to the system temperature controls, which regulate the auxiliary fuel.
The Rotary Kiln Incinerator shall be equipped with a temperature controller, which will shut off the feed when present operating conditions are not met. Feeding will not resume until conditions have been corrected. For the purpose of control consideration, the Rotary Kiln Incinerator is a 'constant flow' system. The total flow of exhaust gases is preset by fan selection and adjustment of fan speed.
2.6 Automatic Ash Removal - The ash shall drop out of the primary chamber once the proper burn time has elapsed. Directly below the opening shall be a collection container or an optional ash conveyor to feed a container. The ash shall be cooled with water spray prior to removal for emptying. Customer is responsible for the furnishing of this container. We suggest using a stainless container or drum with a palette-jack.
As the container shall be located below the primary chamber, the kiln would be raised or the ash receiver placed in a pit, or a conveyor system may be used. The orientation is optional and the foundations shall be part of the customer-supplied footings.