Rotary Kiln Quotation
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
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.
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
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
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
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
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.
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.
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