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297-304,
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SIMULATION
OF
1991
A SLAGGING
M.-Y.
INCINERATION
PROCESS
Dept Chemical Engineering, Kath. Universiteit Leuven, De Croylaan 46, 3030 Heverfee (Leuven),
Belgium
(Received
6 April lPPO;$nal
revision received
received for publication
17 January
7 November
1991)
1990;
Abstract-A
simplified model for the simulation of a high-temperature slagging incineration process,
capable of predicting the temperature and composition distribution along the furnace, and the waste
feeding rate has been developed.
The simulation results indicate that the operating temperature does not have a significant effect on the
outside wall temperature, and the waste channel plays an important role in insulating the furnace. The
melting rate is affected by the operating chamber temperature but the bum out rate of combustible waste
depends almost completely on the waste feeding rate, with little effect of operating temperature.
1. INTRODUCTION
A major area of concern in the design and engineering of hazardous waste incineration processes is to
insure the complete destruction of the waste, and the
production of a flue gas in which hazardous constitu-
ents do not exceed regulatory limits. The high-temperature slagging incineration process (Vanbraband
ei al., 1988) is designed for the treatment of partially
combustible waste, where the ash and melted slag are
formed into an inert state. Due to the very high
temperature, the hazardous chemicals are almost
completely converted into harmless products. The
particles contained in the flue gas are removed when
it is forced to pass through the slagging layer. This
can ensure low particle concentration in exiting flue
gas.
The present work is concerned with the development of a model which can be used to predict the
key parameters of the system such as the feed rate,
the temperature and composition distribution and the
heat transfer between the refractory walls and the
waste.
The basic scheme of a proposed high-temperature
slagging incinerator is shown in Fig. 1 (Van de
Voorde, 1983).
The mixed waste is fed into the combustion
chamber through a vertical annular space, where the
waste is homogeneously distributed by means of
rotating distribution scoops. The waste is pushed
toward the combustion area at the bottom of the
furnace. The refractory wall reflects the intense heat
radiation from the burner gas onto the upper layer of
the waste cone. The temperature of the waste cone
surface reaches the melting point of the incombustible
waste at about 1400C.
In the combustion layer or oxidation zone, the
resulting ash and incombustible waste are melted
together to form a slag. The slag layer and the
underlying waste also provide efficient thermal insulation across which a thermal gradient appears. The
297
MODEL
M.-Y.
298
burner
insulation
material
WEy et al.
The mass balance for the gaseous phase is given by:
r&actoty
material
V*(p,u,)
= - $s.
(4)
(3
combustio
chamber
where
wmbustion
layer
dt =+.
u
high, the temperature is low. The temperature in the outlet zone is high but the voidage
is low).
is
where
(-$ >.
q=s.n
The terms on the right-hand side represent, respectively, conductive heat transfer, heat generated by
combustion-reaction (the difference between the heat
capacity of reactants and products is covered by the
heat of reaction), and heat exchanged from gas to
solid. The term at the left-hand side of the equation
represents the convective heat transfer.
As in Fig. 2, a differential energy balance for a solid
contained in a differential volume can be written as:
P+,C,,V*(T,)
= V(k,,
VT,) + h,S(T*
-_A e_EiRr.
0
-
ri
Energy and mass balance calculations are performed, based on the specification of the design and
on operating conditions, with the primary objective
of calculating the temperature and waste composition
distribution along the incinerator as well as the slag
melting rate.
Incinerator design specifications include the thickness and conductivity of the furnace body and the
volume of the unit.
3.
THE
SOLUTION
OF THE
SIMULATION
MODEL
- T,)- (2)
*as
input
1
reacted
The terms on the right-hand side represent, respectively, conductive heat transfer, heat exchanged from
solid to gas. The term at the left-hand side of the
equation represents the convective heat transfer.
The reaction rate (the net mass of material per unit
area and time in which it is transferred from a solid
to a gas due to occurrence of a reaction), according
to the assumption of zero order, can be written as:
dw
-=
dr
?I,=
SOlid
solid
Fig.
2. Mass
and
output
energy
transfer
phase.
*as output
between
solid
and
gas
Simulation of a slaggingincinerationprocess
299
(8)
Re = 4OOS10,000,
Re = du,p,/p(,(l
eomeby
= 2.5 Re-I*,
- 6).
of furnace
t [V(Lo.= - c) + 1 - .Eo-66
+ f].
(9)
to
(10)
For the convective heat transfer between combustion gas and refractory material or slag film, the
equation developed by Dittus and Boelter is applied
(t)zisik, 1977):
hmfD/kf = 0.23 Re--* x Pr.3,(ml),
(11)
Re = Du,P,/~~,
mpam
meslagmelling
= A x e-xrRT.
(12)
WEy et al.
M.-Y.
300
A = 3 x 1Okg h-1.m-2,
(for 500-800 K)
E/R = 6000 K
(14)
The heat transfer between flue gas and slag film can
be obtained from the following equation:
A, = hm,Az(Tfg - q).
waste
specificheat
density
+ C).
320
320
0.05
0.05
temperature
particle radius
(K)
(m)
1 -58-W)
operotlng
CombWon
chamber
qddlk~,
mmpcsitiin
conductivity
320K
(15)
specitiiticns
Inlet
GJPJ x (1 - c 1, (17)
k=51?iJ/h.m.K)
I
I *=lrS.n~J/h
temperatu
Combustion
*the
coordinate
unit
(18)
(13)
Tf).
5. DISCUSSION OF RESULTS
(16)
BfgYm.
is meter
Fig. 4. General conditions used for simulation of the high-temperature slag incineration process.
Simulationof a slaggingincinerationprocess
complete
cambustion
(0.3.0)
(l..O)
material
Fig. 9. Temperature
distribution for an operating
temperature
of 2100 K.
chamber
302
M.-Y.
scale
WEY er al.
UP ratio=2
3
z
300-
P
2
200
E
B
G
loo0
1700
1
1800
Operating
i
1900
I
ecmo
I
2100
chamber temperature
I
2200
PK)
01
1.0
I
1.2
I
1.4
Scale
I.8
1.6
up ratio
I
2.0
I
2.2
s
e
-
.o
0.8
0.6
z
e
0.6
i?
0
t
.Fj
0.4
L3
640-660
640-6W
0
e
D
E
3
3
0.2
5 0.6
.z
01
i
0.3
L;
0.5
0.7
Feeding
i
0.9
rate
1 .I
1.3
0.4
0.2
go00
d
6000
7oOo
E/R
(m/h)
so00
6om
10.000
I
11,000
(OKI
7.0
1.2
1.4
1 .6
2.0
1.8
2.2
Scale up ratio
imply the
1. The operating
temperature
does not have a
significant effect on the outside wall temperature.
2. The insulation part shows a relatively high temperature. A cooling system can reduce this effect.
3. The melting rate is affected by the operating
chamber temperature,
but the burning out rate
is mostly affected by the waste feed rate.
4. The assumed velocity angle has only little effect
on the outlet combustible waste fraction, within
the range of cases simulated.
5. The slag layer and the underlying waste provide
efficient thermal insulation across which a thermal gradient appears.
NOMENCLATURE
A = Arrhenius frequency factor (kg h~.m~2)
A, = Refractory material area (mZ)
A, = Slag fllm area (m2)
Particle
radius
tm)
,-
z
E
0.4
0)
5
0.3
3
v
p
2
5
.s
o.*
0.1
0.5
M.-Y.
304
u =
u =
v =
dwldt =
a =
fi =
L=
p =
Q=
Velocity (m h-l)
Volume flow rate (m h-l)
Volume of waste channel (m3)
Reaction rate Cknm-2*h-1
Velocity angle Pj
Heat transfer to slag film (J h-)
Void fraction
Density (kg m-j)
2.0376 x 10e4 J me2 K-h-l
(Stefan-Boltzmann
constant)
cp, = Przjection angle from refractory material to slag
rp, = Eje2zp
angle from
a=Air
c = Combustible waste
camp = Composite material
f = Refractory wall
g=Gas
i = Inlet
1 = Slag film
m = Transfer between solid and air
ma = Transfer between furnace wall
air
and
ambient
WEY et al.
mf = Transfer between combustion gas and refractory
material
ml = Transfer between combustion gas and slag film
s = Solid
u = Incombustible waste
fg = Combustion gas
REFERENCES