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Abstract
This paper presents a new development in the study of a rotary kiln incinerator. The modelling of the furnace has been divided
into two parts. On the one hand, a model describing the physico-chemical processes which occur within the burning bed of
municipal solid waste (assumed to be a mixture of wood, cardboard and PVC) has been set. This model mainly relies on the
assumptions of plug flow and macroscopic pyrolysis kinetics of burning waste. On the other hand, C.F.D. has been used to describe
the processes occurring within the gaseous phase of the kiln and of the post combustion chamber (turbulence, combustion,
radiation). A data processing tool has been built to automate the data exchanges between the two parts of the model. Some results of
the overall model are shown in two different situation (working with and without extra burner).
# 2002 Elsevier Science Ltd. All rights reserved.
Keywords: Rotary kiln; Incinerator; Simulation; CAPE; CFD
1. Introduction
The complete and detailed model of a rotary kiln
incinerator should describe the processes that occur at
different spatial scale and in different phases. For
example, the pyrolysis of waste is mainly driven by
intra-particle heat and mass transfer (Gronli & Melaeen,
2000; Jia, Galea, & Patel, 1999; Patisson, Lebas,
Hanrot, Ablitzer, & Houzelo, 2000a), by heat transfer
within the burning bed, which in turn, is controlled by
bed motion, combustion of the volatile matter issued
from pyrolysis, and the subsequent radiation (Patisson,
Lebas, Hanrot, Ablitzer, & Houzelo, 2000b; Lester et
al., 1991; Leger, Cook, Cundy, Sterlimg, Deng, &
Lighty, 1993; Leger, Cundy, & Sterling, 1993; Leger,
Cundy, Sterling, Montestruc, Jackway, & Owens,
1993a,b; Chen & Lee, 1994; Jackway, Sterling, Cundy,
& Cook, 1996). Such influences, due to interaction of
one phase with the other, have already been drawn for
the resolution of classical chemical engineering problems (crystallisation reactors (Urban & Liberis, 1999),
* Tel.: /33-559-722-079; fax: /33-559-722-081.
E-mail address: frederic.marias@univ-pau.fr (F. Marias).
0098-1354/02/$ - see front matter # 2002 Elsevier Science Ltd. All rights reserved.
doi:10.1016/S0098-1354(02)00268-5
814
Nomenclature
Cpk
Dk
Dp,0
Dp
0
/h
f;k/
Hs
L
/m
dry/
/m
pyro/
N
Qw
Ss
Ts
Us
V
yk
Yk
z
Greek symbols
a
os
8gas
8wall
rs,0
rs
Subscripts
Ash
C
Card
Moist
PVC
Vol
Wood
relative
relative
relative
relative
relative
relative
relative
to
to
to
to
to
to
to
ashes
unburned carbon
cardboard material
moisture
PVC material
volatile matter
wood material
2. Bed modelling
According to literature, several models exist for the
description of the physical /chemical phenomena occurring when a bed of solids is dried or burnt inside a rotary
815
2.2.1. Assumptions
The different assumptions involved by the bed
modelling are the following:
. The waste is fed to the furnace with a mass flow-rate
Qw(t ), with a composition Ywood(t ), Ycard(t), YPVC(t),
in spherical pellets of diameter Dp,0(t) and density
rs,0(t).
. The bed is in plug flow, its properties are given as a
function of its axial position (z ).
. The bed receives a specific heat flux from the gaseous
phase (8gas(z , t)) and a specific heat flux from the
kiln wall which is in contact with the bed (8wall(z , t)).
. During the drying of the bed material the particle
diameter (Dp(z , t )) remains constant while particle
density is variable (rs(z, t)). During this step, a
specific mass flux is extracted from the bed to be
transferred to the gaseous phase (/m
dry (z; t)):/
. During the pyrolysis of the particles the density of the
bed remains constant while the particle diameter is
variable. During this step, a specific mass flux is
extracted from the bed to be transferred to the
gaseous phase (/m
pyro (z; t)); the shrinkage in the
particle diameter leads to a reduction of the bed
section (Ss(z , t )).
. Bed velocity (Us(t )) is constant within the furnace.
. Bed porosity (os) is constant.
2.2.2. Geometrical considerations
Fig. 3 sums up the different geometrical variables
used in the model.
816
D2k
8
a(z; t)
k1
yC (z; t) h0f;C (Tref )
h0f;ash (Tref )
(2)
2
pN(z; t)D3p (z; t)
6(1 o s )
(1)
NoX
Comp
yk h0f;k (Tref )
yvol (z; t)
Cpk (T) dT
Tref
Cpash (T) dT :
(4)
Tref
(3)
Tref
(1o s )
@(rs Ss Hs )
@t
(1o s )Us
@(rs Ss Hs )
@z
(5)
HH2 O (z; t) h0f;H2 O (Tref )
NoX
Comp
yk
CpH2 O (T) dT ;
Ts (z; t)
Tref
h0f;k (Tref )
k1
(6)
Ts (z; t)
Cpk (T) dT
(7)
(1o s )Ss
@Ss
@t
@rs
@t
(1o s )Us rs
(1o s )Us Ss
@Ss
@z
@rs
@z
m
pyro L;
@t
(1o s )Us
@N
@z
m
dry L:
yC (z; t)
(10)
(11)
(12)
(13)
(14)
(16)
6Qw (t)
:
prs;0 D3p;0 Us (t)
(17)
(18)
(19)
(20)
(9)
RTs (z; t)
:
2.3. Results
kp exp
Ea
(8)
(1o s )
L(z; t)
Tref
Dr Hpyro :
(1o s )rs
m
pyro
817
(15)
3. CFD modelling
In the gaseous phase, several physical and chemical
processes occur (turbulence, combustion, buoyancy, and
radiation). This part of the paper deals with the manner
in which the simulation of these processes is achieved
using Fluent TM 5.3 software. First of all, a generic
geometry of an incinerator including the rotary kiln
and the post combustion chamber is depicted. Some
elements relative to the meshing of this geometry are
then discussed. In the second part, the model used by the
CFD software, which takes into account the relevant
818
Turbulence
Chemical species transport and reaction
Interaction between turbulence and combustion
Heat transfer (radiation)
819
820
Fig. 9. Profiles of temperature inside the furnace, given the volatile and drying profiles of Fig. 6 and an excess air of 40%.
821
Fig. 10. Specific heat flux received by the bed, given the volatile and drying profiles of Fig. 7 and an excess air of 40%.
fk fk1
;
fk
(21)
4.3. Results
The first set of results, which is presented here, deals
with self-incineration. That is to say, no extra-thermal
power is added to the system in order to burn the waste.
As an illustration of the computation performed, Fig. 13
shows the evolution of the shared variables (specific
mass flux of the volatiles and specific heat flux of the
incident radiation) as a function of the current iteration.
As the computation proceeds, the devolatilization zone
shifts from the left to right of the kiln. Then, at iteration
level 5, computation is stopped because the whole
amount of volatile matter is no longer released from
the residual waste, which reflects the faulty working of
822
Fig. 11. Illustration of the extrapolation scheme used to feed the CFD model with the result of the bed one.
the kiln is sufficient to promote drying and the beginning of pyrolysis. Then, once volatile matter is released
not too far from the entrance of the kiln, its subsequent
combustion is sufficient to ensure complete devolatilization of the waste.
5. Conclusion
This paper has described one of the possible coupling
between gPROMS TM and Fluent TM. It has demonstrated
that applied to a rotary kiln incinerator, such a coupling
was possible and that it was able to give insights into the
running of the process. More precisely, it has been
shown that, given the geometry of the whole incinerator
and a model waste composed of 50% of wood, 40% of
cardboard and 5% of PVC (on a weight basis), self
incineration was not possible. This can be attributed to
the smaller quantity of the incident radiation received by
the bed of waste, which insufficiently ensures its
complete pyrolysis within the kiln. Subsequently, it has
been demonstrated that adding an extra burner, fed with
methane, was a possible solution in order to achieve the
complete pyrolysis of waste within the kiln. Our model is
then able to predict the combustion of the volatile
matter within the incinerator as well as the subsequent
radiation received by its walls, and the thermal and
chemical species contours. This data may be very
interesting in order to check for the efficient running
of the process and then possible enhancements in the
design of the furnace.
823
Fig. 12. Sequence executed by the iterative program and exchange files.
Fig. 13. Illustration of the convergence for the working parameters of Table 1.
824
Fig. 14. Profiles of temperature due to the extra burner inside the furnace (left) and subsequent incident radiation received by the bed (right).
Fig. 15. Illustration of the convergence for the working parameters of Table 1 and the extra burner of 2 MW.
Table 1
Working parameters of the process
Mass flow-rate of model waste
Input size of waste particles
Input density of waste particles
Composition of the model waste
Lower heating value of the model waste
Air required for theoretical combustion
Air excess
Qw /1.7 kg s 1
Dp,0 /0.05 m
rs,0 /750 kg m 3
Ywood /0.5; Ycard /0.45,
YPVC /0.05
LHV/14.65 MJ kg1
1
/m
theo
air 3:72 kg s /
E /40%
Acknowledgements
This study has been performed in the Centre for
Process System Engineering, Imperial College, London.
Thus, the author would like to thank the head of the
department Professor Sandro Macchietto for his welcome at the centre and for his numerous advice. The
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