Incinerator that burns everything
We manufacture incinerators for thermal waste decontamination, gas cleaning units and ceramic heat exchangers.
Our products are manufactured using unique technology of oxidative design in ceramics. Plant consists of a modified incinerator and a unit for high-temperature cleaning of flue gases. Combustion of soot and organic compounds occurs in the channels of the ceramic honeycomb blocks; a ceramic heat exchanger is installed to cool the flow and recover the heat.
The level of emissions for main marker substances is 5 times lower than European standards. For example, the level of carbon monoxide emissions is not more than 10 ppm (parts per million) *
Rate of processing
The rate of processing in the incinerator - 1000 – 5000 kg of waste per hour.
How technology works
From the simulation, it can be seen that, due to the poor distribution of the components inside the “classical” afterburner, incomplete oxidisation of contaminants occurs. At the same time, in this afterburner, the excess of oxygen is high on average. However, there are local zones and “cold corridors” where there is not enough oxygen. It is in these places that pollutants “slip” through.Due to the uneven temperatures, nitrogen oxides are additionally synthesised.
On the other hand, the ceramic cellular blocks used in the Aurora Borealis afterburners both completely eliminate the likelihood of leakage of contaminants and equalise the temperature field inside the device.
If you make a dynamic calculation in which the “cold corridors” change their position several times per second, then the advantages of the Aurora Borealis afterburner become even more obvious.
AURORA incinerator device
High energy efficiency
The only incinerator that uses a heat exchanger that heats the air necessary for combustion, our incinerator is the most energy efficient due to the tightness of loading, unloading and sealing units. The use of modulated burners results in greater fuel economy, and the use of automated monitoring systems, including gas analyzers, which work along the entire combustion cycle, allows working with a minimum excess of oxygen
The unloading system is simple, reliable and very convenient for operation. The ash bin is emptied into a cart. The cart rises and turns itself into a regular eight-cubic-meter garbage can.
Ash disposal bin
When the incinerator is running in continuous mode, ash should be accumulated and discharged non-stop. We made a bunker with a fully opening bottom which is lined with refractory bricks and cannot stick.
We solve the problem of tightness of the rotating drum and stationary ends of the incinerator with a graphite dynamic seal - 128 staggered graphite plates completely isolate the incinerator space.
Incinerator drive system
To rotate the drum, a system of a ring gears, pinion gears and roll rings is used. We have added plating covers for all the drive parts.
The rotating drum
Our drum is lined with refractory bricks. This allows it to reach high operating temperatures, good dredging of waste, operation in a continuous cycle, and simple ash discharge. In order to achieve the optimum conditions for the incineration of a particular type of waste, the rotations speed of the drum and its angle of inclination may be altered.
Waste loading system
A ramp with a bunker is used to lift the waste. We refrained from using transporters and augers, since they cannot be used to move large packages with waste, and pre-grinding entails another complex technological and costly process. The incinerator is designed for maximum versatility - no preliminary waste preparation is required.
Automatic control system
Obtaining data from 8 gas analysis points, from 10 vacuum control points and a huge number of temperature measurement points, the control system independently adjusts the modulated burners, primary and secondary air flow and thrust, and controls the loading process.
Heat exchanger unit
To cool the gases, we do not use their dilution with atmospheric air, but use a heat exchanger. It allows further reduction of the exhaust gases’ temperature, thereby reducing their volume for subsequent cleaning in a wet scrubber.
Principle of air cleaning
Our products use the most reliable and versatile principle of emissions cleaning - afterburning. Any organic components contained in the gases to be cleaned are subject to purification with an efficiency of >99%.
In a temperature of about 1000 ° C and the presence of oxygen, the components of the emission are completely oxidised. The result is pure carbon dioxide CO2 and water vapor H2O. The process takes place with an optimal excess of oxygen and in a uniform temperature field, thanks to which the synthesis of nitrogen oxides is minimal.
A wet scrubber is optionally used for cleaning acidic gases (CO2 and HCL)
Withstands thermal shocks and thermal cycles.
Our products retain their strength even if the block is hot (> 1100 ° C) and is exposed to cold air. This is achieved through the minimum coefficient of thermal expansion inherent in our ceramic products.
Several ceramic cellular blocks with different channel sizes
In one afterburner we use several successively installed ceramic cellular blocks with different channel parameters. Thanks to this approach, we can adapt our devices to any dust content in the flue gases and additionally stabilize and balance the flow of smoke.
All organic components, as well as soot and carbon monoxide, are subject to oxidisation at high temperatures.
After the afterburning process, all components are oxidised to such an extent that they form only two harmless substances: carbon dioxide CO2 and water vapor H2O.
Low pressure loss
Thanks to the patented method of production, the channels in the ceramic cellular blocks have a regular structure. Exhaust gases encounter minimal resistance on their way out. This is of key importance when working with large volumes of gas.
Resistance to extreme environments
We kept our blocks in hot concentrated sulfuric acid. After 200 hours of testing with the material of the blocks, there was no change.
Main advantages of the afterburner
In our afterburner, two ceramic cellular blocks are mounted in series with different channel sizes. A diffuser and diaphragm are used at the entrance to pre-mix the flows.
For visual modelling, we use one of the “classical” models of the afterburner with tangential (“twisting”) input of components.
The temperature front is uniform. There are no eddies after the ceramic cellular block. Temperature difference at a static calculation of not more than 120 degrees at the flow front.
There is a strong temperature gradient along the entire flow front. This is the reason for the synthesis of nitrogen oxides (in the hot zone). A temperature difference in the static calculation of more than 1000 degrees is at the front of the flow.
Concentration of O2 (oxygen)
A uniform distribution of the oxidising agent is observed throughout the gas flow section.
Due to the irregularity of the vortex, in the middle of the channel there is a lack of O2 for the oxidisation of the reaction products. As a result, in the middle of the stream there is no complete combustion of the pollutant components in the gaseous emissions.
CO concentration (carbon monoxide)
There is a complete oxidisation of carbon monoxide to carbon dioxide.
An incomplete oxidisation of carbon monoxide is observed inside the stream due to a lack of oxygen, although the flow is turbulent.
Concentration N0 (nitrogen oxides)
The main zone of synthesis for nitrogen oxides is the area of the burner flame. The synthesis of oxides inside the flue flow does not occur. On the contrary, there is a partial reduction to harmless N2. Maximum concentrations are 3 orders of magnitude lower than in a device without a ceramic cellular block.
The main synthesis zone of N0 is the upper part of the afterburner, where optimal conditions for the process were created due to the local high temperature.
Gas cleaning unit
Ceramic fitted cellular blocks
In the channels of the cellular blocks, the diameter of which is less than 1 mm², oxidisation of contaminating components occurs. They are made from various types of ceramics and metal-ceramic composites.
Designed to compensate for the changing parameters of the flue gases. Allows the pre-mixing of the flow of oxidant, fuel and gas.
Made of quartz glass. Designed for periodic visual monitoring of the ceramic cellular blocks.
Purified gas outlet
It is connected to a chimney or to an additional water heat exchanger to provide thermal energy for economic needs.
Increases the temperature of the flue gases to 1100 ° C and stabilizes combustion to ensure guaranteed cleaning. Highly-adjustable modulated burners are set to automatically adjust to the specific properties of the afterburning gas.
Gas inlet for cleaning
It is connected to a chimney or to an additional water heat exchanger to provide thermal energy for economic needs.
Installed after each ceramic cellular block. They measure the flow rate, the content of marker pollutants, the temperature of the flow, and any pressure drops. On the basis of these readings, automatic adjustment of oxygen consumption and the flow of the gas being cleaned takes place, and the burner is adapted.
Ceramic heat exchanger
Designed for heat recovery of flue gases and fuel economy. It is 40 times more efficient than any other heat exchanger that provides air / air heat exchange. This is achieved by a high heat exchange area per unit volume, due to the use of the technology of oxidative design for ceramics.
It is made of 8mm thick steel. It has a modular fully collapsible design. The support frame allows cleaning or replacement of cellular blocks with minimal effort.
A layer of lightweight refractory bricks keeps the temperature inside the burner. The outer wall is not heated above 50 ° C when the internal temperature is more than 1100 ° C.
We have implemented a lock gate, which provides:
- Continuous loading
- It is not exacting to the loaded material (material can be fibrous, winding and can be large and solid size 200 x 200 x 200)
Ensures the tightness of the combustion chamber. This is important for three things:
— No smoke
— The ability to install the device indoors
— The absence of air leaks (if the loading device does not ensure tightness, then at the moment of loading the temperature inside the waste incineration chamber changes significantly).
- Dredging waste
- Ash removal in the simplest, most effective and reliable way.
Our drum is lined with refractory bricks and it gives:
- The ability to maintain high temperatures inside the combustion chamber with less fuel consumption
- Many times increases the service life of the combustion chamber
We use a ring seal system using graphite plates that provide:
- Almost complete tightness.
- High temperature resistance
- Large service interval (once every three years to change plates for round-the-clock work)
- The seal not only effectively compensates for the distortion of the geometry of the shape of the pipe, but even allows for a change in the angle of inclination of the drum without losing tightness.
Sediment chamber and discharge unit
In the sediment chamber, due to the increase in the conditional passage, the speed of movement of the flue gases is significantly reduced. As a result, the number of settling particles increases.
The design of the bunker provides:
- Purification of waste residues. The ash is kept at a high temperature for a long time, which ensures a guaranteed purification of all the components and contributes to an increase in the productivity of the incinerator by approximately 10%.
- The design of the unloading mechanism for the storage bin eliminates the possibility of jamming. The ash from the rotating drum enters the storage bin, in which it can be at high temperature for a few more hours. This ensures complete combustion of waste and increases productivity.
According to the results of the introduction of the thermal gas cleaning unit at the incinerator, the following indicators were achieved:
- –Excluded salvo emissions of soot and pollution at the time of loading the next batch of waste.
- –Increased plant capacity by 30%, thanks to an efficient supply of secondary air.
- –Reduced natural gas consumption by 20%, due to heat recovery and maintaining optimal excess oxygen.
Indicators of the main pollutants:
- - CO gas - 5-10 ppm - Nitrogen oxides 1 NOx - 2 ppm
- –Total organic pollutants СxNy – less then 1 ppm
The oxygen content is 2-4%.
The volume of purified emissions is from 7000 m3
Instead of stainless steel for mounting instrumentation
No moving parts in hot equipment areas
Predictive diagnosis of the problem, thanks to the tools integrated into the incinerator
Sophisticated incinerator design facilitates access to necessary nodes.
Critical components (directional rotating drum) are coated with aluminum and stainless steel. Such coatings are orders of magnitude superior to conventional paintwork.