Direct fired Rotary Kiln Incineration has been proven to be the Best Available Technique (BAT) for large scale waste disposal requirements and has become our preferred thermal treatment solution for safe and effective destruction of difficult to handle wastes. This includes hazardous, chemical , toxic, (bio-)medical and infectious wastes.
Counter-Current Rotary Kiln Incineration – as engineered and constructed by us – is a stable and reliable processing technology at well controlled combustion conditions, that is capable of accepting and treating the most difficult waste mixtures presented and being able to accommodate large variations in waste sizes, waste composition and calorific value.
If built correctly, counter-current rotary kiln technology is the most versatile in waste acceptance and utmost reliable in day to day operations and maintenance.
A counter-current rotary kiln incinerator is the multipurpose workhorse of all incinerator types, with largest operating margin and widest variation of physical, chemical and thermal properties.
Compared to the cheaper conventional static (non-rotating) incinerators, the rotary kiln incinerator constantly lifts and tumbles the waste. The continuous rotating process circumvents the possible risk of waste solidification at the bottom and warrants maximum combustion efficiency with minimal high quality bottom ash. Where the waste calorific value and oxygen supply are sufficient, this will lead to a thermal chain reaction and self-supporting combustion, without the need for additional fossil fuels (diesel or gas).
Our advanced design characteristics
We developed advanced incinerator design characteristics that clearly distinguish DI-systems from its competitors.
Originally, our incinerators are designed and built for treatment of most difficult wastes and can be easily applied for refinery and petrochemical wastes, medical and pharmaceutical wastes, non-recyclable chemicals, oil contaminated wastes and wastewaters, combustible toxic liquids, paints, solvents, mercury, pesticides, high chlorinated hydrocarbons and PCB’s, etc.
Non-hazardous wastes and non-recyclable wastes at the end of the recycling line can be perfectly processed within DI incinerators as well; such as: RDF/SRF, E-waste, scrap tyres, car frag, combustible C&D waste, fines, poultry litter, etc.
PHYSICAL SHAPE AND WASTE COMPOSITION
Our waste feeding system is adaptable and can be designed upon the waste’s physical shape and composition. Feed design options available for low and high calorific value wastes, in the form of solids, dust, gases, liquids, semi-liquids, wastewaters, emulsions, pastes, sludges, slurries, etc.
As a design rule, we adopted the KISS principle (Keep It Smart & Simple). Systems work best when the design is kept simple and straightforward, rather than made complicated. For the fact that every project is unique, we always design our incinerators on a case-by-case basis. Taking the particular waste type, physical shape and the waste composition into account.
When well maintained, incinerator lifetimes range from 20–25 years.
Our rotary kiln incinerators have an operating range on thermal input from 70% to 130% of the design capacity, accepting considerable waste input fluctuations in calorific value and in low or peak periods. DI incinerators have a proven record of operational reliability with a typical annual uptime of 95% – 98%.
The gradual build-up of dust and slags, known as slag agglomeration or clogging, is a common highly underestimated problem in waste incineration. We have successfully resolved slag agglomeration with specific non-clogging design measures. That’s the justification of our optimal operational reliability and typical uptime.
Our incinerators require only 1 prescheduled complete shutdown per year, of maximum 10-15 consecutive days, for general annual maintenance service and wear and tear repairs. Daily or weekly routine inspection and systematic upkeep is performed by the incinerator operator, for smooth operation and to maximize the life of the mechanical system. All our designs demand for low wear and tear repairs and minor replacement parts.
Fossil fuel consumption is negligible
Diesel or gas is only required throughout process start-up (+/- 5 hours), for heating the kiln and initial ignition of the waste. After boot phase, a thermal chain reaction and self-supporting combustion of the waste arises. Subsequently, no additional fuel is necessitated to maintain the temperature and combustion process.
Low need for operating manpower
Our systems require less skilled operators for operational control, with minimum supervisory support. As for safety precaution, we recommend 2 operators per shift.
Consumables- & utility costs remain low
Restricted to fossil fuel, electricity, process water and emission controlling additives. Total consumption is directly related to waste type, contaminant concentrations and hourly throughput.
Comprehensive operator training
The ample training comprises of 3 subjects:
- best operating techniques
- safety tuition
- daily overall inspection and routine maintenance services
Special attention to Occupational Health and Safety
It’s the top priority of our design and construction. A full automated shutdown will be induced immediately, in case of excessive operating conditions, fire or loss of electrical power.
Noise and odour nuisance control
The environmental noise emission level is within the international standard. Unpleasant odours are extremely well controlled and prevented from escaping into the atmosphere.
Disposal of combusted ash residues
Kiln bottom ash
For non-hazardous waste materials, it has been shown that the ash residue is a non-hazardous remainder that can be safely applied as covering layer on landﬁlls, as a secondary construction material or as substitute for gravel. Ash samples can be tested for eco-toxic metals.
Filtered from the ﬂue gases and could still consist of environmentally harmful substances (heavy metals). It must be safely disposed at a secured hazardous landﬁll site or sent to a specialist treatment plant. It should be done properly to avoid concerns for local residents and the environment.
Each customer is unique. That’s why we work closely with our clients, to provide the right answers to highly individual needs and industry or country specific requirements. Our in-house expertise designs customized reliable solutions for difficult uncommon wastes, integrates effective energy recovery systems and merges auxiliary equipment.
Indoor – outdoor design
Our facilities are engineered for outdoor application and are in full compliance with EU directives and local regulations. Mechanical equipment, appliances and supports are designed and installed to resist the harshest nature and weather conditions. For operator comfort, the plant could be designed inside a building as well.
Our engineers are the ﬁnest in the world and trained thoroughly to think outside the box, with the ongoing attitude that every problem has its own creative solution.
INVESTMENT / COSTS
Investment and operation costs vary greatly according to the type of incinerator. High-tech rotary kiln incinerators have a higher initial capital investment, but are signiﬁcant lower in operation and maintenance cost, compared to double chamber pyrolytic incinerators.
DI is a skilled EPC contractor that provides top-notch design options and cutting-edge technology. Our creations are built with state-of-the-art materials, industry-best instrumentation and supreme electrical hard-/software. With our comprehensive turnkey packages, everything is thought out and planned from start to finish, to make sure our customers are 100% satisfied and confident to receive a complete, reliable, high quality incinerator installation.