Low Operating Cost Rotary Kiln Heat Recovery High Thermal Energy Utilization

Low Operating Cost Rotary Kiln Heat Recovery High Thermal Energy Utilization

Overview:

Modern rotary kilns have become an important technical equipment for hazardous waste disposal. Its high temperature and long residence time can ensure the complete decomposition of hazardous substances such as medical waste and chemical waste. Equipped with a complete tail gas treatment system (quench tower, bag dust removal, SCR denitrification, etc.), the dioxin emission concentration can be controlled below 0.1ng TEQ/m³, which is far better than the EU standard. Some cement kiln co-disposal projects can also convert inorganic components in waste into cement mineral components, realizing real resource utilization.

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Product Introduction:

This incineration system is designed for high-salt organic wastewater in the chemical industry (such as wastewater from acrylic acid and ester production). Through the deep integration of the furnace and the waste heat boiler, it realizes the efficient coordination of incineration and heat recovery. The system focuses on low operating costs and high thermal energy utilization (>85%), directly treats wastewater with a salt content of 19%, and simultaneously solves the problem of coordinated disposal of waste liquid, waste gas, and solid waste. During the incineration process, waste heat steam drives salt to react with carbon dioxide to generate solid salt (such as sodium carbonate/calcium carbonate), realizing the dual control of salt resource recovery and carbon emissions. At the same time, the salt-resistant furnace structure extends the equipment life and avoids the blockage and corrosion problems caused by salt crystallization in traditional incinerators.
Waste gas treatment capacity: 16,000 m³/h (tank waste gas)
Waste liquid treatment capacity: 3,500 kg/h (heavy component waste liquid)
High-salt wastewater treatment capacity: 10,000 kg/h (salt content 19%)
Waste heat steam production: 28,000 kg/h (saturated steam, used for salt recovery and carbon emission reduction)
‌Applicable materials‌: high-salt organic wastewater, waste solvents, organic waste gas, small amounts of solid waste
‌Core technology‌: furnace-boiler integrated design, combined multi-nozzle burner, salt-carbon reaction recovery technology

Theory:

A rotary kiln’s body is a long and inclined cylinder that rotates to uniformly heat wastes in a high-temperature environment. During waste treating, high-temperature combustion is employed to effectively decompose and process organic materials and other components in waste. The design of the rotary kiln allows waste to stay in a high-temperature environment for a certain duration, ensuring thorough combustion of the waste while effectively dealing with hazardous substances.

Ruiding has independently developed a rotary kiln that combines all the advantages of a traditional rotary kiln incinerator. Significant advancements have been achieved in enhancing heat exchange and ash burnout rates. The incorporation of high-temperature grate technology has elevated the traditional second-stage combustion chamber to a more efficient second-stage furnace, resulting in improved ash burnout rates and a further increase in the incineration efficiency of the rotary kiln.This rotary kiln system is equipped with a chain-type evaporator that addresses the issue of inadequate contact between air and waste in traditional rotary kilns. This optimization enhances waste heat exchange and combustion effectiveness, prevents slag formation inside the kiln, and significantly boosts both combustion efficiency and equipment lifespan. With a high operational uptime, user-friendly maintenance, and suitability for medium to large-capacity processing needs, this rotary kiln solution offers customers an economically viable option for waste treatment.

Ruiding provides customized solutions for hazardous waste by analyzing critical parameters such as elemental composition, calorific value, moisture content, viscosity, ash residue rate, and combustion rate. These tailored solutions are designed to meet the specific needs and characteristics of the waste for each customer.

Advantages:
(1) ‌Efficient heat utilization and cost control‌:
The integrated design reduces the heat loss of traditional incinerators by more than 40%, and the waste heat steam is directly reused in the production process, reducing the comprehensive energy consumption by 30%. Saturated steam drives the salt recovery reaction, reducing the amount of chemical agents added, the salt recovery rate is ≥90%, and the carbon emissions are reduced by 15-20%.
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‌(2) ‌Anti-salt corrosion and long-life design‌:
The inner wall of the furnace adopts gradient refractory materials (zirconia/silicon carbide composite layer), combined with the optimization of the salt gas-solid reaction path, to avoid high-temperature molten salt corrosion, and extend the equipment life by more than 50%. The automated salt discharge system removes the salt slag in the furnace in real time to ensure continuous operation time ≥8,000 hours/year.

‌(3) ‌Environmental protection and resource benefits‌:
Dioxin emissions <0.1 ng TEQ/m³, particulate matter <10 mg/m³, which is better than the national standard (GB 18484-2020). The salt recovery product (carbonate) can be directly used as an industrial raw material, and the annual resource benefits reach millions of yuan. It has been successfully put into operation in many large chemical companies, with a single system processing 320,000 tons of waste liquid annually.

R&D and Production:

Ruiding has established the jiangsu province clean incineration resource engineering technology center and the key laboratory of the JICUI-Ruidings joint innovation center.

This laboratory is equipped with advanced detection equipment such as ICP inductively coupled plasma emission spectrometry, atomic absorption spectrophotometry, atomic fluorescence spectrophotometry, high-temperature combustion ion chromatography analyzer, high-temperature combustion rate analyzer, and rapid equilibrium flash point tester. it possesses capabilities for heavy metal analysis, elemental analysis, off-gas calorific value analysis, ash melting point detection, incineration boiler water quality testing, sewage analysis, and volatile waste analysis, etc.

Related Products:

Main Clients:

Company Introduction:

Ruiding is expertized in the engineering, fabrication, construction, commissioning service of industrial waste combustion treatment system including thermal oxidizer (also referred to as incinerator), heat recovery system (boiler), pressurized vessel, flue gas treatment system (DeSOX, DeNOx) and plate heat exchanger, etc.

Ruiding has been authorized with the Environmental Protection Engineering Class 2 (waste gas, waste liquid, waste solid treatment) EPC certificate, ASME Certificate, Class A boiler manufacturing license, Class A boiler installation and Revamping & Maintenance certificate, A2 designing and manufacturing certificate for press vessel, GC1, GC2 press pipeline designing & construction certificate.

Ruiding covers a building area of over 250,000 square meters and has nearly 300 professional and technical staffs. We have completed over 500 engineering projects, spread across various domestic and international industries, with a significant market share in the petrochemical industry.

Faq:

1. What is the company's main business? ‌
Focus on the R&D, design, production, installation and commissioning of industrial three wastes (waste gas/waste liquid/solid waste) incineration treatment equipment and special boilers, and provide supporting equipment (such as heat exchangers, sludge dryers, etc.) ‌.
2. Do you have industry qualification certification? ‌
The company has now passed the quality, environment, occupational health, and occupational hygiene and safety management system certifications, and has the second-level qualification for environmental protection engineering contracting, Class B special environmental engineering design, Class A boiler manufacturing qualification, Class A boiler installation, inspection and maintenance certificate, A2 pressure vessel design and manufacturing certificate, GC1, GC2 pressure pipeline design and installation certificate, and Class A environmental pollution control (waste, waste gas, waste liquid) qualification certificate.
‌3. What are the core products? ‌
(1) Waste gas incinerator:
Regenerative thermal oxidation furnace (RTO), regenerative catalytic oxidation furnace (RC0), catalytic oxidation furnace (C0), high temperature thermal incinerator (T0), catalytic denitrification furnace (SCR)
(2) Waste liquid incinerator:
Organic waste liquid incinerator, salt-containing waste liquid incinerator, heavy component residue incinerator
(3) Solid incinerator:
Combined rotary kiln incinerator, gas-controlled pyrolysis incinerator, fluidized bed incinerator, step-type incinerator
(4) A-level boiler:
Modular waste heat boiler, tunnel waste heat boiler, furnace-boiler integrated incineration boiler, large cavity membrane wall boiler, fire tube boiler
(5) Plate heat exchanger:
Fully welded pressure plate heat exchanger, high-efficiency vortex tube heat exchanger, high-efficiency spiral tube heat exchanger
(6) Incineration auxiliary machine:
Sludge dryer, customized burner, solid waste crusher, VOC catalyst ‌
4. In what aspects are the technical advantages reflected? Have you ever had experience in cross-border cooperation?

We have 29 patented technologies, covering the fields of incinerator structure optimization, heat recovery, etc. The company has a first-class design team in China, which has mastered the incinerator technology and is familiar with the operation of incinerators. The designers have a solid theoretical foundation and rich design and practical experience. During the design process, they combine the operation of advanced devices at home and abroad to carry out process and structural design. The design response is fast, and the plan can be modified in time according to the buyer's requirements, and optimization suggestions can be made according to the buyer's data and processes.
5. What does the service scope include?
We provide full-process services from project consultation, scheme design, equipment manufacturing to installation and commissioning, and support pressure pipeline and boiler renovation.
6. Are there any successful cases for reference?
It has served multiple industries including petroleum, chemical, pharmaceutical, and solid waste disposal. Typical cases include organic waste gas RTO system, chemical waste liquid incineration project, etc.
7. How to obtain cooperation or quotation?
You can submit your needs through the official website online form, or contact directly:
Tel: +86 15606162805 ; +86 0510-87418884
Email: ruiding@rdee.com.cn
Address: Xinzhuang Industrial Concentration Zone, Yixing City, Jiangsu Province, China.
8. Is there any international business cooperation? ‌
Holding the independent import and export rights, we can provide equipment export and technical solution customization services for overseas customers.