ROTARY KILN

Solid Waste
1500 kg/m3

Density (Assumed)
Mass to be fed in to the RK

120 kg/hr

calorific value (assumed)

4000 kcal/kg

A/F ratio ( 32% Extra)

5.41

Waste composition :
organics
inorganics
moisture
Total
Temperature

Sp. =1.5(appox)

7.30

%
65
32
3

kg /hr
78
38
4
120

T2

700 C

T1

30 C

Air Required for combustion of organics =

D.G.
Moist

836
9.27

569 kg/hr
558 kg/hr
11 kg/hr

Heat absorbed by waste =

1 by organics

m*[0.6*(150-T1)+160+0.3(T2-150)]
30966.00 kcal/hr

2 by inorganics

m*0.3*(T1-T2)
7718.40 kcal/hr

3 by moisture

m*{70+540+0.5(T2-100)}
3276.00 kcal/hr

4 heat by Combustion air

Air * 0.28 *(T2-T1)

106779.89 kcal/hr

5 heat by steam for =

atomization
TOTAL HEAT REQUIRED =

1+2+3+4+5

0 kcal/hr

148740.29 kcal/hr
148.74 x 10 kcal/hr
Heat released by wastes =
Mass flow
DG
Moisture

456000.00
650.79
636
15

kcal/hr
kg/hr
kg/hr
kg/hr

------------------------------A
0.15 Mkcal/Hr

AQUEOUS
Mass to be fed in to the MCC

Density =

1000 kg/m^3
10000 kg/hr

Sp.Gr. = 1.0 (approx.)

Therefore,

Waste composition :

%
2
59
40

Organic
Moisture
Inorganics

calorific value (dry basis)

Kcal/kg

Kg/hr
200
5900
4000
10100
4000 kcal/kg

temperature

T2

700 C

T1

30 C

A/F Ratio
Consider ( 45% extra)

5.405405405
8.00

Combustion air reqiured

D.G
Moist (Say 2 %)

1600 kg/hr
1568 kg/hr
32 kg/hr

Heat required for waste =

1 by organics

m*0.6*(T2-T1)
80400.00 kcal/hr

2 by inorganics

m*0.2*(T2-T1)
536000.00 kcal/hr

3 by moisture

m*{70+540+0.5(T2-100)}
5369000.00 kcal/hr

4 heat by Combustible air =

Air * 0.28 *(T2-T1)

300160.00 kcal/hr

TOTAL HEAT REQUIRED =

1+2+3+4

Heat Released by Organics

6434300.29 kcal/hr
6.434300292 MKcal/hr

--------------------------------------D

800000.00 kcal/hr

--------------------------------------E

Total Heat absorbed =

7241344.64 Kcal/Hr

Total Heat released =

1130400.00 Kcal/hr

Net heat Available (Released - Absorbed)

-6110944.64 kcal/hr

Fuel used (Natural Gas ) = CV =

Fuel used Natural Gas )
Air required for Fuel
D.G. =
Moist =
Mass out

10500 kcal/kg ,A/F=

14.1891891892

-836.46 kg/hr

6583040.583784

836 kg/hr
1183 cum/hr

14242 kg/hr
13958 kg/hr
285 kg/hr
21942

Thermal capacity of Chamber

D.G =
Moist =
=

17.03

15726 kg/hr
6217 kg/hr
5.4783 Mkcal/hr.

CALCULATIONS FOR S.C.C:

Mass to SCC :
Liquid Waste
Mass flowrate =

50 Kg/hr
0 Kg/hr

Waste composition :

%
85
8
7

Organic
Moisture
Inorganics

calorific Value =

Kg/hr
0
0
0
0
6000

A/F (32% extra)

kcal/kg

8.108108108

Air Required =
D.G.=
Moist.=

0 kg/hr
0 kg/hr
0 kg/hr

D.G. =
Moist.=

21942 Kg/hr
15726 Kg/hr
6217 Kg/hr

2) Flue gas from RK

3) Flue gas SDP

0 kg/hr , At
0 kg/hr
0 kg/hr

D.G. =
Moist.=
Temperature

10.68

T1

700 C

T2

950 C

600
Deg C

250

Heat and Mass Balance :

1) Heat absorbed by Liquid waste =
m*[0.6*(150-T1)+160+0.3(T2-150)]

1 by organics

0.00 kcal/hr
m*0.3*(T2-T1)

2 by inorganics

0 kcal/hr
m*{70+540+0.5(T2-100)}

3 by moisture

0 kcal/hr
Air * 0.28 *(T2-T1)

4 heat by Combustible
air

0 kcal/hr

Total heat absorded by Liquid waste =

0 kcal/hr

Total heat released by Liquid waste =

0 kcal/hr

Heat released by SDP Wastes =

kcal/hr

2) Heat absorbed by Flue gas from RK

3) Heat absorbed by Flue gas from SDPs

Total Heat absorbed

1956523 kcal/hr.

0 kcal/hr.

70500

2152176 Kcal/hr

1956523.382857

Total Heat released

Net heat available

0 Kcal/hr

= R- A

-2152176 kcal/hr.

Fuel required (Natural Gas ) =

comb Air Required

-352.0 kg/hr
=

5994 Kg/Hr
5874 kg/hr
120 kg/hr

D.G. =
Moist.=
MASS OUT FROM S.C.C @

950 deg C

Dry gas =
Moist

21952 Kg/hr

Thermal Capacity of SCC

total fuel

352.0
404
Nm3/hr

Total mass
Out =

28288 kg/hr

6337 Kg/hr
=

9.266 Mkcal/hr.
10.00 Mkcal/hr
1188.48
1697.82 cum/hr

0.2240056427

5994

9335117.7023
Lets SCC =

10 Mkcal/hr

Flue gas =

28288.24 Kg/hr

D.G. =

21952 Kg/hr

Moist.=

6337 Kg/hr

Total air reqired for Combustion =

Total air reqired for Combustion Fuel =
Combustion Air in SCC =

2169 Kg/hr
20236 Kg/hr
Kg/hr

Total amount of air =

22405 Kg/hr
19232 m3/hr
23079 m3/hr

COOLING AIR REQUIREMENT:

Cooling Air Requirement to cool to

850 deg C
4233 Kg/hr

Mass out from After cooling to @900 C

Dry gas =
Moist

32521 Kg/hr
26100 Kg/hr
6421 Kg/hr

for SDP
3000
2169

300

-352.0171

m^3/hr per cyclone

WHRB
Total Gas =
Dry gas
moisture

32521 kg/hr
26100 kg/hr
6421 kg/hr

inlet temp
outlet temp

850 C
600 C

Enthalpy @ t1

850 C
D.G
MOIST

233 Kcal/hr
1022 Kcal/hr

Enthalpy @ t2

600 C
D.G
MOIST

151 Kcal/hr
916 Kcal/hr

Steam @ 150 deg. C

4442 Kg/hr

Assumption

SDA after BOILER

Total Gas =
Dry gas
moisture

32521 kg/hr
26100 kg/hr
6421 kg/hr

inlet temp
outlet temp

600 C
250 C

Enthalpy @ t1

600 C
D.G
MOIST

Enthalpy @ t2

151 Kcal/hr
916 Kcal/hr
250 C

D.G
MOIST

Assumption

water evaporated
45 % Total Dissloved Salts

60 Kcal/hr
719 Kcal/hr
5056 Kg/hr
506 Kg/hr

850
220
ENTHALPY in kcal/kg
TEMP
air
75
17.73
100
23.765
200
48.14
250
60.525
300
73.048
400 98.4268
600 151.4507
700 178.6064
800 206.0226
900 233.7183
1000 261.7603
1100 290.0246
1150 304.5091
1200 318.9124

1030.57
MOIST
626.8
640.228
692.9
719.34
746.11
800.9361
916.5375
960.0029
991.2487
1022.492
1086.95
1153.168
1187.163
1221.185

cyclones

Total =
Dry gas
moisture

3000 cum/hr /cyclone

23.333333333

VENTURI SCRUBBER
37577
26100 kg/hr
11477 kg/hr

inlet temp T1
outlet temp T2

HUMIDITY
TEMP
HUMIDITY kgmoist/kg gas
15
0.0106
70
0.2782
75
0.3851
80
0.5511
85
0.8352
90
1.414
95
3.173
99
18.73
30
0.0273
60
0.153
65
0.2051

250 C
75 C

enthalpy @ t1

250 C
D.G
MOIST

48.15 Kcal/hr
693 Kcal/hr

enthalpy @ t2

75 C
D.G
MOIST

17.73 Kcal/hr
626 Kcal/hr

water evaporated

2562 kg/hr

@ venturi inlet
average mol. Wt.

24.44 kg

density of gas@
Avg.Temp.

0.684 kg/m
0.0427 lb/ft

vol flow rate

54949.779 m/hr
1940317.050 ft/hr

velocity of gas @ throat

70 m/s
229.66 ft/s

c/s area of throat

assume

0.218054678 m
2.3472 ft

diameter
lenth

0.5268 m
0.7902 m

Pr. Drop

300 mm WC assume
11.811 inch WC
L

9.8312417218 gal/1000ftgas

water circulated

19075.73 gal/hr
72.202 M/hr

@ venturi Outlet
Dry gas
moisture

Extra 20 % =

79 M/hr

40139
26100 kg/hr
14039 kg/hr

Moisture Holding Capacity @ 75 C

For the Dry Air

10051 kg/Kg of moist ,as the

Amount of water being condensed =

Humidity @ 75 C

0.3851
kg/Kg of moist

3988 kg/hr

REHEATER
Dry gas in
moisture in
inlet temp T1
Outlet temp. T2

26100
14039
75
95

kg/hr
kg/hr
C
C

Heat Required to reheat the Flue gas to higher temperature.

Q=

286551.609488817 kcal/hr

Fuel Required =
Natural gas

0 kg/hr

Air required =
D.G.
Moist.

0 kg/hr
0 kg/hr
0 kg/hr

Total mass out of Reheater

Dry gas out
moisture out

26100 kg/hr
14039 kg/hr

I D FAN
INLET TEMP
D.G.
MOIST
TOTAL

75
26100
14039
40139

Deg C
kg/hr
kg/hr
kg/hr

MOL WT

23.89 kg

DENSITY

0.837 kg/m

VOL FLOW

47974 m/hr

20% Extra

57569 m/hr

Power Required for this System

Assume

Pr.drop =
Power =

Taking 20% loss =

13.326170254 1.33261703

850 mm of water column;

1.30292 mm

Efficiency =

278.82 HP or

208 Kw

307 HP
350

229 Kw

0.65

EQPT

Solid Waste
1
2
3
Measure Waste
Fuel
Air
kg/hr
120
0
429
deg. C
30
30
30
Kcal/hr
Organic
kg/hr
78
420
Inorganic kg/hr
41
Moisture kg/hr
1
9
Kcal/kg 3000 (dry) 10000

Solid Waste
1
2
3
Measure Waste
Fuel
Air
kg/hr
120
0
429
deg. C
30
30
30
Kcal/hr
kg/hr
78
420
kg/hr
41
kg/hr
1
9
Kcal/kg 3000 (dry) 10000

Aqueous Wastes
4
Flue Gas Waste
549
10000
700
30
182444
498
200
41
4000
10
5800
3000

Fuel
850

Air
14600

900

14308
292

EQPT

Aqueous Wastes
4
Flue Gas Waste
549
10000
700
30
182444
498
200
41
4000
10
5800
3000

Fuel
850

Air
14600

900

14308
292

queous Wastes
5
Inorganics Flue Gas Fuel
4000
21450
350
700
30
6176800
15408
4000
4000
120
6092
10000

queous Wastes
5
Inorganics Flue Gas Fuel
4000
21450
350
700
30
6176800
15408
4000
4000
120
6092
10000

SCC
6
Air
5600
30
5488
112

SCC
6
Air
5600
30
5488
112

PLENUM
SPRAY DRIER
7
8
9
10
11
Flue Gas cool air Flue Gas Spray Drier Cyclone
27400
4250
31650
9000
900
1000
30
850
30
200
10448000
20896
4165
25061
900
6204
85
6289
9000

PLENUM
BOILER
7
8
9
Flue Gas cool air Flue Gas Soft water Steam
27400
4250
31650
4500
4500
1000
30
850
30
150
10448000
20896
4165
25061
6204

85

6289

RAY DRIER

SCRUBBER
12
13
Flue Gas Makeup water
39750
3000
250
30
25061

ID FAN & STACK

14
Gas
42750
75

3000

25061
0
17389

10
FG
Spray Drier
31650
5000
600
30

SPRAY DRIER
11
Cyclone
500
200

14389

BOILER

25061

SCRUBBER
12
13
Flue Gas Makeup water
36150
2500
250
30
25061

900
6289

5000

10789

2500

ID FAN & STACK

14
Gas
38650
75
25061
0
13289