METHOD AND APPARATUS FOR INCINERATION OF SUBSTANCES USING ROTARY GENERATED THERMAL ENERGY

Abstract

A method for disposal of harmful and/or toxic substances by incineration is provided, the method comprising generation of a heated fluidic medium by at least one rotary apparatus comprising: a casing with at least one inlet and at least one exit, a rotor comprising at least one row of rotor blades arranged over a circumference of a rotor hub mounted onto a rotor shaft, and a stator configured as an assembly of stationary vanes arranged at least upstream of the at least one row of rotor blades. In the method, an amount of thermal energy is imparted to a stream of fluidic medium directed along a flow path formed inside the casing between the inlet and the exit by virtue of a series of energy transformations occurring when said stream of fluidic medium passes through the stationary guide vanes and the at least one row of rotor blades, respectively. The method further comprises: integration of said at least one rotary apparatus into an incineration process facility configured as an incineration facility and further configured to carry out incineration process or processes related to disposal of harmful and/or toxic substances by incineration at temperatures essentially equal to or exceeding 500 degrees Celsius (° C.), and conducting an amount of input energy into the at least one rotary apparatus integrated into the incineration process facility, the input energy comprises electrical energy. A rotary apparatus and related uses are further provided.

Description

FIELD OF THE INVENTION

The present invention generally relates to systems and methods for inputting thermal energy (heat) into fluids. In particular, the invention relates to tools and processes for optimizing energy efficiency and reducing greenhouse gas and particle emissions in industrial processes related to disposal of harmful and/or toxic substances by incineration carried out at high and extremely high temperatures.

BACKGROUND

Industry and governments have been combating to find technologies to achieve significant reductions in greenhouse gas (GHG) emission reduction. Emission of volatile organic compounds (VOCs) and hazardous air pollutants (HAPs) into the atmosphere is of significant environmental concern because some have potential for photochemical ozone creation potential (POCP), ozone depletion potential (ODP), global warming potential (GWP), toxicity, carcinogenicity and local nuisance from odour. Uncontrolled emission of VOCs into the atmosphere results in that they may act as greenhouse gases. Prevention of VOC emissions is therefore considered one of the most important issues facing the operation of key industry processes.

Waste gases are produced by almost any industrial facility including, but not limited to: oil refining and petrochemicals, processing of natural gas, processing of biogas, chemical processing, food and beverage processing, mining, production of paints/sprays, pharmaceutical industry and medical device manufacturing, and soil- and groundwater remediation. In these industries, incineration may be used for disposal of waste streams and/or for air quality management.

Incineration is one of the best-known methods for disposal of virtually any waste substance, including industrial gaseous streams, various liquids, solids and mixtures thereof. Gaseous pollutants, such as VOCs and HAPs, from industrial air streams are typically destroyed in thermal incinerators also referred to as thermal oxidizers. These pollutants are generally hydrocarbon based and may be composed of a complex mixture of organic compounds. Sometimes, the pollutants may include, in addition to hydrogen and carbon, a variety of sulfur-(S) and nitrogen (N) -containing compounds. When destroyed via thermal combustion they are chemically oxidized to form carbon dioxide and water. Combustion of such a mixture of organic compounds containing carbon, hydrogen, oxygen, and, in some instances, also nitrogen and sulfur, can be described by the overall exothermic reactions according to Equations 1A and 1B:

$\begin{array}{cc}{C}_x{H}_y{O}_z+\left[x+\frac{y}{4}-\frac{z}{2}\right]O_2⟶{x\mathrm{CO}}_2+\frac{y}{2}{H}_{2}O& \left(1A\right)\end{array}$ $\begin{array}{cc}{C}_a{H}_b{O}_c{N}_d{S}_e+\left[a+\frac{b}{4}-\frac{c}{2}+\frac{\mathrm{xd}}{2}+e\right]O_2⟶{a\mathrm{CO}}_2+\frac{b}{2}{H}_{2}O+{d\mathrm{NO}}_x+{e\mathrm{SO}}_2& \left(1B\right)\end{array}$

In addition to carbon dioxide and water, exhaust gases from thermal oxidizers may also contain nitrogen oxides, acidic gases, trace metals and other hazardous air pollutants generated from combustion of compounds present in the waste or from the combustion of supplemental fuels. Provision of a scrubber or similar equipment for removal of these compounds after the incinerator/oxidizer may provide a cost effective and environmentally beneficial approach to control waste streams; however, it greatly increases installation- and operational costs of the incineration system.

Main types of thermal oxidizers include direct flame/direct fired thermal oxidizers (afterburners), catalytic thermal oxidizers (CTO), regenerative thermal oxidizers (RTO), and recuperative oxidizers. Factors to be considered in designing effective thermal oxidizers include the temperature inside the oxidizer (in the combustion chamber), residence time and turbulence. The temperature has to be high enough to ignite organic compounds in the waste gas. Depending on a nature of waste substances to be burned, thermal oxidizers operate at temperature ranges within 590-1200° C. Residence time (time the waste stream spends in the combustion chamber) must be sufficient the combustion reaction to occur, which is typically 0.2-1 seconds depending on the type of waste gas. Turbulence, in turn, defines the proper flow of the combustion air needed to mix oxygen with the waste gases to achieve full combustion of the latter.

Conventional thermal oxidizer system is illustrated on FIG. 1C. Waste gas is burned in an incinerator 101 provided as a combustion chamber, in which the flame is maintained (in a simplest direct fired system) by a combination of auxiliary fuel (Qaf), waste gas and supplemental air (Qa) added when necessary. Often, the energy released by the combustion of the total organics (VOCs and others) in the waste gas stream is not sufficient to raise its own temperature to the desired levels. In these cases, auxiliary fuel (e.g., natural gas) must be added to raise the temperature (rf. Qaf, FIG. 1C). Symbol “Q” denote the thermal energy (heat) produced and/or inputted into the process. Upon passing through the flame, the waste gas is heated from its inlet temperature (Qwi) to its ignition temperature (the latter depends on a nature of waste). A waste gas preheater 102, and a heat recovery device 104 (configured hereby as a secondary energy recovery heat exchanger) are energy recovery devices provided in the incineration facility. In some instances, the heat recovery devices do not form a part of the incinerator/a combustion chamber (the latter defined as a chamber where ignition and burning of (waste) substances occurs); however, many industrial thermal oxidizers have at least a preheater (102) integrated into the incinerator to preheat waste gas. Exhaust gases (flue gases) at the inlet and outlet of the first heat exchanger 102 are denoted as fi and fo, accordingly.

Wastewater incineration is a process of oxidation of organic and inorganic wastewater contaminants with air and simultaneous heating and/or evaporation of the aqueous part at a pressure typically close to the atmospheric pressure and a temperature range between 730° C. and 1200° C. Incineration is an effective route to treat waste waters from chemical multiproduct plants with diverse toxic wastewater streams, which cannot be routed to a conventional wastewater treatment plant. Wastewater can originate from industrial or municipal or any other source.

Solid waste incinerators operate in a manner similar to gaseous waste oxidizers except for receiving solid waste as a feedstock. Upon incineration, solid waste materials are converted into ash, flue gas and heat. The ash is mostly formed by inorganic constituents of waste and may take the form of solid lumps or particulates carried by the flue gas. The flue gases must be cleaned of gaseous and particulate pollutants before they are dispersed into the atmosphere. Different designs for solid waste incinerators are recognized, all utilizing thermal energy to combust (solid) waste materials and destroy VOCs and HAPs. These designs include grate incinerators (fixed or moving), rotary kilns, multiple hearth incinerators, fluid bed incinerators, controlled air incinerators, and excess air incinerators.

Incinerators and oxidizers may be small, prefabricated, modular designs or large units that must be constructed onsite. Some of the larger units, particularly those used to combust municipal waste, include heat recovery systems that can be used for steam and/or electricity production. Hence, direct flame incinerators may include recuperative heat exchangers or regenerative systems that operate in a cyclic mode to achieve high energy recovery. Known catalytic incinerator systems include fixed-bed (packed-bed or monolith) systems and fluid-bed systems, both of which provide for energy recovery.

Electrification of incineration processes has been seen as a solution to reduce emissions. One of the obstacles for electrification was achieving high temperatures needed in incineration processes. By way of example, thermal incinerators typically utilized for destruction of gaseous pollutants, such as VOCs, operate at temperatures within a range of 590-650 degrees Celsius (° C.) where most of organic compounds ignite. Hazardous gaseous waste incinerators operate at higher ranges of 980-1200° C. Since the inlet waste gas temperature (rf. Qwi, FIG. 1C) is generally much lower than that required for combustion, additional thermal energy must be supplied to the incinerator to preheat waste gas and to maintain combustion conditions stable. However, the amount of energy released during the waste combustion process is often insufficient to maintain the process temperature at the desired level. In these cases, additional heat is typically provided by continuously delivering air and fuel (e.g. natural gas) into the incinerator (rf. Qa and Qaf, respectively, FIG. 1C). Supply of additional air and fuel into the incinerator is also required for combusting organic waste gases deficient in oxygen, which is the case with VOC-containing industrial waste gases originating from chemical plants (e.g. from process vent lines). On the other hand, a majority of VOC-containing gases disposed in industrial deodorization systems are dilute mixtures of combustible gases in air; hence, their oxygen content exceeds that required to combust both waste organics and support fuel, but their heating values are low. Catalytic systems also require utilization of support fuel, although, they operate a lower temperatures compared to (non-catalytic) thermal oxidizers. Yet, when VOC or other waste is destroyed in an incinerator using a fossil fuel, then both carbon in the VOC and carbon in the fossil fuel contribute to CO₂ emissions. Thermal oxidizers are also a source of NO_x emissions. In minimizing NO_x emissions, low operating temperature and uniform temperature profile are important factors to consider.

High-temperature process requirements and the need to comply to strict environmental regulations set serious burdens to incineration facilities in regard to utilized technologies and energy sources. Although electricity finds its application in some high temperature industrial processes, existing incineration technologies and the current state of economics are not in place to do so.

A number of rotary solutions have been proposed for heating purposes. Thus, U.S. Pat. No. 11,098,725 B2 (Sanger et al) discloses a hydrodynamic heater pump device operable to selectively generate a stream of heated fluid and/or pressurized fluid. Mentioned hydrodynamic heater pump is designed to be incorporated in an automotive vehicle cooling system to provide heat for warming a passenger compartment of the vehicle and to provide other capabilities, such as window deicing and engine cooling. The disclosed device may also provide a stream of pressurized fluid for cooling an engine. Disclosed technology is based on friction; and, since the fluid to be heated is liquid, the presented design is not suitable for conditions involving extreme turbulence of gas aerodynamics.

U.S. Pat. No. 7,614,367 B1 (Frick) discloses a system and method for flamelessly heating, concentrating or evaporating a fluid by converting rotary kinetic energy into heat. Configured for fluid heating, the system may comprise a rotary kinetic energy generator, a rotary heating device and a primary heat exchanger all in closed-loop fluid communication. The rotary heating device may be a water brake dynamometer. The document discloses the use of the system for heating water in offshore drilling or production platforms. However, the presented system is not suitable for heating gaseous media, neither is it feasible for use with high- and extremely high temperatures (due to liquid stability, vapor pressure, etc.).

Additionally, some rotary turbomachine-type devices are known to implement the processes of hydrocarbon (steam) cracking and aim at maximizing the yields of the target products, such as ethylene and propylene.

In this regard, an update in the field of technology related to design and manufacturing of efficient heating system, in particular those suitable for high- and extremely high temperature related applications, is still desired, in view of addressing challenges associated with raising temperatures of fluidic substances in efficient and environmentally friendly manner.

SUMMARY OF THE INVENTION

An objective of the present invention is to solve or to at least mitigate at least some of the problems arising from the limitations and disadvantages of the related art. One or more objectives are achieved by various embodiments of the methods for generation of a heated fluidic medium described herein, the rotary apparatuses and related uses as defined herein.

In an aspect, a method for disposal of substances, such as harmful and/or toxic substances, or waste substances, by incineration comprises generation of a heated fluidic medium by at least one rotary apparatus integrated into an incineration facility.

According to an embodiment, a method for disposal of substances by incineration, which comprises generation of a heated fluidic medium by at least one rotary apparatus integrated into an incineration facility, improves energy efficiency or reduces greenhouse gas and particle emissions, or both.

In an embodiment, the method for disposal of substances by incineration comprises generation of a heated fluidic medium by at least one rotary apparatus integrated into an incineration facility, the at least one rotary apparatus comprising: a casing with at least one inlet and at least one exit, a rotor comprising at least one row of rotor blades arranged over a circumference of a rotor hub mounted onto a rotor shaft, and a plurality of stationary vanes arranged into an assembly at least upstream of the at least one row of rotor blades, wherein an amount of thermal energy is imparted to a stream of fluidic medium directed along a flow path formed inside the casing between the inlet and the exit by virtue of a series of energy transformations occurring when said stream of fluidic medium passes through the stationary vanes and the at least one row of rotor blades, respectively, whereby a stream of heated fluidic medium is generated, the method further comprising: conducting an amount of input energy into the at least one rotary apparatus integrated into the incineration facility, the input energy comprising electrical energy, supplying the stream of heated fluidic medium generated by the at least one rotary apparatus into the incineration facility, and operating said at least one rotary apparatus and said incineration facility to carry out incineration process or processes at temperatures essentially equal to or exceeding about 500 degrees Celsius (° C.).

In another aspect, a method is provided for inputting thermal energy into fluidic medium during a process or processes related to incineration.

In an embodiment, the method comprises inputting thermal energy into a process or processes related to incineration in an incineration facility, the method comprises generation of a heated fluidic medium by at least one rotary apparatus integrated into the incineration facility, the at least one rotary apparatus comprising: a casing with at least one inlet and at least one exit, a rotor comprising at least one row of rotor blades arranged over a circumference of a rotor hub mounted onto a rotor shaft, and a plurality of stationary vanes arranged into an assembly at least upstream of the at least one row of rotor blades, the method further comprises: integrating the at least one rotary apparatus into the incineration facility configured to carry out process or processes related to incineration at temperatures essentially equal to or exceeding about 500 degrees Celsius (° C.), conducting an amount of input energy into the at least one rotary apparatus integrated into the incineration facility, the input energy comprising electrical energy, and operating the at least one rotary apparatus integrated into the incineration facility such, that an amount of thermal energy is imparted to a stream of fluidic medium directed along a flow path formed inside the casing between the inlet and the exit by virtue of a series of energy transformations occurring when said stream of fluidic medium passes through the stationary vanes and the at least one row of rotor blades, respectively, whereby a stream of heated fluidic medium is generated.

In an embodiment, the method comprises operating the at least one rotary apparatus operatively connected to at least one incineration unit within the incineration facility, said at least one incineration unit configured to carry out incineration process or processes at temperatures essentially equal to or exceeding about 500 degrees Celsius (° C.). In embodiments, in said method, the heated fluidic medium generated by the at least one rotary apparatus or in the at least one rotary apparatus is supplied into at least one incineration unit within the incineration facility. In embodiments, the at least one incineration unit comprises or consists of: an incinerator, a furnace, an oven, a kiln, a burner, a heater, a dryer, a boiler, a conveyor device, a reactor, or any combination thereof.

As used herein, an “incinerator” refers to an apparatus, in which solid, semi-solid, liquid or gaseous combustible wastes are ignited and burned. A “furnace” is used herein in relation to an apparatus in which heat is produced or added as part of a combustion and/or an incineration process. A “burner” is used herein in relation to an apparatus installed in an incinerator combustion chamber to ignite the material to be burned and/or to mix support fuel gases and/or air. The “burner” as used herein, is a part of incinerator or furnace.

In an embodiment, the method comprises generation, by at least one rotary apparatus, of the fluidic medium heated to the temperature essentially equal to or exceeding about 500 degrees Celsius (° C.), or to the temperature essentially equal to or exceeding about 1200° C., or to the temperature essentially equal to or exceeding about 1500° C.

In an embodiment, the method comprises adjusting velocity and/or pressure of the stream of fluidic medium propagating through the rotary apparatus, to produce conditions at which the stream of the heated fluidic medium is generated.

In embodiments, in said method, the heated fluidic medium is generated by at least one rotary apparatus comprising two or more rows of rotor blades sequentially arranged along the rotor shaft.

In an embodiment, in said method, the heated fluidic medium is generated by at least one rotary apparatus further comprising a diffuser area arranged downstream of the at least one row of rotor blades, the method furthers comprises operating the at least one rotary apparatus integrated into the incineration facility such, that an amount of thermal energy is imparted to a stream of fluidic medium directed along a flow path formed inside the casing between the inlet and the exit by virtue of a series of energy transformations occurring when said stream of fluidic medium successively passes through the stationary guide vanes, the at least one row of rotor blades and the diffuser area, respectively, whereby a stream of heated fluidic medium is generated. The diffuser area may be configured with or without stationary vanes.

In an embodiment, in said method, the amount of thermal energy added to the stream of fluidic medium propagating through the rotary apparatus is controlled by adjusting the amount of input energy conducted into the at least one rotary apparatus integrated into the incineration facility.

In embodiments, the method further comprises arranging an additional heating apparatus downstream of the at least one rotary apparatus and introducing a reactive compound or a mixture of reactive compounds to the stream of fluidic medium propagating through said additional heating apparatus, whereupon the amount of thermal energy is added to said stream of fluidic medium through exothermic reaction(s). In embodiments, in said method, the reactive compound or a mixture of reactive compounds is introduced to the stream of fluidic medium preheated to a predetermined temperature. In embodiments, in said method, the reactive compound or a mixture of reactive compounds is introduced to the stream of fluidic medium preheated to a temperature essentially equal to or exceeding about 1500° C. In embodiments, in said method, preheating of the stream of fluidic medium to the predetermined temperature is implemented in the rotary apparatus.

In an embodiment, the method further comprises generation of the heated fluidic medium by at least two rotary apparatuses integrated into the incineration facility, wherein the at least two rotary apparatuses are connected in parallel or in series. In embodiments, the method comprises generation of the heated fluidic medium by at least two sequentially connected rotary apparatuses, wherein the stream of fluidic medium is preheated to a predetermined temperature in at least a first rotary apparatus in a sequence, and wherein said stream of fluidic medium is further heated in at least a second rotary apparatus in the sequence by inputting an additional amount of thermal energy into the stream of preheated fluidic medium propagating through said second rotary apparatus. In embodiments, in at least the first rotary apparatus in the sequence, the stream of fluidic medium is preheated to a temperature essentially equal to or exceeding about 1500° C. In embodiments, in said method, the additional amount of thermal energy is added to the stream of fluidic medium propagating through said at least second rotary apparatus in the sequence by virtue of introducing the reactive compound or a mixture of reactive compounds into said stream. In embodiments, the method comprises introducing the reactive compound or a mixture of reactive compounds into the incineration process.

In an embodiment, in said method, the fluidic medium that enters the rotary apparatus is an essentially gaseous medium.

In an embodiment, the method comprises generation of the heated fluidic medium in the rotary apparatus. In embodiments, in said method, the heated fluidic medium generated in the rotary apparatus is a harmful and/or toxic gas. In embodiments, in said method, the heated fluidic medium generated in the rotary apparatus is a gas containing any one of: Volatile Organic Compounds (VOCs), hazardous air pollutants (HAPs), odorous gases, or any combination thereof. In embodiments, the heated fluidic medium generated in the at least one rotary apparatus comprises or consists of a waste gas originating from any industrial facility, including, but not limited to: oil refining and petrochemicals, processing of natural gas, processing of biogas, chemical processing, food and beverage processing, mining, production of paints/sprays, pharmaceutical industry and medical waste and device manufacturing, soil- and groundwater remediation, or any combination thereof. In embodiments, the heated fluidic medium generated in the rotary apparatus comprises inert gas, such as for example nitrogen (N₂), or air. In some configurations, the heated fluidic medium generated in the rotary apparatus comprises any one of: air, steam (H₂O), nitrogen (N₂), hydrogen (H₂), carbon dioxide (CO₂), carbon monoxide (CO), methane (CH₄), or any combination thereof.

In embodiments, in said method, the heated fluidic medium generated in the rotary apparatus is a recycle gas recycled from exhaust gases generated during incineration process(es) in the incineration facility.

In embodiments, the method further comprises generation of a heated fluidic medium, such as gas, vapor, liquid, and mixtures thereof, and/or heated solid materials outside the rotary apparatus through a process of heat transfer between the heated fluidic medium generated in the rotary apparatus and any one of the above-mentioned substances bypassing the rotary apparatus. In embodiments, the heated fluidic medium, such as gas, generated in the rotary apparatus is used as a combustion medium for solid materials supplied into the incineration unit/process,

In embodiments, in said method, the heated fluidic medium generated by the at least one rotary apparatus or in the at least one the rotary apparatus is further supplied into at least one incineration unit within the incineration facility, the at least one incineration unit comprises or consists of: an incinerator, a furnace, an oven, a kiln, a burner, a heater, a dryer, a boiler, a conveyor device, a reactor, or a combination thereof.

In embodiments, the method further comprises increasing pressure in the stream of fluidic medium propagating through the rotary apparatus.

In embodiments, in said method, the amount of electrical energy conducted as the input energy into the at least one rotary apparatus integrated in the incineration facility is within a range of about 5 percent to 100 percent. In embodiments, in said method, the amount of electrical energy conducted as the input energy into the at least one rotary apparatus integrated in incineration facility is obtainable from a source of renewable energy or a combination of different sources of energy, optionally, renewable energy. In embodiments, in said method, the at least one rotary apparatus is utilized to balance variations, such as oversupply and shortage, in the amount of electrical energy, optionally renewable electrical energy, by virtue of being integrated, into the incineration facility, together with an at least one non-electrical energy operable heater device.

In another aspect, an incineration facility is provided, said incineration facility comprising at least one rotary apparatus configured to generate a heated fluidic medium and at least one incineration unit configured to carry out a process of processes related to incineration.

In an embodiment, in said incineration facility, the at least one rotary apparatus comprises: a casing with at least one inlet and at least one exit, a rotor comprising at least one row of rotor blades arranged over a circumference of a rotor hub mounted onto a rotor shaft, and a plurality of stationary vanes arranged into an assembly at least upstream the at least one row of rotor blades, wherein the at least one rotary apparatus is configured to operate such that an amount of thermal energy is imparted to a stream of fluidic medium directed along a flow path formed inside the casing between the inlet and the exit by virtue of a series of energy transformations occurring when said stream of fluidic medium passes through the stationary vanes and the at least one row of rotor blades, respectively, whereby a stream of heated fluidic medium is generated, and wherein said at least one rotary apparatus is configured to receive an amount of input energy, the input energy comprising electrical energy, and to generate a heated fluidic medium for inputting thermal energy into at least one operational unit configured to carry out incineration process(es) at temperatures essentially equal to or exceeding about 500 degrees Celsius (° C.).

In embodiments, in said incineration facility, the at least one rotary apparatus is connected to at least one incineration unit comprising or consisting of: an incinerator, a furnace, an oven, a kiln, a burner, a heater, a dryer, a conveyor device, a reactor, or a combination thereof.

In embodiments, in said incineration production facility, the at least one rotary apparatus comprises two or more rows of rotor blades sequentially arranged along the rotor shaft. In an embodiment, stationary vanes arranged into the assembly upstream of the at least one row of rotor blades are configured as stationary guide vanes. In an embodiment, the at least one rotary apparatus further comprises a diffuser area arranged downstream of the at least one row of rotor blades. The diffuser area may be configured with or without stationary diffuser vanes. In some configurations, vaned diffuser may be implemented as a plurality of stationary vanes arranged into an assembly downstream of the at least one row of rotor blades.

In an embodiment, the at least one rotary apparatus provided within said incineration facility is further configured to increase pressure in the fluidic stream propagating therethrough.

In some configurations, the least one rotary apparatus provided within said incineration facility is configured to implement a fluidic flow, between the inlet and the exit, along a flow path established in accordance with any one of: an essentially helical trajectory formed within an essentially toroidal-shaped casing; an essentially helical trajectory formed within an essentially tubular casing, an essentially radial trajectory, and along the flow path established by virtue of the stream of fluidic medium in the form of two spirals rolled up into vortex rings of right and left directions.

In an embodiment, the incineration facility comprises at least two rotary apparatuses arranged into an assembly and connected in parallel or in series.

In embodiments, the incineration facility is configured to implement incineration of waste gas via a process of thermal oxidation.

In a further aspect, an assembly is provided and comprises at least two rotary apparatuses according to some previous aspect, said rotary apparatuses being connected in parallel or in series.

In a further aspect, an arrangement is provided and comprises at least one rotary apparatus according to some previous aspect, said at least one rotary apparatus being connected to at least one incineration unit within the incineration facility.

In a further aspect, an incineration facility is provided and is configured to implement an incineration process through a method according to some previously defined aspects and embodiments; and it comprises at least one rotary apparatus according to some previous aspect. In a further aspect, an incineration facility is provided and is configured to implement a process or processes for disposal of harmful and/or toxic substances by incineration through a method according to some previously defined aspects and embodiments. In an aspect, use of the method and/or of the facility according to some previously defined aspects and embodiments is provided in disposal of harmful and/or toxic substances by incineration.

The utility of the present invention arises from a variety of reasons depending on each particular embodiment thereof.

Overall, embodiments offer an electrified rotary fluid heater to provide high temperature fluids, such as gases, to be used in incineration processes instead of fuel-fired burners, for example. The presented method enables inputting thermal energy into the heat-consuming utilities, such as furnaces used in incineration facilities operating at high- and extremely high temperatures, such as temperatures generally exceeding 500° C. The invention offers apparatuses and methods for heating the fluidic substances to the temperatures within a range of about 500° C. to about 1500° C. and beyond, up to about 2000° C., i.e. the temperatures used in incineration/combustion of a variety of waste materials.

Combustion of various substances in incinerators typically employs utilities with high demand for thermal energy and hence, for heat consumption, such as fuel-fired burners, for example. Said heat-consuming utilities are used to heat fluids to the temperatures needed for the incineration process. The invention presented herewith enables replacing conventional heat-consuming utilities, such as fuel-fired burners, by a rotary apparatus. In the method, the advantages accompanied by replacing fired heaters with the rotary apparatus include at least:

• • Support for electrified heating;
  • Elimination or at least significant reduction of greenhouse gas (such as NO, CO₂, CO, NO_X), other harmful components (such as for example HCl, H₂S, SO₂, and heavy metals) originating from fuels, particle emissions and soot emissions;
  • Reduced volume of a heater: the volume of the rotary apparatus may be at least one order of magnitude smaller as compared to the volume of conventional process heaters or heat exchangers;
  • Decreased investment costs;
  • Improved safety in case of using flammable, hazardous fluids/gases;
  • Feasibility in handling large volumes of gases;
  • Absence of pressure drop;
  • Possibility of using the rotary (heater) apparatus also for compression of gases (a blower function);
  • Independency on temperature difference in direct heating of gases. Temperature rise in the rotary apparatus can be in range of about 10 to 1700° C. or more;
  • Possibility for using the rotary apparatus in indirect heating of fluids optionally by optimizing temperature difference in heat exchanger(s);
  • Possibility for at least partial recycling of hot process gases, thus improving and making simpler the heat recovery and improving energy efficiency;
  • Possibility for further raising the temperature of gases to be heated by adding reactive chemicals which further increase the gas temperature up to e.g. 2000° C. or higher by exothermic reactions.

In embodiments, the rotary apparatus can be used to replace conventional fuel-fired heaters or burners in incineration processes. Traditionally such heat has been mainly produced through burning of fossil fuels leading to significant CO₂ emissions. Replacing fossil fuels with wood or other bio-based materials has significant resource limitations and other significant environmental implications such as sustainable land use. With the increased cost-efficiency of renewable electricity, namely the rapid development of wind and solar power, it is possible to replace fossil fuel firing with the rotary apparatus powered with renewable electricity leading to significant greenhouse gas emission reductions. The rotary apparatus allows electrified heating of fluids to temperatures up to 1700° C. and higher. Such temperatures are difficult or impossible to reach with current electrical heating applications.

The rotary apparatus can be used for direct heating of process gases (waste gases), inert gases, air or any other gases or for indirect heating of process fluids (liquid, vapor, gas, vapor/liquid mixtures etc.). The rotary apparatus can be used for direct heating of recycled gas recycled from exhaust gases generated from combusting (waste) substances, such as solids and/or liquids in incineration. Heated fluid generated in said rotary apparatus can be used for heating any one of gases, vapor, liquid, and solid materials. The rotary apparatus can at least partly replace- or it can be combined with (e.g. as preheater) multiple types of furnaces, heaters, kilns, gasifiers, and reactors that are traditionally fired or heated with solid, liquid or gaseous fossil fuels or in some cases bio-based fuels, including incinerator devices or combustion furnaces used in incineration. Such appliances include but are not limited to: incinerators, burners, (combustion) furnaces, ovens, heaters, dryers, conveyor devices, reactors, and their combinations. Heated gases can be flammable, reactive, or inert and can be recycled back to the rotary apparatus. In addition to heating, the rotary apparatus may act as combined blower and heater allowing to increase pressure and to recycle gases.

Heated fluids, such as gases, can be used in a variety of applications. A heated object can be a solid material, liquid or gas, which gas further takes part in a number of reactions or is used as a heating media. Hence, hot gases can be used for heating solid materials like in incineration plants.

By integration of the rotary apparatus into incineration facility, the need in directing auxiliary fuels into the combustion process is eliminated fully or partly. Naturally, this allows for reducing flue gas emissions. Hence, the invention enables the reduction of greenhouse gas (CO, CO₂, NO_x) and particle emissions when replacing fired heaters. By using the rotary apparatus, it is possible to have closed or semi-closed heating loops for processes, and to improve energy efficiency of the processes by reducing heat losses through flue gas. In conventional heaters, flue gases can be recycled only partly.

Additionally, the present solution enables improved optimization of the temperature difference(s) in the heat exchangers in indirect heating.

The rotary apparatus integrated into the incineration facility further provides high turbulence and hence perfect mixing of waste gas. Supplementary oxygen (air) or support fuel gases can also be injected into rotary apparatus. Temperature profile of the fluidic medium heated in the rotary apparatus is uniform, i.e. no temperature peaks appear as it is encountered with conventional burners. Uniform temperature profile allows to significantly reduce formation of NO_x and CO/CO₂ emissions.

The invention further provides for flexibly using electrical energy, such as electrical energy obtainable from renewable sources. Production of renewable energy varies on daily basis and even on hourly basis. The invention allows for balancing renewable electricity production by integration of the rotary apparatus disclosed herewith with conventional fuel-operated (fuel-fired) burners to provide heat to the incineration process.

The invention further enables a reduction in the on-site investment costs as compared to traditional fossil fired furnaces.

The term “gasified” is utilized hereby to indicate matter being converted into a gaseous form by any possible means.

The expression “a number of” refers hereby to any positive integer starting from one (1), e.g. to one, two, or three. The expression “a plurality of” refers hereby to any positive integer starting from two (2), e.g. to two, three, or four. The terms “first” and “second”, are used hereby to merely distinguish an element from another element without indicating any particular order or importance, unless explicitly stated otherwise.

Different embodiments of the present invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are block diagrams representing, at 1000, layouts for an incineration facility configured to implement a method according to the embodiments. FIG. 1C illustrates a conventional incineration system.

FIGS. 2A-2D show exemplary layouts for the rotary apparatus or apparatuses 100 within the hydrogen production facility, according to the embodiments.

FIG. 3 is a schematic representation of the facility and method according to the embodiments.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Detailed embodiments of the present invention are disclosed herein with the reference to accompanying drawings.

FIGS. 1A and 1B are block diagrams representing, at 1000, a layout for a high temperature incineration facility configured to implement a method according to the embodiments. FIG. 1A is an exemplary layout for incineration of gaseous or liquid feeds, and FIG. 1B is an exemplary layout for incineration of solid or liquid feeds optionally in combination with oxygen-containing waste gas. FIGS. 2A-2D and FIG. 3 describe apparatuses and methods according to the embodiments. Figures and related examples serve illustrative purposes and are not intended to limit applicability of the inventive concept to the layouts expressly presented in this disclosure. Block diagram sections shown by dotted lines are optional.

The process facility 1000 is a facility configured to carry out incineration process or processes 101 at temperatures essentially equal to or exceeding 500 degrees Celsius (° C.). In present disclosure, the terms “incineration” and “oxidation” generally refer to thermal treatments of organic substances in waste materials. The term “incineration” is generally used to describe a process for combustion of solid and liquid wastes, such as hazardous-, medical, municipal, or sewage waste. With respect to gaseous waste streams containing volatile organic compounds (VOCs), organic hazardous air pollutants (HAP), and/or odorous gases, the terms “incineration” and “oxidation”, as well as “incinerator” and “oxidizer” are used in present disclosure interchangeably and generally encompass thermal and/or catalytic oxidizers.

Facility 1000 can be represented with an industrial plant, a factory, or any industrial system comprising equipment designed to perform the incineration of substances, in particular, incineration of waste substances. Facility 1000 can be configured for disposal of substances collected from an external industrial facility by incineration. Facility 1000 can be configured for incineration of harmful and/or toxic substances. Additionally or alternatively, facility 1000 may be configured for incineration of waste substances and/or so called odorous compounds (mainly sulfur-containing compounds contained in gases typically originating from a process of kraft pulping). In some instances, incineration may process via processes of thermal and/or catalytic oxidation.

In embodiments, facility 1000 is configured to carry out the industrial incineration process(es) at temperatures within a range of 500-1700° C. In embodiments, facility 1000 is configured to carry out the industrial incineration process(es) which start at temperatures essentially within a range of about 800-900° C. or higher.

In embodiments, facility 1000 is configured to carry out the industrial incineration process(es) at temperatures essentially equal to- or exceeding 1000° C. In embodiments, facility 1000 is configured to carry out the industrial incineration process(es) which start at temperatures essentially within a range of about 1100-1200° C. or higher. In embodiments, the facility is configured to carry out the industrial incineration process(es) at temperatures essentially equal to- or exceeding 1200° C. In embodiments, the facility is configured to carry out the industrial incineration process(es) at temperatures within a range of about 1300-1700° C. In embodiments, the facility is configured to carry out the industrial incineration process(es) at temperatures essentially equal to- or exceeding 1500° C. In embodiments, the facility is configured to carry out the industrial incineration process(es) at temperatures essentially equal to- or exceeding 1700° C. It should be pointed out that facility 1000 is not excluded from carrying out of at least a part of industrial incineration processes at temperatures below 500° C. and at temperatures above 1700° C., e.g. up to about 2000° C.

Further description utilizes reference numbers as illustrated on FIGS. 1A and 1B unless otherwise explicitly noted. Process(es) related to incineration and corresponding operational units configured to carry out said processes within the facility 1000 and referred to as incineration process unit(s)/utility(/ies) is/are collectively designated by a reference numeral 101. The facility 1000 may comprise a number of operational units 101 configured to perform same or different processes related to incineration. In embodiments, the operational unit 101 comprises or consists of at least one device configured to carry out a process related to incineration. In embodiment, the unit 101 is a thermal incinerator/thermal oxidizer configured to carry out incineration of waste streams. Incineration unit 101 may adopt any possible configuration, including, but not limited to direct fired thermal oxidizers, catalytic thermal oxidizers, regenerative thermal oxidizers, and recuperative oxidizers. In embodiments, the unit 101 comprises or consist of a combustion furnace/combustion chamber of any suitable type. In additional or alternative embodiments, the operational unit 101 may comprise or consist of a kiln, a reactor, a furnace or any other heat-consuming device configured to receive waste gases and/or any harmful/toxic gases as a support fuel used in heat production. Combustion of materials through the incineration process typically has high thermal (heat) energy demand and consumption and, in conventional solutions, produce considerable industrial emissions such as carbon dioxide into the atmosphere. The present disclosure offers methods and apparatuses for inputting thermal energy into incineration processes 101 which have high heat energy demand, whereby energy efficiency in said processes can be markedly improved and/or the amount of air pollutants released into the atmosphere reduced. Layout 1000 (FIG. 1) schematically outlines these improved facility and method.

In embodiments, the method comprises generation of a heated fluidic medium by virtue of a rotary heater unit 100 comprising or consisting of at least one rotary apparatus, hereafter, the apparatus 100. For the sake of clarity, the rotary heater unit is designated in the present disclosure by the same reference number, 100, as the rotary apparatus. The rotary heater unit is preferably integrated into the process facility 1000. In an embodiment, the heated fluidic medium is produced by the at least one rotary apparatus; however, a plurality of rotary apparatuses may be used in series or in parallel.

The rotary apparatus 100 can be provided as a standalone apparatus or as a number of apparatuses arranged in series (in sequence) or in parallel. One or more apparatuses may be connected to a common operational unit 101, such as an incineration unit. Connection may be direct or through a number of heat exchangers.

Operational unit(s) 101 is/are provided as one or more incinerators, combustion furnaces or other utilities adapted to implement processes related to incineration of substances. In some configurations, thermal energy of the fluid, such as gas, heated in 100 is used to implement processes in the unit 101. In such as case, the fluid heated in 100 (e.g. a waste gas) forms, at least partly, the process fluid of 101. In some other configurations, the fluid heated in 100 transfers its thermal energy to a process fluid used in a kiln, a reactor, a furnace or any other heat-consuming device (designated herewith with reference number 101) to indirectly provide heat of reaction to said process. In an event of indirect heating, the fluid heated in 100 is different than the process fluid used in the operational unit/process 101. For example, thermal energy of fluidic medium, such as air or nitrogen gas generated in the rotary apparatus 100 can fully or partly replace thermal energy generated by fuel-fired burners in industrial kilns or furnaces (101) adapted for disposal of waste gases and/or any harmful/toxic gases. For the purposes of the invention the terms “process fluid”, “process stream” or “process fluid stream” are used to indicate any one of gas, liquid, vapor, solid, including pelletized, granulized or powered materials, or a mixture thereof. In configurations which involve said indirect heating, the thermal energy added into the fluid in the rotary apparatus 100 may be transferred to the operational unit(s)/process(-es) 101 through the use of so-called “heat exchanger”-type configurations represented, in the present context, with any existing fired heater, furnace or reactor, or any conventional heat exchanger device, wherein all these devices are viewed as units 101.

The process unit(s)/utility(/ies) 101 adapted for incineration is/are typically one or more incinerators, oxidizers, and/or combustion furnaces. In some configurations, a number of rotary apparatus units can be connected to several process utilities 101. Different configurations may be conceived, such as n+x rotary apparatuses connected to n utilities (e.g. furnaces), wherein n is equal to or more than zero (0) and x is equal to or more than one (1). Thus, in some configurations, the facility 1000 and, in particular, the rotary heater unit 100, may comprise one, two, three or four parallel rotary apparatus units connected to the common process unit, such as incineration unit, for example; the number of rotary apparatuses exceeding four (4) is not excluded. When connecting, in parallel, a number of rotary apparatuses to the common process unit, one or more of said apparatuses 100 may have different type of drive engine, e.g. the electric motor driven reactor(s) can be combined with those driven by steam turbine, gas turbine and/or gas engine.

In an embodiment, an amount of input energy E₁ is conducted into the at least one rotary apparatus 100 integrated, as a (rotary) heater unit, into the process facility 1000. The input energy E₁ preferably comprises electrical energy. In embodiments, the amount of electrical energy conducted as the input energy into the at least one rotary apparatus integrated in the incineration process facility is provided within a range of about 5 to about 100 percent, preferably, within a range of about 50 to about 100 percent. Thus, the amount of electrical energy conducted as the input energy into the at least one rotary apparatus integrated in the incineration process facility can constitute any one of: 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, and 100 percent (from the total energy input), or any intermediate value falling in between the above indicated points.

Electrical energy can be supplied from external or internal source. In practice, electrical input energy E1 supplied into the apparatus can be defined in terms of electric power, the latter being defined as a rate of energy transfer per unit time (measured in Watt).

Particulars of some embodiments of the invention, as implemented in the facility layouts of FIGS. 1A and 1B, are described along the following lines. For FIGS. 1A and 1B, the following designations are used for the members. Streams: 1. Feed; 2. Preheated feed or feed mixture; 3. Feed heated by virtue of a rotary apparatus 100; 4. Hot fluidic medium (effluent) exiting incineration process 101; 5. Fluidic medium directed to purification; 6. Exhaust stream (products of combustion, e.g. oxidized waste gas); 7. Feed stream to heat recovery; 8. Hot fluidic stream from heat recovery; 9. Process stream (typically, solid or liquid waste) to be heated/combusted by the hot fluidic medium in the incineration process 101; 10. Solid residue/ash. Sections (units): 100. Rotary heater unit (rotary apparatus(es)); 101.

Incineration process/unit; 102. Preheater unit; 104. Heat recovery unit; 105. Purification unit.

The rotary apparatus 100 is configured to receive a feed stream 1, hereafter, the feed 1. Overall, the feed 1 can comprise or consist of any fluid, such as liquid or gas or a combination thereof, provided as a pure component or a mixture of components. In embodiments, feed 1 is a gaseous substance, such as a waste gas (VOCs, HAPs, odorous gases, etc.), to be processed by incineration (FIG. 1A). Waste gas can be diluted with air or other inert gas. Additionally or alternatively, gaseous feed 1 can include inert gases, such as air (FIG. 1B). Overall, feed stream 1 may include inert gases (e.g. nitrogen), reactive gases, e.g. oxygen, flammable gases, such as hydrocarbons, or any other gas (e.g. air) or (water) steam.

It is preferred that the feed 1 enters the apparatus 100 in essentially gaseous form. Preheating of the feed or conversion of liquid or essentially liquid feed(s) into a gaseous form can be performed in an optional preheater unit 102 configured as a (pre)heater apparatus or a group of apparatuses. In the preheater unit 102, the feed stream(s) originally provided in a gaseous form (e.g. the process gas or gases) can be further heated (e.g. superheated). In the preheater unit 102, the feed 1 can be vaporized if not already in gas form and optionally superheated.

The preheater unit 102 can be any conventional device/system configured to provide heat to fluidic substance. In some configurations, the preheater unit 102 can be a fired heater (viz. a direct-fired heat exchanger that uses hot combustion gases (flue gases) to raise the temperature of a fluidic feed, such as a process fluid, flowing through the coils arranged inside the heater). Additionally or alternatively, the preheater unit 102 can be configured to exploit energy made available by the other units in the incineration facility (for example by extracting thermal energy from hot stream 13 arriving from heat recovery). The preheater unit 102 can thus be configured to utilize other steam streams, as well as electricity and/or waste heat streams (not shown).

Depending on an operational process 101 and related equipment, which in this embodiment is incineration of (waste) substances, the feed stream 1 used to produce the heated fluidic medium, by virtue of the rotary heater unit (the apparatus 100) may comprise fresh feed, i.e. exhaust gases arriving from any industrial facility and/or recycle stream(s). Hence, the feed 1 may consist of any one of fresh feed, recycle (fluidic) stream, and a mixture thereof. Stream 2 representing (pre)heated feed may include, in addition to feed 1, all recycle streams, such as those arriving from a heat recovery section 104 (rf. stream 8, FIGS. 1A, 1B) and/or from a purification section 105 (not shown).

In the rotary heater unit/the rotary apparatus 100, the temperature is raised to a level which is required by the incineration process 101 or to a maximum level achieved by the rotary apparatus. In an event the temperature rise achieved by the rotary apparatus 100 is not sufficient for the industrial incineration process and/or if, for example, the temperature of the fluid needs to be raised again after it has transferred its heat to said process, further temperature rise can be achieved by virtue of arranging additional heater units (100B, 103), further referred to as “booster” heater(s), downstream of the rotary heater unit 100 (100A); rf. description to FIG. 2B. Each additional heater unit comprises or consists of an additional heating apparatus implemented according to the description below.

In the processes of disposal of (waste) substances by incineration described herein, the main sources of heat consumption are the heating of combustible feedstocks. By providing heat recovery between selected inlet streams and the effluent stream it is generally possible to improve energy efficiency of the process. Heat recovery section is indicated on FIGS. 1A and 1B with ref. no. 104. Heat recovered from the effluent stream 4 containing the products of combustion, along with any inert compounds that may have been present in or added to the inlet streams of 101, can be used to preheat the incoming waste stream 1, auxiliary air (not shown), or both. Additionally or alternatively, heat recovered in 104 can be further used for heating a recycle stream (rf. stream 8).

Heat recovery may be arranged through collecting gases exiting the process unit 101 and recycling these gases to the preheater unit 102 and/or the rotary apparatus 100. The heat recovery installation 104 may be represented with at least one heat exchanger device. Heat exchangers based on any appropriate technology can be utilized. Heat recovery may be optional for heating feed gas if the heat is consumed elsewhere or if it is not possible to recover heat due to safety- or any other reason. It is noted that the heat exchanger device can also be used as a preheater unit 102.

In the facility layout 1000, the heat recovery unit 104 can be arranged before and/or after the preheater 102. In the latter configuration, the heat recovery unit 104 is arranged to recover heat from the hot effluent (stream 4) flowing from the incinerator 101, which may be further utilized to heat the feed stream 1, such as waste gas feed stream, for example, and the recycle stream 8. On the other hand, when the heat recovery unit 104 is arranged before the preheater 102, the feed 1 is first led to the unit 104 (as stream 7) and then returned to preheating 102 as stream 8. In such a case, the unit 104 acts as a first preheater.

Combustion gases exiting the incineration process unit 101 may further be directed to a purification unit 105 (optionally bypassing the heat recovery unit 104), and, after purification, returned to the heat recovery (not shown). Purification unit 105 is configured to perform purification and separation of streams discharged from the incineration process(es) 101. Unit 105 can be configured to remove impurities and/or hazardous compounds contained in exhaust gases discharged from incineration 101 as streams 4,5 (FIGS. 1A, 1B). In some instances, purification unit 105 may be a scrubber.

Purification unit 105 can be further adapted to purify exhaust gas(es) discharged from the incineration process, e.g. carbon dioxide, for further carbon capture. Exhaust gases discharged from the incineration facility as stream 6 (FIGS. 1A, 1B) can thus be further directed to carbon capture (not shown). Suitable methods for purification of exhaust gases include for example Pressure Swing Adsorption (PSA), distillation, absorption, and any combination of these methods.

Exhaust gases discharged from incineration 101 may contain nitrogen oxides, acidic gases, halogens, trace metals (e.g., arsenic, beryllium, cadmium, chromium, nickel, and mercury), and other hazardous air pollutants (e.g., dioxins and furans) generated from combustion of compounds present in the waste or from the combustion of supplemental fuels. By way of example, nitrogen oxide formation can be controlled through the use of reducing agents such as ammonia- and urea-based scrubbers. Particulates, including trace metals can be controlled through use of mechanical collectors, wet scrubbers, fabric filters, and electrostatic precipitators. Formation of dioxins and furans may be controlled using a spray dryer, water sprays, or injection of carbon in combination with particulate matter control devices.

In order to remove HCl, SO₂ and other acid gases contained in emissions resulting from incineration of waste streams containing halogenated and sulfur compounds, purification unit 105 may be configured as an acid gas removal system, such as a wet scrubber, for example.

Additionally or alternatively, the purification unit 105 can be configured as a secondary heat recovery unit. Configuration, where the purification unit 105 is provided in a heat exchanger configuration adapted for heat recovery is shown on FIG. 3.

In embodiments, heated fluidic medium required for carrying out incineration process(es) 101 is generated by virtue of at least one rotary apparatus 100. The at least one rotary apparatus 100 integrated into the incineration facility may thus replace, fully or partly, the fuel-fired burners in the incineration unit 101 and/or incineration facility 1000.

In an embodiment, the heated fluidic medium is generated in the rotary apparatus 100, where an amount of thermal energy is added directly into fluidic medium propagated through said apparatus. Such configuration may be adopted in incineration or thermal oxidizing of waste gases and liquids (FIG. 1A). Configuration of FIG. 1A utilizes, as feed 1, gaseous substances, such as VOCs, HAPs and/or any other flammable gas which can undergo combustion in the incineration unit 101. A number of non-VOC organic compounds may include acetone, methane, and methylene chloride.

VOCs are generally defined as any non-solid organic compound found in waste gas, irrespective of its volatility. The term VOCs covers a diverse group of substances and includes all organic compounds released to air in the gas phase, whether hydrocarbons or substituted hydrocarbons. HAPs are generally defined as gaseous toxic compounds that are known carcinogens and can cause other serious health impacts. HAPs include dioxin/furans, HCl, H₂S, methylene chloride, etc.

So called “odorous gases” are gases originating from pulp and paper industry, e.g. from a process of kraft pulping (chemical removal of lignin from wood biomass materials). During pulping, a large number of low molecular weight and volatile compounds are formed, such as sulfur compounds, as well as methanol, ethanol, acetone and terpenes. In pulp and paper industry, odorous gases are typically combusted in a lime kiln.

The heated fluidic medium generated in the rotary apparatus is thus a waste (feed) gas, which may be optionally diluted (see FIG. 1A, streams 1-3). Streams 4, 5 designate exhaust gases and optionally particulate matter discharged from the incineration unit/process 101 and are also referred to as a hot fluidic medium or hot effluent. In direct heating, streams 1-5 may be referred to as a working- or process fluid.

FIG. 1B illustrates a layout, where the heated fluidic medium generated in the rotary apparatus 100 can be further used as a carrier to transfer thermal energy to the operation unit 101 configured to implement or mediate a process or processes (101) related to incineration of (waste) substances. Such configuration may be adapted for incineration of solid substances. In some instances, configuration 1B can be adopted to combined incineration of solid substances with incineration of oxygen-containing waste gas feed.

In the layout of FIG. 1B, the feed stream 1 cam be represented with air or oxygen-containing waste gas. Feed 1 can be heated in the rotary apparatus 100 and further used to convey the heat generated by the rotary apparatus to the combustion furnace adapted to perform the incineration process 101. Waste stream to be combusted in the incinerator 101 is designated on FIG. 1B with the reference numeral 9. Stream 9 can be represented with any solid or liquid waste (municipal-, hospital- or medical waste, contaminated earth, wastewater, and the like). Utilization of any media, such as gas, vapor, liquid, solid, and mixtures thereof, as stream 9 is not excluded.

In this regard, generation of a heated medium (e.g. fluidic or solid streams exploited by the process 101) can be performed outside the rotary apparatus through a process of heat transfer between the heated fluidic medium generated in the rotary apparatus and a suitable (waste) medium exploited by the process 101 and thus bypassing the rotary apparatus. Waste stream 9 bypassing the rotary apparatus 100 may thus be referred to, in present context, as a process stream), while streams 1-3 arriving to the incinerator 101 via the rotary heater 100 may be referred to as a “heat transfer medium”, that input thermal energy into the incineration process 101. It is further noted, that in practice, the hot effluent 3 arriving from the rotary apparatus 100 into the incineration 101 acts as a combustion medium to burn substances contained in the waste stream 9. In an event the solid waste 9 is burned in the combustion chamber/incinerator 101, stream 10 represents solid residue/ash withdrawn from the process.

In some instances, incineration of solid waste may be combined with burning of waste gas directed through the rotary apparatus 100. In such an event, oxygen-containing waste gas heated in the rotary apparatus 100 is used as a heat-transfer medium for inputting heat into a process of incineration of solid waste stream 9.

In configurations of FIGS. 1A and 1B, the existing incinerator 101 can be retrofitted with the rotary apparatus 100.

The rotary apparatus 100 configured for generating the heated fluidic medium to be supplied into the incineration facility according to the embodiments comprises a rotor comprising a plurality of rotor blades arranged into at least one row over a circumference of a rotor hub or a rotor disk mounted onto a rotor shaft, and a casing with at least one inlet and at least one exit, the rotor being enclosed within the casing. In the apparatus 100, an amount of thermal energy is imparted to a stream of fluidic medium directed along a flow path formed inside the casing between the inlet and the exit by virtue of a series of energy transformations occurring when said stream of fluidic medium passes through the at least one row of rotor blades when propagating inside the casing of the rotary apparatus, between the inlet and the exit, whereby a stream of heated fluidic medium is generated.

Implementation of the rotary apparatus 100 may generally follow the disclosures of a rotary reactor apparatus according to the U.S. Pat. No. 7,232,937 (Bushuev), U.S. Pat. No. -9,494,038 (Bushuev) and U.S. Pat. No. 9,234,140 (Seppälä et al), and of a radial reactor apparatus according to the U.S. Pat. No. 10,744,480 (Xu & Rosic), the entire contents of which are incorporated by reference herewith. Any other implementation, which can be configured to adopt the method according to the embodiments, can be utilized.

In the patent documents referenced above, the rotary turbomachine-type apparatuses were designed as reactors for processing hydrocarbons, in particular, for steam cracking.

General requirements for these applications are: rapid heating of gases, high temperature, short residence time, and plug flow (a flow model which implies no axial mixing). These requirements have led to designs where the turbomachine type reactors have several heating stages accommodated in a relatively small volume.

The present disclosure is based on an observation that the rotary apparatus (including, but not limited to the ones referenced above) can be electrified and used as a heater to generate the heated fluidic medium further supplied in the process or processes 101 related to incineration of harmful and/or toxic substances, or waste. By integration of the rotary apparatus heater unit(s) into incineration process or processes, significant reductions in greenhouse gas- and particle emissions can be achieved. By way of example, the rotary apparatus can replace fuel-fired burners in a variety of applications (described hereinbelow). The temperature range can be extended from about 1000° C. (generally achievable with the above referenced reactor devices) to up to at least about 1700° C. and further up to 2500° C. Construction of the rotary apparatuses capable of achieving these high temperatures is possible due to an absence of aerodynamic hurdles.

The rotary apparatus 100 integrated into the incineration facility according to the embodiments and configured to generate the heated fluidic medium for the method(s) according to the embodiments thus comprises the rotor shaft positioned along a horizontal (longitudinal) axis with at least one rotor unit mounted onto the rotor shaft. The rotor unit comprises a plurality of rotor (working) blades arranged over the circumference of a rotor hub or a rotor disk and together forming a rotor blade cascade. The rotary apparatus 100 thus comprises a plurality of rotor (working) blades arranged into at least one row over the circumference of a rotor hub or a rotor disk mounted onto the rotor shaft, and forming an essentially annular rotor blade assembly or rotor blade cascade.

In embodiments, the apparatus further comprises a plurality of stationary vanes arranged into an assembly disposed at least upstream of the at least one row of rotor blades. In this configuration, the rotary apparatus is operated such that the amount of thermal energy is imparted to a stream of fluidic medium directed along a flow path formed inside the casing between the inlet and the exit by virtue of a series of energy transformations occurring when said stream of fluidic medium passes through the stationary vanes and the at least one row of rotor blades, respectively, whereby a stream of heated fluidic medium is generated.

In some embodiments, the plurality of stationary vanes can be arranged into a stationary vane cascade (a stator), provided as an essentially annular assembly upstream of the at least one row of rotor blades. The stationary vanes arranged into the assembly disposed upstream of the at least one row of rotor blades may be provided as stationary guide vanes, such as (inlet) guiding vanes (IGV), and be configured, in terms of profiles, dimensions and disposition thereof around the central shaft, to direct the fluid flow into the rotor in a predetermined direction such, as to control and, in some instances, to maximize the rotor-specific work input capability.

The rotary apparatus can be configured with two or more essentially annular rows of rotor blades (blade cascades) sequentially arranged on/along the rotor shaft. In such an event, the stationary guide vanes may be installed upstream of the first row of the rotor blades, upstream of each row of rotor blades in the sequence, or upstream of any selected row of rotor blades in a sequential arrangement of the latter.

In embodiments, the rotary apparatus 100 further comprises a diffuser area arranged downstream of the at least one row of rotor blades (rotor blade cascade). In such an event, the rotary apparatus is operated such that an amount of thermal energy is imparted to a stream of fluidic medium directed along a flow path formed inside the casing between the inlet and the exit by virtue of a series of energy transformations occurring when said stream of fluidic medium successively passes through the stationary guide vanes, the at least one row of rotor blades and the diffuser area, respectively, whereby a stream of heated fluidic medium is generated. The diffuser area can be configured with or without stationary diffuser vanes. In some configurations, a vaned or vaneless diffuser is arranged, in said diffuser area, downstream of the at least one rotor blade cascade. In some configurations, the diffuser can be implemented as a plurality of stationary (stator) vanes arranged into a diffuser vane cascade, provided as an essentially annular assembly downstream of the rotor.

The rotor, the stationary guide vanes and the diffuser area are enclosed within an internal passageway (a duct) formed in the casing.

In some configurations, such as described for example in U.S. Pat. No. 10,744,480 to Xu and Rosic, provision of a diffuser (device) may be omitted, and the diffuser area may be represented with an essentially vaneless portion of the duct (a so-called vaneless space) located downstream of the rotor and configured, in terms of its geometry and/or dimensional parameters, to diffuse a high speed fluid flow arriving from the rotor.

Provision of the vaneless portion of the duct is common for all configurations of the rotary apparatus 100 described above. Depending on configuration, the vaneless portion (vaneless space) is arranged downstream of the rotor blades (rf. U.S. Pat. No. 10,744,480 to Xu and Rosic) or downstream of the diffuser vane cascade (rf. U.S. Pat. No. 9,494,038 to Bushuev and U.S. Pat. No. 9,234,140 to Seppälä et al). In some configuration described for example by Seppälä et al, arrangement of rotating and stationary blade rows in the internal passageway within the casing is such that vaneless portion(s) is/are created between an exit from the stationary diffuser vanes disposed downstream of the rotor blades and an entrance to the stationary guide blades disposed upstream of the rotor blades of a subsequent rotor blade cascade unit.

The terms “upstream” and “downstream” refer hereby to spatial and/or functional arrangement of structural parts or components with relation to a predetermined part- or component, hereby, the rotor, in a direction of fluidic flow stream throughout the apparatus (from inlet to exit).

Overall, the rotor with the working blade cascade can be positioned between the rows of stationary (stator) vanes arranged into essentially annular assemblies (referred to as cascades) at one or both sides of the working blade row. Configurations including two or more rows of rotor blades/rotor blade cascades arranged in series (in sequence) on/along the rotor shaft may be conceived with or without stationary blades in between. In an absence of stationary vanes between the rotor blade rows, the speed of fluidic medium propagating through the duct increases in each subsequent row. In such an event, a plurality of stationary vanes may be arranged into assemblies upstream of a first rotor blade cascade in said sequence (as stationary guide vanes) and downstream of a lastmost rotor blade cascade (as stationary diffuser vanes).

The row of rotor blades (rotor blade cascade) and a portion of the duct downstream said rotor blades enclosed inside the casing optionally provided with an assembly of stationary diffuser vanes (diffuser area) may be viewed as a minimal process stage (hereafter, the stage), configured to mediate a complete energy conversion cycle. Hence, an amount of kinetic energy added to the stream of fluidic medium by at least one row of rotating blades is sufficient to raise the temperature of the fluidic medium to a predetermined value when said stream of fluidic medium exits the rotor blades and propagates, in the duct, towards a subsequent row of rotor blades, or enters the same row of rotor blades following an essentially helical trajectory formed within the essentially toroidal-shaped casing. The duct (which encloses the periphery of the rotor) is preferably shaped such, that upon propagation of the fluidic stream in the duct, the stream decelerates and dissipates kinetic energy into an internal energy of the fluidic medium, and an amount of thermal energy is added to the stream of fluidic medium.

The stationary guide blade row(s) disposed upstream of the at least one row of rotor blades prepare required flow conditions at the entrance of the rotating blade row (cascade) during the energy conversion cycle.

In some configurations, the process stage is established with the assembly of stationary guide vanes (upstream of the rotor blades), the row of rotor blades and the diffuser area arranged downstream of said rotor blades, the diffuser area provided as the essentially vaneless portion of the duct optionally supplied with diffuser vanes. During the energy conversion cycle, enabled with successive propagation of the stream of fluidic medium through the stationary guide vanes, the at least one row of rotor blades and the diffuser area, respectively, in a controlled manner, mechanical energy of the rotor shaft is converted into kinetic energy and further—into internal energy of the fluid, followed by the rise of fluid temperature. An amount of kinetic energy added to the stream of fluidic medium by rotating blades of the rotor is sufficient to raise the temperature of the fluidic medium to a predetermined value when said stream of fluidic medium exits the rotor blades and passes, inside n the duct, through the diffuser area, whereupon the stream decelerates and dissipates kinetic energy into an internal energy of the fluidic medium, and an amount of thermal energy is added to the stream of fluidic medium. In the rotor blade row, the flow accelerates, and mechanical energy of the shaft and rotating blades is transferred to fluidic stream. In at least part of each rotor blade row the flow may reach a supersonic flow condition. In the diffuser area, the high-speed fluid flow arriving from the rotor is diffused with the significant entropy increase, whereby the flow dissipates kinetic energy into the internal energy of the fluidic substance, thus providing thermal energy into the fluid. If the flow upstream of the diffuser is supersonic, the kinetic energy of the fluidic stream is converted into internal energy of the fluid through a system of multiple shocks and viscous mixing and dissipation. An increase in the internal energy of the fluid results in a rise of fluid temperature. The energy conversion function may be performed by the vaneless portion of the duct located downstream of the rotor blades (rf. U.S. Pat. No. 10,744,480 to Xu & Rosic) and/or by an assembly of diffusing vanes, for example (rf. U.S. Pat. No. 9,234,140 to Seppälä et al).

The rotary apparatus 100 can be configured as a multistage- or a single-stage solution. Multistage configurations can be conceived comprising a number of rotor units (e.g. 1-5 rows of rotor blades sequentially arranged on/along the rotor shaft) alternating with common diffuser area(s) (vaneless or vaned).

In an exemplary configuration outlined in U.S. Pat. No. 9,234,140 to Seppälä et al, the rotary apparatus 100 can be implemented substantially in a shape of a ring torus, where a cross-section of the duct in the meridian plane forms a ring-shaped profile. The apparatus comprises a rotor unit disposed between stationary guide vanes (nozzle vanes), and stationary diffusing vanes. The stages are formed with rows of stationary nozzle vanes, rotor blades and diffusing vanes, through which the fluidic stream propagates, in a successive manner, following a flow path established in accordance with an essentially helical trajectory. In this configuration, fluidic stream circulates through the rotating rotor blade cascade a number of times while propagating inside the apparatus between the inlet and the exit. Similar ring-shaped configuration is described in U.S. Pat. No. 9,494,038 to Bushuev.

In another exemplary configuration outlined in U.S. Pat. No. 9,234,140 to Seppälä et al, the rotary apparatus 100 can be configured as an essentially tubular, axial-type turbomachine. In such configuration, the apparatus comprises an extended (elongated) rotor hub, along which a plurality of rotor blades is arranged into a number of sequential rows. The rotor is enclosed within the casing, inner surface of which is provided with the stationary (stator) vanes and diffuser vanes, arranged such that blades/vanes of the stator, rotor- and diffuser cascades alternate along the rotor hub in a longitudinal direction (along the length of the rotor shaft, for inlet to exit). Blades of the rotor cascade at certain position along the rotor in the longitudinal direction form the stage with the adjacent pairs of stationary guide (nozzle) vanes and diffusing vanes, respectively.

In described configurations, the subsequent stages have blade/vane-free space between them.

In still another exemplary configuration outlined in U.S. Pat. No. 10,744,480 to Xu and Rosic, the rotary apparatus 100 can be configured as a radial turbomachine that generally follows a design for centrifugal compressors or centrifugal pumps. The term “centrifugal” implies that fluid flow within the device is radial; therefore, the apparatus may be referred, in the present disclosure, as a “radial-flow apparatus. The apparatus comprises a number of rotor units mounted onto elongated shaft, wherein each rotor unit is preceded with stationary guide vanes. A vaneless portion of the duct shaped in a manner enabling energy conversion (U-bend or S-bend, for example) is located after the rotor unit(s). Additionally, configuration may comprise a separate diffuser device (vaned or vaneless) disposed downstream of the rotor.

In all configurations described above, the rotary apparatus 100 performs, in the method disclosed herein, in similar manner. In operation, the amount of input energy conducted into the at least one rotary apparatus integrated into the incineration process facility is converted into mechanical energy of the rotor. Conditions in the rotary apparatus are adjusted such, as to produce flow rate conditions, at which an amount of kinetic energy added to the stream of fluidic medium by rotating blades of the rotor is sufficient to raise the temperature of the fluidic medium to a predetermined value when said stream of fluidic medium exits the at least one row rotor blades and passes through the duct and/or through the diffuser area to enter the subsequent row of rotor blades or the same row of rotor blades in accordance to the description above. The row(s) of rotor blades may be preceded with stationary guide vanes.

Hence, the adjustable condition comprises adjusting at least a flow of fluidic medium propagating inside the casing of the rotary apparatus, between the inlet and the exit. Adjusting the flow may include adjusting such apparatus operation related parameters, as temperature, mass flow rate, pressure, etc. Additionally or alternatively, flow conditions can be adjusted by modifying shape of the duct formed inside the casing.

In some exemplary configurations, the rotary apparatus can be configured to implement a fluidic flow between its inlet(s) and outlet(s) along a flow path established in accordance with any one of: an essentially helical trajectory formed within an essentially toroidal-shaped casing, as discussed in any one of the patent documents U.S. Pat. No. 9,494,038 to Bushuev and U.S. Pat. No. 9,234,140 to Seppälä et al; an essentially helical trajectory formed within an essentially tubular casing, as discussed in the patent document U.S. Pat. No. 9,234,140 to Seppälä et al; an essentially radial trajectory as discussed in the patent document U.S. Pat. No. 10,744,480 to Xu & Rosic; and along the flow path established by virtue of the stream of fluidic medium in the form of two spirals rolled up into vortex rings of right and left directions, as discussed in the patent document U.S. Pat. No. 7,232,937 to Bushuev). The aerodynamic design of the rotary apparatus can vary.

The rotary apparatus utilizes a drive engine. In preferred embodiments, the apparatus utilizes electrical energy as the input energy and is therefore electric motor-driven. For the purposes of the present disclosure, any appropriate type of electric motor (i.e. a device capable of transferring energy from an electrical source to a mechanical load) can be utilized. Suitable coupling(s) arranged between a motor drive shaft and the rotor shaft, as well as various appliances, such as power converters, controllers and the like, are not described herewith. Additionally, the apparatus can be directly driven by gas- or steam turbine, for example, or any other appropriate drive device. In layouts involving parallel connection of a number of rotary apparatuses 100 to a common process unit 101, such as a furnace, for example, one or more of said apparatuses may utilize different type of drive engine, e.g. the electric motor driven apparatuses can be combined with those driven by steam turbine, gas turbine and/or gas engine.

Electric power (defined as the rate of energy transfer per unit time) can be supplied into the rotary apparatus through supplying electric current to the electric motor used to propel a rotary shaft of the apparatus. Supply of electric power into the rotary apparatus can be implemented from an external source or sources (as related to the rotary heater unit/the apparatus 100 and/or the incineration process facility 1000). Additionally or alternatively, electrical energy can be produced internally, within the facility 1000.

An external source or sources include a variety of supporting facilities rendered for sustainable energy production. Thus, electric power can be supplied from an electricity generating system that exploits at least one source of renewable energy or a combination of the electricity generating systems exploiting different sources of renewable energy. External sources of renewable energy can be provided as solar, wind- and/or hydropower. Thus, electric power may be received into the process from at least one of the following units: a photovoltaic electricity generating system, a wind-powered electricity generating system, and a hydroelectric power system. In some exemplary instances, a nuclear power plant may be provided as the external source of electrical power. Nuclear power plants are generally regarded as emission-free. The term “nuclear power plant” should be interpreted as using traditional nuclear power and, additionally or alternatively, fusion power.

Electricity can be supplied from a power plant that utilizes a turbine as a kinetic energy source to drive electricity generators. In some instances, electric power to drive the at least one apparatus 100 can be supplied from at least one gas turbine (GT) provided as a separate installation or within a cogeneration facility and/or a combined cycle power facility, for example. Electric power can thus be supplied from at least one of the following units: a combined cycle power facility, such as a combined cycle gas turbine plant (CCGT), and/or a cogeneration facility configured for electricity production combined with heat recovery and utilization through combined heat and power (CHP), for example. In some examples, the CHP plant can be a biomass fired plant to increase the share of renewable energy in the process described. Additionally or alternatively, supply of electric power can be realized from a spark ignition engine, such as a gas engine, for example, and/or a compression engine, such as a diesel engine, for example, optionally provided as a part of an engine power plant. Still further, any conventional power plant configured to produce electrical energy from fossil raw materials, such as coal, oil, natural gas, gasoline, and the like, typically mediated with the use of steam turbines, can be used to generate electrical energy as an input energy for the rotary apparatus 100. Also hydrogen can be utilized as a source of renewable energy, to be reconverted into electricity, for example, using fuel cells.

Any combination of the abovementioned sources of electric power, realized as external and internal sources, may be conceived. Importing low emission electric power from an alternative (external) source improves energy efficiency of the incineration process facility.

Conducting input energy, comprising electrical power, into a drive engine of the rotary apparatus can be further accompanied with conducting mechanical shaft power thereto from a power turbine, for example, optionally utilizing thermal energy generated elsewhere in the facility 1000 or outside said facility. Shaft power is defined as mechanical power transmitted from one rotating element to another and calculated as a sum of the torque and the speed of rotation of the shaft. Mechanical power is defined, in turn, as an amount of work or energy per unit time (measured in Watt).

In practice, the shaft power from the electric motor and the power turbine, for example, can be divided so that any one of those can provide the full shaft power or a fraction of it.

FIGS. 2A-2D show exemplary layouts for the rotary apparatus 100 representing the rotary heater unit or units within the incineration facility 1000 with regard to preheater unit 102, temperature booster section 103, and heat recovery unit 104. The following citations are used for the members: 100, 100A, 100B—Rotary heater unit(s) (rotary apparatus(es)); 101—Incineration unit/process; 102—Preheater unit; 103—Additional heating apparatus (booster heater).

FIG. 2A schematically illustrates a basic implementation for the rotary apparatus 100 configured to input heat into a stream of fluidic medium (feed stream 1) directed therethrough. Heated stream exiting the apparatus 100 is designated with reference number 2, respectively. In basic implementation, the rotor system of the rotary apparatus 100 is aerodynamically configured so that a volume of fluid is heated to a predetermined temperature while propagating along the flow path formed in the casing of the apparatus 100, between inlet and exit (so called “one-pass” implementation). The apparatus 100 enables temperature rise (delta T, ΔT) within a range of about 10° C. to about 120° C., in some configurations—up to about 500° C., in one stage. Hence, in case of a multistage implementation, the fluid can be heated to 1000° C. in “one-pass” implementation (taken 100° C. temperature rise per stage in a 10-stage apparatus). Since residence time the fluidic medium spends to pass through the apparatus stage is in scale of fractions of seconds, such as about 0.01-1.0 milliseconds, fast and efficient heating can be achieved already in the basic configuration. Temperature rise can be optimized as required.

FIG. 2B illustrates a basic concept involving so-called booster heating. Booster heating is an optional method to heat a fluidic medium, such as a process gas, for example, beyond capability of a standalone heater apparatus 100.

Temperature boost may be viewed as thermal, chemical or both. In a first configuration (a) also referred to as a “thermal boost”, an additional rotary heater apparatus (designated as 100B on FIGS. 2B, 2C and 2D) is arranged downstream of a “primary” rotary heater apparatus (designated as 100A on FIGS. 2B, 2C and 2D). Apparatuses 100A, 100B are generally recognized, within the present disclosure, as rotary heater units 100. Generation of the heated fluidic medium is can thus be achieved by provision of at least two sequentially connected rotary apparatuses 100A, 100B, wherein the stream of fluidic medium (rf. feed stream 1) is heated to a predetermined temperature in at least a first rotary apparatus (100A) in a sequence, referred to hereby as a primary heater, and wherein said stream of fluidic medium (rf. stream 2) is further heated in at least a second rotary apparatus (100B) in the sequence by inputting an additional amount of thermal energy into the stream of fluidic medium “preheated” in the first rotary apparatus 100A and propagating through the second rotary apparatus 100B (rf. stream 3). The apparatus 100B is therefore referred to as a booster heater. The apparatuses 100A, 100B may be identical and vary in terms of size or internal design. A sequence of two or more booster apparatuses such as 100B can be arranged after a primary heater 100A. Booster apparatuses can be arranged in parallel or in series, or in any combination that allows for optimization of rotating speed and aerodynamics thereof.

In a second, additional or alternative, configuration (further referred to as “chemical boost”), the additional heating apparatus designated as 103 (FIGS. 1, 2B) is adapted to receive, into the stream of fluidic medium propagating therethrough, reactive components 5, such as for example combustible fuel, to provide heat by exothermic reactions prior to directing said stream of fluidic medium to incineration process 101. In this configuration, temperature boosting can be achieved by virtue of introducing (e.g. by injecting) a reactive chemical or chemicals 5 into to the stream of fluidic medium directed through the additional heater unit/heating apparatus 103. It is noted that stream 5 of FIG. 2B corresponds to stream 8 shown on FIG. 1.

The reactive chemical-based booster heater unit 103 may be located after the thermal booster heater unit 100, 100B (FIG. 2B) or directly after the primary heater 100, 100A (FIG. 1). The reactive chemical (reactant) 5 may include combustion gases, such as hydrogen gas, hydrocarbons, ammonia, oxygen, air, other gas and/or any other appropriate reactive compound, optionally a catalyst. In the unit 103, by virtue of exothermic reactions, the fluidic stream can be heated to a level, which is typically not possible to achieve by a single rotary apparatus not involving chemical-mediated heating (rf. stream 4). For example, a fuel gas, such as hydrogen, can be introduced into an oxygen-containing process gas, such as air. At elevated temperatures, hydrogen and oxygen enter an exothermic reaction to produce water molecules (hydrogen combustion).

Fuel gas can be injected into the booster heater unit 103 through burners along with air (or enriched oxygen) to rise the temperature of gases. If heated gas contains flammable gases and it is possible to consume these gases for heating only air/or oxygen can be added. Process gases can contain H₂, NH₃, CO, fuel gases (methane, propane, etc.) which may be burned to generate heat. Other reactive gases can be injected to generate heat if feasible.

The additional heater 103 adapted for chemical boost may be configured as a piece of pipe or as a chamber where exothermic reactions take place, and/or it can comprise as at least one rotary apparatus 100 arranged to receive reactive compounds to accommodate exothermic reactions to produce additional heat energy. The booster section 103 can thus comprise at least one rotary apparatus 100. Optionally, the reactive chemicals can be injected directly to the heat consuming process 101 (not shown). Additionally or alternatively, the reactive chemical mediated boost can be implemented in a single apparatus 100, 103, modified accordingly.

In an arrangement involving booster heating, the temperature of the stream of fluidic medium preheated to a predetermined temperature in a first rotary apparatus (100A) can be further raised to a maximum limit in subsequent heater units (100B, 103). By way of example, the temperature of the stream of fluidic medium preheated to about 1700° C. in a primary heater (100A) can be further raised in subsequent heater units (100B, 103) up to 2500° C. and beyond.

Mentioned concepts can be used separately or in combination, so that the reactive chemical 5 can be introduced into any one of the apparatuses 100 connected in parallel or in series (in sequence). Provision of the booster heater(s) is optional.

In additional or alternative configurations, preheating and additional heating can be implemented in the same apparatus 100 (not shown). This can be achieved in multistage configurations, comprising a number of rotor units (e.g. 1-5 rows of rotor blades sequentially arranged on/along the rotor shaft) alternating with common diffuser area(s) (vaneless or vaned).

Upon connecting the at least two rotary apparatuses, such as 100A, 100B, and optionally 103 (in an event 103 is implemented as a rotary apparatus 100) in parallel or in series, a rotary apparatus assembly can be established (see for example FIGS. 2B-2D). Connection between the rotary apparatuses 100 implemented as “primary” heater(s) 100A or “booster” heater(s) 100B, 103 can be mechanical and/or functional. Functional (in terms of achievable heat input, for example) connection can be established upon association between at least two individual, physically integrated- or non-integrated individual apparatus units. In a latter case, association between the at least two rotary apparatuses can be established via a number of auxiliary installations (not shown). In some configurations, the assembly comprises the at least two apparatuses connected such, as to mirror each other, whereby said at least two apparatuses are at least functionally connected via their central (rotor) shafts. Such mirrored configuration can be further defined as having the at least two rotary apparatuses 100 mechanically connected in series (in a sequence), whereas functional connection can be viewed as connection in parallel (in arrays). In some instances, the aforesaid “mirrored” arrangement can be further modified to comprise at least two inlets and a common exhaust (discharge) module placed essentially in the center of the arrangement.

Rotary apparatuses (100A, 100B, 103, rf. FIG. 2B) can be assembled on the same (rotor) shaft. Each rotary apparatus can be optionally provided with a separate drive (a motor) which allows independent optimization of the apparatuses. When two or more separate rotary apparatuses are used, construction costs (materials etc.) can be optimized in view of operation temperature and pressure.

Additionally or alternatively, at least one rotary apparatus within the assembly can be designed to increase pressure of the fluidic stream. Hence, the at least one rotary apparatus in the assembly can be assigned with a combined heater and blower functionality. The apparatus 100 adapted to act as blower provides necessary pressure increase for the fluid to circulate in the incinerator 101. The apparatus 100 may thus replace a separate air blower/system fan, otherwise necessary in conventional fuel-fired incinerators.

Additionally or alternatively, a stream containing reactive or inert gases can be fed to the rotary apparatus 100 (not shown) or to any equipment downstream said apparatus (e.g. into the incineration unit 101).

FIG. 2C illustrates the use of the rotary heater apparatuses 100A, optionally 100B with indirect process heating. The rotary apparatus 100 (100A, 100B) can be used for indirect heating of fluids in the process unit 101, wherein heat is transferred between two non-mixing fluids as in heat exchanger-type configurations. Hence, fluids, such as gases or liquids, can be evaporated (vaporized) or superheated in a feasible heat exchanger arrangement 101 against fluid heated in the rotary apparatus 100. The process unit 101 configured to accommodate a process of disposal of essentially gaseous substances can be represented with any (existing) fired heater, incinerator, furnace, reactor, or any conventional heat exchanger device. Type of said “heat exchanger” configuration (101) can be selected as needed for optimal heat transfer. Heating gas (see streams 1-3) can be selected to be most suitable for heating and safety (for example: steam, N₂, air). Gas heated in the rotary apparatus 100A, 100B can be close to atmospheric pressure or pressure can be raised to improve heat transfer. Heat transfer medium 3 heated in the apparatus 100 (rf. stream 3 exiting 100B) is directed to the process unit 101, where its heat is transferred from stream 3 to a “cold” process stream 6 to produce a “hot” process stream 7. Stream 4 designates the heat transfer medium outflow, respectively. Configuration involving indirect heating of process gases 6 is feasible in an event, when the process gas 6 (e.g. waste gas to be disposed) cannot be heated in the apparatus 100 (for example when stream 6 is an oxygen-containing gas, which also contains toxic compounds and/or particles potentially harmful for the inner surfaces of the rotary apparatus 100). In such an event, the heat transfer fluid/gas (streams 1, 2 and 3) is heated in the rotary apparatus 100 and is further supplied into the operational unit 101 to transfer thermal energy to the process gas (oxygen-containing waste gas 6). As a result of heat transfer in the unit 101, the toxic compounds contained in the process gas 6 are combusted. Stream 7 hence represents a hot gas stream void of toxic/harmful substances.

Process streams 6 and 7 of FIG. 2C may be viewed as generally corresponding to the streams 9 and 10 of FIG. 1B, respectively, except that in the layout of FIG. 1B the solid waste 9 can be burned directly in the combustion chamber 101 where the hot effluent of the rotary apparatus (stream 3, FIGS. 1B and 2C) acts as a combustion medium.

FIG. 2D illustrates the rotary heater apparatus 100A with a preheater 102 and with a recycle process fluid (stream 4) recycled from the incineration process 101 (not shown). Preheater can be electric, fired, combustion engine, gas turbine, etc. or it can be a heat exchanger for recovering excess heat from any high temperature flow in the process. Provision of the preheater 102 is optional. The concept can further include an optional booster heater 100B downstream the apparatus 100A. Thermal or chemical booster heating may be utilized. Stream 1′ designates a (feed) fluid sent to the preheater 102. Said fluid is further propagated through the rotary apparatuses 100A, 100B, where the feed is heated and sent to the incineration process at stream 3. Any one of the rotary apparatuses 100A, 100B can be equipped with a fluid recycle arrangement (see stream 4, FIG. 2D). Any combination of the rotary apparatuses the fluid recycle arrangement can be conceived. Recycling is made possible through recirculation of the streams of fluidic medium by the at least one rotary apparatus.

In some configurations, the rotary apparatus 100 can utilize flue gases with low oxygen content exhausted from a conventional fired heater. In such an event, hot flue gases exhausted from the fired heater are mixed with recycle gases (stream 4, FIG. 2D) to be used for heating in the rotary heater 100, 100A. Oxygen content in the flue gases used in described case is preferably below a flammability limit to provide safe heating.

FIG. 3 illustrates, at Example 1, a process of thermal oxidation of waste gas discharged from any industrial plant or factory in a facility layout 1000 comprising the at least one rotary apparatus 100 and at least one thermal oxidizer 101, where the rotary apparatus 100 replaces the fired heaters of the thermal oxidizer 101.

Example 1 aims at destruction of about 99% of hydrocarbons, such as benzene and methyl chloride, in the waste gas. Main oxidation products are CO₂, H₂O and HCl. Waste gas properties are shown in Table 1

TABLE 1
Combustion of waste gas in incineration facility 1000 using
the rotary apparatus to replace the fired heater(s).
	Preheater inlet waste gas flow	50 000	m3/h
	Preheater inlet waste gas temperature	38°	C.
	Composition
	Benzene, ppmv	1000
	Methyl chloride, ppmv	1000
	Air	balanced
	Destruction and removal efficiency (DRE), %	99

Incineration facility 1000 of FIG. 3 utilizes a concept of direct heating of waste gas in the rotary apparatus 100. Facility comprises the rotary apparatus 100, the incineration unit/thermal oxidizer 101, the heat recovery unit 104 also acting as a preheater (102), and a waste gas purification unit 105 for removal of acid gases (e.g. HCl). Purification unit 105 may be configured as a secondary heat exchanger. Waste gas feed stream 1 is directed to the rotary apparatus 100 through the preheater (102, 104). In the preheater 102, 104, the temperature of waste gas stream 2 rises from about 38° C. to about 718° C. Example 1 utilizes fractional heat recovery in the preheater 102, 104 of 82% (11.4 MW). The fractional energy recovery in the preheater 102, 104 in heat exchanger configuration is defined as an amount of energy actually recovered from exhaust gases entering the preheater 102, 104 divided by a maximum amount of energy recoverable if the exhaust gas approaches the lowest temperature available to the heat exchanger.

To achieve destruction efficiency of 99%, the temperature in the combustion chamber must be about 871° C. (1600° F.) and the residence time—about 1 second. In present example, an amount of thermal energy inputted by the rotary apparatus into the incineration process in order to increase the waste gas temperature (stream 3) to about 759° C. is 0.724 MW. To achieve required combustion temperature level (871° C.), the rest of energy is obtained from burning the waste gas (benzene and methyl chloride). Streams 5 and 6 are incineration product gas streams directed to- and from purification unit 105.

In Example 1, the rotary apparatus 100 efficiently replaces a fuel-fired burner by producing about 0.724 MW of thermal energy to be inputted into the incineration process 101. Carbon dioxide emissions are reduced, accordingly. Nitrogen oxide (NOx) emissions are also reduced because in an absence of fuel-powered burners, there is no peak temperature which increase NO_x formation. Use of the rotary apparatus upstream the thermal oxidizer further allows for improving rate and efficiency of the combustion process through attaining optimal turbulence levels.

It is clear to a person skilled in the art that with the advancement of technology the basic ideas of the present invention may be implemented and combined in various ways. The invention and its embodiments are thus not limited to the examples described herein above, instead they may generally vary within the scope of the appended claims.

Claims

1. A method for disposal of substances by incineration, the method comprising generation of a heated fluidic medium by at least one rotary apparatus integrated into an incineration facility, the at least one rotary apparatus comprising:

a casing with at least one inlet and at least one exit,

a rotor comprising at least one row of rotor blades arranged over a circumference of a rotor hub mounted onto a rotor shaft, and

a plurality of stationary vanes arranged into an assembly at least upstream of the at least one row of rotor blades,

wherein an amount of thermal energy is imparted to a stream of fluidic medium directed along a flow path formed inside the casing between the inlet and the exit by virtue of a series of energy transformations occurring when said stream of fluidic medium passes through the stationary vanes and the at least one row of rotor blades, respectively, whereby a stream of heated fluidic medium is generated,

the method further comprising: conducting an amount of input energy into the at least one rotary apparatus integrated into the incineration facility, the input energy comprising electrical energy, supplying the stream of heated fluidic medium generated by the at least one rotary apparatus into the incineration production facility, and operating said at least one rotary apparatus and said incineration facility to carry out incineration process or processes at temperatures essentially equal to or exceeding about 500 degrees Celsius (° C.).

2. The method of claim 1, wherein, in the incineration facility, the at least one rotary apparatus is connected to at least one incineration unit configured to carry out incineration process or processes at temperatures essentially equal to or exceeding about 500 degrees Celsius (° C.).

3. The method of claim 1, comprising supplying the stream of heated fluidic medium generated by at least one rotary apparatus into the at least one incineration unit within the incineration facility.

4. The method of claim 3, wherein the at least one incineration unit comprises or consists of: an incinerator, a furnace, an oven, a kiln, a burner, a heater, a dryer, a conveyor device, a reactor, or a combination thereof.

5. The method of claim 1, comprising generation, by at least one rotary apparatus, of the fluidic medium heated to the temperature essentially equal to or exceeding about 500 degrees Celsius (° C.), preferably, to the temperature essentially equal to or exceeding about 1200° C., still preferably, to the temperature essentially equal to or exceeding about 1500° C.

6. The method of claim 1, comprising adjusting velocity and/or pressure of the stream of fluidic medium propagating through the rotary apparatus, to produce conditions at which the stream of the heated fluidic medium is generated.

7. The method of claim 1, in which the heated fluidic medium is generated by at least one rotary apparatus comprising two or more rows of rotor blades sequentially arranged along the rotor shaft.

8. The method of claim 1, in which the heated fluidic medium is generated by at least one rotary apparatus further comprising a diffuser area arranged downstream of the at least one row of rotor blades, the method comprises operating the at least one rotary apparatus integrated into the incineration facility such, that an amount of thermal energy is imparted to a stream of fluidic medium directed along a flow path formed inside the casing between the inlet and the exit by virtue of a series of energy transformations occurring when said stream of fluidic medium successively passes through the stationary vanes, the rotor blades and the diffuser area, respectively, whereby a stream of heated fluidic medium is generated.

9. The method of claim 8, wherein, in said rotary apparatus, the diffuser area is configured with or without stationary diffuser vanes.

10. The method of claim 1, in which the amount of thermal energy added to the stream of fluidic medium propagating through the rotary apparatus is controlled by adjusting the amount of input energy conducted into the at least one rotary apparatus integrated into the incineration facility.

11. The method of claim 1, further comprising arranging an additional heating apparatus downstream of the at least one rotary apparatus and introducing a reactive compound or a mixture of reactive compounds to the stream of fluidic medium propagating through said additional heating apparatus, whereupon the amount of thermal energy is added to said stream of fluidic medium through exothermic reaction(s).

12. The method of claim 11, wherein the reactive compound or a mixture of reactive compounds is introduced to the stream of fluidic medium preheated to a predetermined temperature.

13. The method of claim 12, wherein the reactive compound or a mixture of reactive compounds is introduced to the stream of fluidic medium preheated to a temperature essentially equal to or exceeding about 1500° C.

14. The method of claim 12, wherein preheating of the stream of fluidic medium to the predetermined temperature is implemented in the rotary apparatus.

15. The method of claim 1, comprising generation of the heated fluidic medium by at least two rotary apparatuses integrated into the incineration facility, wherein the at least two rotary apparatuses are connected in parallel or in series.

16. The method of claim 15, comprising generation of the heated fluidic medium by at least two sequentially connected rotary apparatuses, wherein the stream of fluidic medium is preheated to a predetermined temperature in at least a first rotary apparatus in a sequence, and wherein said stream of fluidic medium is further heated in at least a second rotary apparatus in the sequence by inputting an additional amount of thermal energy into the stream of preheated fluidic medium propagating through said second rotary apparatus.

17. The method of claim 16, wherein, in at least the first rotary apparatus in the sequence, the stream of fluidic medium is preheated to a temperature essentially equal to or exceeding about 1500° C.

18. The method of claim 16, wherein the additional amount of thermal energy is added to the stream of fluidic medium propagating through said at least second rotary apparatus in the sequence by virtue of introducing the reactive compound or a mixture of reactive compounds into said stream.

19. The method of claim 1, comprising introducing the reactive compound or a mixture of reactive compounds into the incineration process.

20. The method of claim 1, wherein the fluidic medium that enters the rotary apparatus is an essentially gaseous medium.

21. The method of claim 1, comprising generation of the heated fluidic medium in the rotary apparatus.

22. The method of claim 21, wherein the heated fluidic medium generated in the rotary apparatus is a harmful and/or toxic gas.

23. The method of claim 21, wherein the heated fluidic medium generated in the rotary apparatus is a gas containing any one of: Volatile Organic Compounds (VOCs), hazardous air pollutants (HAPs), odorous gases, or any combination thereof.

24. The method of claim 21, wherein the heated fluidic medium generated in the rotary apparatus comprises any one of: air, steam (H2O), nitrogen (N2), hydrogen (H2), carbon dioxide (CO2), carbon monoxide (CO), methane (CH4), or any combination thereof.

25. The method of claim 21, wherein the heated fluidic medium generated in the rotary apparatus is a recycle gas recycled from exhaust gases generated during incineration process(es) in the incineration facility.

26. The method of claim 1, further comprising generation of a heated fluidic medium, such as gas, vapor, liquid, and mixtures thereof, and/or heated solid materials outside the rotary apparatus through a process of heat transfer between the heated fluidic medium generated in the rotary apparatus and any one of the above-mentioned substances bypassing the rotary apparatus.

27. The method of claim 1, further comprising increasing pressure in the stream of fluidic medium propagating through the rotary apparatus.

28. The method of claim 1, in which the amount of electrical energy conducted as the input energy into the at least one rotary apparatus integrated in the incineration facility is within a range of about 5 percent to 100 percent.

29. The method of claim 1, wherein the amount of electrical energy conducted as the input energy into the at least one rotary apparatus integrated in the incineration facility is obtainable from a source of renewable energy or a combination of different sources of energy, optionally, renewable energy.

30. The method of claim 1, wherein the at least one rotary apparatus is utilized to balance variations, such as oversupply and shortage, in the amount of electrical energy, optionally renewable electrical energy, by virtue of being integrated, into the incineration facility, together with an at least one non-electrical energy operable heater device.

31. The method of claim 1, wherein energy efficiency of the incineration facility is improved and/or wherein greenhouse gas and particle emissions in the incineration facility are reduced.

32. An incineration facility comprising at least one rotary apparatus configured to generate a heated fluidic medium, and at least one incineration unit configured to carry out a process or processes related to incineration, the at least one rotary apparatus comprising:

a casing with at least one inlet and at least one exit,

a rotor comprising at least one row of rotor blades arranged over a circumference of a rotor hub mounted onto a rotor shaft, and

a plurality of stationary vanes arranged into an assembly at least upstream of the at least one row of rotor blades,

wherein the at least one rotary apparatus is configured to operate such that an amount of thermal energy is imparted to a stream of fluidic medium directed along a flow path formed inside the casing between the inlet and the exit by virtue of a series of energy transformations occurring when said stream of fluidic medium passes through the stationary vanes and the at least one row of rotor blades, respectively, whereby a stream of heated fluidic medium is generated, and

wherein said at least one rotary apparatus is configured to receive an amount of input energy, the input energy comprising electrical energy, and to generate a heated fluidic medium for inputting thermal energy into at least one incineration unit configured to carry out incineration process(es) at temperatures essentially equal to or exceeding about 500 degrees Celsius (° C.).

33. The incineration facility of claim 32, wherein the at least one incineration unit comprises or consists of: an incinerator, a furnace, an oven, a kiln, a burner, a heater, a dryer, a conveyor device, a reactor, or a combination thereof.

34. The incineration facility of claim 32, wherein the at least one rotary apparatus comprises two or more rows of rotor blades sequentially arranged along the rotor shaft.

35. The incineration facility of claim 32, wherein the at least one rotary apparatus further comprises a diffuser area arranged downstream of the at least one row of rotor blades.

36. The incineration facility of claim 32, wherein the rotary apparatus comprises the diffuser area configured with or without stationary diffuser vanes.

37. The incineration facility of claim 32, wherein the at least one rotary apparatus is further configured to increase pressure in the fluidic stream propagating therethrough.

38. The incineration facility of claim 32, wherein at least two rotary apparatuses are arranged into an assembly and connected in parallel or in series.

39. The incineration facility of claim 32, configured to implement incineration of waste gas via a process of thermal oxidation.

40. An incineration facility, configured to implement a process or processes for disposal of harmful and/or toxic substances by incineration through a method as defined in claim 1.

41. Use of the method as defined in claim 1 for disposal of harmful and/or toxic substances by incineration.

42. Use of the facility as defined in claim 32 for disposal of harmful and/or toxic substances by incineration.