A sludge carbonization system and method of use thereof

Abstract

The present application relates to a kind of sludge carbonization system and its using method, including kiln body and kiln car installed in kiln body, the green brick is placed on the kiln car, sludge tank for containing sludge is installed on the kiln car, the height of the sludge tank is proportional to green brick firing time, the sludge tank extends along up and down direction, the upper end of sludge tank is open, the sludge tank extends along up and down direction, the upper end of sludge tank is open, the sludge tank includes tank body and several heat-conducting plates installed on the inner wall of tank body, support frame is installed on the kiln car, the sludge tank is installed on support frame, the diameter of the sludge tank is 40-80 centimeters, the sludge tank is cylindrical, the sludge tank uses high-temperature-resistant material, the green body can be carbonized while being fired in the present application, carbonization can completely convert organic matter in sludge into inorganic matter, so that any amount of sludge after carbonization can be added during the process of making green body.

Description

Technical Field

[0001] This invention relates to the field of brick-making technology, and more particularly to the field of sludge carbonization, specifically to a sludge carbonization system and its application method. Background Technology

[0002] Currently, the main methods for treating and disposing of sludge in my country are landfill, composting, and incineration. Landfilling requires a large area, has high costs for sludge dewatering, and easily pollutes groundwater. Composting for agricultural use produces foul odors that disturb residents, and the heavy metals and persistent organic pollutants in the sludge can seriously pollute arable land and crops. Sludge incineration requires too much energy and produces a large amount of gaseous pollutants during the combustion process, causing secondary pollution. Dewatering the sludge, turning it into powder, and then adding it to building materials to make building bricks is one of the environmentally friendly solutions for treating sludge.

[0003] In the process of converting sludge into valuable resources, the sludge needs to be dried. Sludge drying can evaporate the water in sludge with high water content through heating, convection drying and other methods, so as to reduce the water content and facilitate transportation and disposal. After drying, the sludge undergoes some fine grinding, is then mixed with other raw materials, pressed into shape, and then fired to make sludge bricks.

[0004] In existing technologies, carbonization treatment of sludge generally involves drying, which requires specialized drying equipment. While the standalone drying equipment provided by Xutai can remove most of the external water from the sludge, it cannot remove the internal water, meaning that a large amount of inorganic matter remains. In this case, the sludge content in the brick-making process is about 10%-20%. When the sludge content exceeds 30%, the organic matter in the sludge will greatly reduce the mechanical properties of the brick, and the compressive strength of such sludge bricks will not meet the performance standards of bricks. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a sludge carbonization system and its usage method. The system can carbonize sludge while firing green bodies, and the carbonization process can completely convert the organic matter in the sludge into inorganic matter, thereby allowing any amount of carbonized sludge to be added during the body-making process.

[0006] This invention is achieved through the following technical solution: providing a sludge carbonization system and its usage method, including a kiln body and a kiln car installed inside the kiln body, on which brick blanks are placed, and on which a sludge tank for holding sludge is installed; the usage method of the sludge carbonization system is as follows: a) pouring sludge into the sludge tank until the sludge is level with the upper surface of the sludge tank, and placing the sludge tank and brick blanks on the kiln car; b) pushing the kiln car into the kiln body, starting to add fuel and gradually increasing the temperature inside the kiln body until the temperature is maintained within the firing temperature range required for the brick blanks. c: The flame bakes the brick blanks and sludge tanks. The sludge in the sludge tanks pyrolyzes, producing carbon monoxide and further raising the temperature of the sludge. d: The water vapor in the sludge in the sludge tanks evaporates and rises, keeping the sludge at the top of the sludge tank moist and preventing it from burning. The water vapor cancels out the flame at the opening of the sludge tank, and the sludge at the top of the sludge tank prevents gas from entering the sludge tank. The carbon monoxide and other gases inside the sludge tank create an anaerobic environment. The sludge in the sludge tank reaches a high temperature for ignition but cannot burn. The sludge completes the pyrolysis process inside the sludge tank until the brick blanks are fired. e: The kiln body is cooled, and the fired brick blanks and sludge are removed. The sludge is crushed into carbonized sludge powder. At this point, the organic matter in the sludge is completely converted into inorganic matter. Any amount of carbonized sludge powder can be added when making the brick blanks.

[0007] This invention fires brick blanks in a kiln and places them on kiln cars, which also hold sludge tanks. During the brick firing process, the sludge is carbonized, eliminating the need for an additional sludge drying box and saving energy. Simultaneously, the sludge in the tank is baked together with the brick blanks inside the kiln. The baking process generates carbon monoxide, creating an anaerobic environment within the tank. This allows the sludge to reach high ignition temperatures without burning, completely converting the organic matter in the sludge into inorganic matter. This allows any amount of carbonized sludge to be added during brick production.

[0008] As an optimization, the height of the sludge tank is linearly related to the brick firing time, and the diameter of the sludge tank is 40-80 cm. This optimized design ensures that the sludge is completely decomposed after baking in the kiln without burning during the baking process. By selecting sludge tanks of different heights according to the different brick firing times, the carbonization of the sludge in the sludge tank can achieve the best effect.

[0009] As an optimization, the sludge tank is cylindrical, extending vertically, with an open upper end. This optimized design allows for more uniform heating, prevents deformation of the sludge tank, and allows water vapor to rise and be discharged from the tank opening.

[0010] As an optimization, the sludge tank extends vertically, with its upper end open. This optimization allows the sludge moisture inside the tank to rise and counteract the heat, preventing the sludge on the upper surface of the tank from igniting.

[0011] As an optimization, the sludge tank includes a tank body and several heat-conducting plates installed on the inner wall of the tank body. The heat-conducting plates are fixed to the inner wall of the tank body circumferentially and extend radially along the tank body. This optimized design can conduct heat to the interior of the sludge tank, enhancing heat conduction.

[0012] As an optimization, a support frame is installed on the kiln car, and the sludge tank is mounted on the support frame. A baking gap is provided between the support frame and the brick blank to allow the hot air from the flame to pass through. This optimized design facilitates the installation of the sludge tank, ensuring that the sludge tank does not interfere with the loading of the brick blank, while the hot air from the flame passing through the baking gap does not affect the baking of the brick blank.

[0013] As an optimization, a tunnel kiln is adopted, employing continuous drying, and the temperature inside the kiln is maintained between 900 and 1050 degrees Celsius during firing. This optimized scheme ensures successful firing of the brick blanks, and this temperature range represents the optimal firing temperature for the brick blanks.

[0014] As an optimization, the sludge tank is made of high-temperature resistant and corrosion-resistant material. This optimization design can enhance the service life of the sludge tank and prevent it from burning out in high-temperature environments.

[0015] As an optimization, a moving rail is provided inside the kiln body, and the kiln car slides on the moving rail, which extends from the left end face of the kiln body to the right end face. This optimized design facilitates the transportation of sludge tanks and brick blanks using kiln cars.

[0016] The beneficial effects of this invention are as follows: This invention can complete the carbonization of sludge while firing the brick blanks. The water content in the carbonized sludge tends to be zero. During the sludge baking process, the sludge tank forms an anaerobic environment. The sludge reaches the ignition temperature but cannot burn, so that the organic matter in the sludge is completely converted into inorganic matter. Therefore, any amount of carbonized sludge can be added when making sludge brick blanks without causing the brick to deform or break. This invention saves a lot of energy, improves the sludge treatment efficiency, protects the environment, and makes the proportion of sludge added to the brick blanks unlimited, instead of 30%. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of the present invention;

[0018] Figure 2 This is a side view of the present invention;

[0019] Figure 3 Top view of the sludge tank;

[0020] Figure 4 This is a diagram of the sludge tank heating process.

[0021] As shown in the figure:

[0022] 1. Kiln body, 2. Moving rail, 3. Kiln car, 4. Support frame, 5. Brick blank, 6. Sludge tank, 61. Tank body, 62. Heat conduction plate. Detailed Implementation

[0023] To clearly illustrate the technical features of this solution, the following detailed implementation method will be used to explain the solution.

[0024] like Figures 1-4 The present invention discloses a sludge carbonization system and its usage method, comprising a kiln body 1 and a kiln car 3 installed inside the kiln body 1. The kiln body extends in the left-right direction and is a tunnel kiln. The kiln body is a prior art technology. The kiln body includes a kiln cavity, a flue, and a combustion system. The kiln cavity extends in the left-right direction and is constructed of refractory material (such as refractory bricks), which has good high-temperature resistance. The flue is located on the upper side of the kiln cavity and is used to discharge the flue gas and exhaust gas generated by combustion. The combustion system includes combustion equipment for supplying fuel and air. The fuel can be wood, coal, or natural gas, etc., which is supplied to the kiln cavity through the combustion system. At the same time, fresh air also enters the kiln cavity through the combustion system and burns with the fuel to generate high-temperature gas.

[0025] The kiln car 3 extends in the front-to-back direction. A moving rail 2 is provided inside the kiln body 1. The moving rail 2 is located on the lower end face of the kiln body 1 and extends in the left-to-right direction. The moving rail 2 extends from the left end face of the kiln body to the right end face of the kiln body. The kiln car 3 slides on the moving rail 2 and slides in the left-to-right direction. A support frame 4 is installed on the kiln car. The support frame 4 is installed on the upper end face of the kiln car 3. The support frame 4 includes four vertical beams fixed to the four corners of the kiln car and a mounting plate installed on the top of the vertical beams. The vertical beams extend in the up-down direction, and the mounting plate is fixed to the vertical beams.

[0026] A brick blank 5 is placed on the kiln car 3. The brick blank 5 is supported on the upper surface of the kiln car 3. The brick blank 5 is located below the mounting plate of the support frame. There is a baking gap between the mounting plate of the support frame and the brick blank 5, which ensures that the hot air of the flame can pass through the baking gap to bake the brick blank.

[0027] A sludge tank 6 for holding sludge is installed on the kiln car 3. The sludge tank is mounted on the support frame 4 and extends vertically. The upper end of the sludge tank 6 is open, and the sludge inside is filled to be flush with the upper surface of the sludge tank 6. The sludge tank is cylindrical and made of high-temperature resistant and corrosion-resistant material. The diameter of the sludge tank is 40-80 cm. The height of the sludge tank is directly proportional to the brick firing time. The longer the brick firing time, the higher the sludge tank. In this embodiment, the ambient temperature for firing bricks in the kiln is 900-1050 degrees Celsius, the bricks are fired for 40 hours, and the height of the sludge tank is 50 cm.

[0028] The sludge tank 6 includes a tank body 61 and several heat-conducting plates 62 installed on the inner wall of the tank body 61. The tank body 61 extends in the vertical direction, and the upper end of the tank body 61 is open. The heat-conducting plates 62 are distributed around the tank body 61 and extend radially along the tank body 61. The outer end face of the heat-conducting plate 62 is fixed to the inner wall of the tank body 61. The heat-conducting plate 62 extends from the lower end face of the tank body 61 to the middle section of the tank body 61.

[0029] In this embodiment, during use, sludge is poured into sludge tank 6 until the sludge is level with the upper surface of sludge tank 6. Sludge tank 6 and brick blanks are placed on kiln car 3, with brick blanks stacked, leaving a gap between the brick blanks and the lower surface of the mounting plate of support frame 4. Kiln car 3 is pushed into kiln body 1, kiln body 1 is sealed, fuel is started and the temperature inside kiln body 1 is gradually increased. After preheating, fuel is added more to raise the temperature to between 900 and 1050 degrees Celsius, ultimately maintaining the ambient temperature inside kiln body 1 within the required firing temperature range for the brick blanks. The flame bakes the brick blanks 5 and sludge tank 6, and the sludge in sludge tank 6 pyrolyzes to produce carbon monoxide and... As the sludge temperature rises further, the sludge moisture in sludge tank 6 continuously evaporates and rises, keeping the sludge at the top of the tank moist and preventing it from burning. The moisture at the opening of the sludge tank cancels out the flame. Gases such as methane produced by carbonization in the sludge overflow with the water vapor. The gases overflowing from sludge tank 6 ignite, playing a role in combustion and increasing the ambient temperature inside the kiln. The sludge at the top of sludge tank 6 prevents oxygen from entering the sludge tank. Gases such as carbon monoxide inside the sludge tank create an anaerobic environment. The sludge in sludge tank 6 reaches a high temperature for ignition but cannot burn. The sludge completes the pyrolysis process inside the sludge tank until the brick blank 5 is fired.

[0030] Cool the kiln body 1, remove the fired brick blanks and sludge, and crush the sludge into carbonized sludge powder. At this time, the organic matter in the sludge is completely converted into inorganic matter, the water content in the sludge is reduced from 65% to close to zero, there is no longer any organic matter in the sludge, and the treated sludge will no longer cause the brick to deform or crack. Any amount of carbonized sludge powder can be added when making the brick blanks.

[0031] Of course, the above description is not limited to the examples above. Technical features not described in this invention can be implemented by or using existing technology, and will not be repeated here. The above embodiments and drawings are only used to illustrate the technical solutions of this invention and are not intended to limit this invention. This invention has been described in detail with reference to preferred embodiments. Those skilled in the art should understand that any changes, modifications, additions or substitutions made by those skilled in the art within the scope of this invention do not depart from the spirit of this invention and should also fall within the scope of protection of the claims of this invention.

Claims

1. A method of using a sludge carbonization system, characterized by: The sludge carbonization system comprises a kiln body (1) and a kiln car (3) installed in the kiln body (1), and the kiln car is provided with a sludge tank (6) for containing sludge and a brick billet (5) placed on the kiln car. The use method comprises the following steps: a: pouring sludge into the sludge tank (6) until the sludge is flush with the upper end face of the sludge tank (6), and placing the sludge tank (6) and the brick billet on the kiln car (3); b: pushing the kiln car (3) into the kiln body (1), starting to add fuel and gradually increasing the temperature in the kiln body (1), and finally maintaining the temperature in the required firing temperature range of the brick billet; c: flame baking the brick billet (5) and the sludge tank (6), and pyrolysis of the sludge in the sludge tank (6) generates carbon monoxide and further increases the temperature of the sludge; d: the water vapor in the sludge tank (6) evaporates and rises, the sludge at the upper end of the sludge tank remains moist and is not burned, the water vapor counteracts the flame at the opening of the sludge tank, the sludge at the upper end of the sludge tank prevents gas from entering the inside of the sludge tank, the carbon monoxide in the inside of the sludge tank forms an anaerobic environment, the sludge in the sludge tank (6) reaches the ignition temperature but cannot burn, and the sludge completes the pyrolysis process in the sludge tank until the brick billet (5) is fired; e: cooling the kiln body (1), taking out the fired brick billet and sludge, crushing the sludge into carbonized sludge powder, at this time, the organic matter in the sludge is completely converted into inorganic matter, and the carbonized sludge powder is added to the brick billet in any amount.

2. A method of using a sludge carbonization system according to claim 1, characterized in that: The height of the sludge tank is in a linear relationship with the firing time of the brick billet, and the diameter of the sludge tank is 40-80 cm.

3. A method of using a sludge carbonization system according to claim 1, characterized in that: The sludge tank is in a cylindrical shape and extends in the upward and downward directions, and the upper end of the sludge tank is open.

4. A method of using a sludge carbonization system according to claim 1, characterized in that: The sludge tank comprises a tank body (61) and a plurality of heat-conducting plates (62) installed on the inner wall of the tank body (61), the heat-conducting plates are fixedly connected to the inner wall of the tank body (61) in the circumferential direction, and the heat-conducting plates extend in the radial direction of the tank body (61).

5. A method of using a sludge carbonization system according to claim 1, characterized in that: The kiln car is provided with a support frame (4), the sludge tank is installed on the support frame (4), and the support frame is provided with a baking gap for the flame hot gas to pass through between the support frame and the brick billet.

6. A method of using a sludge carbonization system according to claim 1, characterized in that: The kiln body adopts a tunnel kiln, and continuous drying is adopted, and the temperature in the kiln body is maintained at 900-1050 degrees during firing.

7. A method of using a sludge carbonization system according to claim 1, characterized in that: The sludge tank is made of high-temperature-resistant and corrosion-resistant materials.

8. A method of using a sludge carbonization system according to claim 1, characterized in that: The kiln body is provided with a moving rail (2), the kiln car is slidably connected to the moving rail (2), and the moving rail extends from the left end face of the kiln body to the right end face of the kiln body.

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