System for steam / hot water generation using thermal energy of FLUE gas from waste incineration

Abstract

The present invention relates to a system (100) and a process for steam / hot water generation by utilizing thermal energy from flue gases generated by waste incineration. The system (100) includes a muffle furnace (105), a waste heat recovery unit (WHRU) (110), a wet scrubber (115 a), an absorber system (115 b), a chimney (120), a venturi (125) and an ash chamber (130). The muffle furnace (105) includes an incinerator chamber for pharmaceutical waste combustion (105 a), biomass briquette combustion chamber (105 b) and a four-pass holding chamber (105 c) having four passes (105 cl), (105 c2), (105 c3) and (105 c4). The system enables saving fuel and utilizes high calorific pharmaceutical waste.

Description

[0001] SYSTEM FOR STEAM / HOT WATER GENERATION USING THERMAL ENERGY OF FLUE GAS FROM WASTE INCINERATION

[0002] FIELD OF THE INVENTION:

[0003] The present invention relates to a system for steam / hot water generation, and more particularly to a system that utilizes the thermal energy generated from flue gases by waste incineration for the purpose of steam / hot water generation.

[0004] BACKGROUND OF THE INVENTION:

[0005] A large amount of waste is generated in the industries at various stages of production and processing. The waste generated is categorized as hazardous or non- hazardous waste. The hazardous waste includes liquids, solids, gases, or sludges. The hazardous waste is classified into two categories: (1) listed waste, including pharmaceutical waste resulting from commercial chemical products, and (2) characteristic waste, that is regulated based on the characteristics including toxicity, reactivity, flammability, and ignitability. The waste that is not specified or exhibit these characteristics is classified as solid trash and must be disposed of in accordance with state or local regulations, including those governing regulated medical waste.

[0006] As per regulations, the hazardous waste needs to be incinerated inhouse or send to pollution control board authorized agency for further disposals. The cost of agency disposal exceeds that of in-house incineration, despite additional expenses for utilities, manpower, and fuel. This incurs both CAPEX and OPEX. The management of various product wastes pose a significant concern, particularly in regulated sectors like pharmaceuticals.

[0007] Various methods are known in the art for safe disposal of pharmaceutical waste that involve minimal risks to public health and the environment. Pharmaceutical companies follow the guidelines from health and environmental ministries for waste treatment and disposal. The methods include waste immobilization-encapsulation where solid and semisolid waste is filled in clean drums to their 75% capacity, then sealed with lime, cement, etc., before being landfilled.

[0008] Another method is waste immobilization-inertization, where paper or cardboard materials are removed, and the remaining solid or semi-solid waste is ground, mixed with cement or lime to form a homogeneous paste, and safely landfilled. Further, chemical disinfection methods are also used for biological or chemical materials that need inactivation before disposal.

[0009] Another method includes autoclaving and microwaving the material, then burying it at least two meters deep in the ground. However, these practices, such as burying or landfilling the garbage, may cause it to leach into the earth, polluting the ecosystem and endangering living things. Furthermore, landfills need gas extraction systems since anaerobic waste decomposition produces gases like CO2 and methane. An alternative method includes purpose-built high-temperature incineration of the waste. This waste generates adequate flue gases. However, the heat energy produced by the frequent on-site or off-site incineration of pharmaceutical waste is not used. FIG. 1 describes a typical traditional setup of pharmaceutical waste incineration used in the state of art.

[0010] The Chinese Patent Application No. CN106989404A to Chen Xia teaches an incineration method for saline organic mixed waste liquid. The waste liquid is atomized and introduced into a waste liquid combustor followed by waste heat recovery and tail gas purification. However, this approach involves higher temperatures and longer combustion periods.

[0011] The United States Patent Application No. US2006144305 Al to Vera Rodrigo B. teaches a method and apparatus for plasma gasification of waste materials having a refractory-lined reactor vessel with a processing chamber that continuously receives waste materials via a feeder mechanism at a controlled rate. A DC electrode device heats the chamber to convert organic waste into synthetic gas (hydrogen and carbon monoxide) and carbon particulates, and inorganic waste into a molten material with a metallic layer and slag layer. However, this method releases toxic gases into the atmosphere.

[0012] The article "Pharmaceutical waste: overview, management, and impact of improper disposal" to Milcah Njoki Nyaga and others addresses the sources of pharmaceutical waste, disposal costs, secure disposal methods, the consequences of improper disposal, and the role of pharmacists in waste disposal. The article discusses that incinerating pharmaceutical waste requires a significant amount of money and the energy produced remains unutilized. Therefore, there is a need to devise a practical and environmentally sustainable approach to waste management; and a means to utilize the heat generated from the incineration of waste to save costs and reduce the emission of greenhouse gases.

[0013] SUMMARY OF THE INVENTION:

[0014] The present invention relates to a system (100) that utilizes the thermal energy from flue gases generated by waste incineration for steam / hot water generation. The system (100) includes a muffle furnace (105), a waste heat recovery unit (WHRU) (110) and an air pollution control system (115).

[0015] The muffle furnace (105) includes an incinerator chamber (105 a) for combustion of pharmaceutical waste, a biomass briquette combustion chamber (105 b) for combustion of biomass briquettes, and a four-pass holding chamber (105 c) for thermal treatment of flue gases. The waste heat recovery unit (WHRU) (110) includes a waste heat recovery condenser (110 a) and a boiler (110 b). The air pollution control system (115) includes a wet scrubber (115 a), and an absorber system (115 b).

[0016] The pharmaceutical waste and biomass briquettes undergo combustion together, producing hot flue gases such that the hot flue gases pass through the holding chamber (105 c) to neutralize dioxins and furans. The thermal energy is recovered from the flue gases in the waste heat recovery condenser (110 a) and is transferred to the boiler (110 b). In the system (100), the flue gases are treated in the holding chamber (105 c) through a four-pass process including a first pass (105 cl), a second pass (105 c2), a third pass (105 c3), and a fourth pass (105 c4). The flue gases are maintained at a temperature range of 900-1100°C with a residence time of 3.1 to 3.8 seconds to facilitate inactivation of pollutants.

[0017] The gas volumes and flow rates in the holding chamber (105 c) is maintained at a predefined volumes in respective passes such that the first pass (105 cl) has a volume of 0.85 m3(3.4 x 0.6 x 0.42), the second pass (105 c2) has a volume of 0.35 m3(1.3 x 0.46 x 0.6), the third pass (105 c3) has a volume of 1.56 m3(2.9 x 0.6 x 0.9) and the fourth pass (105 c4) has a volume of 1.82 m3(2.9 x 0.35 x 0.9 x 2); and the gas flow rate is maintained at 1.29 m3 / s.

[0018] The waste heat recovery unit (110) is installed downstream of the muffle furnace (105) and the thermal energy from combustion is transferred to the waste heat recovery unit (110) to generate steam or hot water. The thermal energy captured by the waste heat recovery condenser (110 a) is further transferred to the boiler (110 b) for boiling water or converting it into steam.

[0019] The air pollution control system (115) includes the wet scrubber (115 a) and absorber system (115 b). The wet scrubber (115 a) removes particulate matter, acidic gases, and trace pollutants from the exhaust stream. The absorber system (115 b) reduces the temperature of the exhaust stream to a level suitable for release into the atmosphere. The pharmaceutical waste is selected from chemical ingredients, oils, gelatine, active pharmaceutical ingredients, excipients, and similar materials. The boiler (110 b) is selected from a fire-tube type boiler, a water tube type boiler, a hot water generator and the like.

[0020] The system (100) reduces carbon emissions by avoiding the use of fossil fuels in waste incinerators and boilers. The system (100) is highly efficient, economical, eco-friendly and utilizes heat energy for steam / hot water generation than the existing technologies.

[0021] BRIEF DESCRIPTION OF DRAWINGS:

[0022] The objectives and advantages of the present invention will become apparent from the following description read in accordance with the accompanying drawings wherein,

[0023] FIG. 1 shows a typical traditional incinerator setup in accordance with the state of the art;

[0024] FIG. 2 shows a system (100) for steam / hot water generation by utilizing thermal energy from flue gases by waste incineration in accordance with the present invention;

[0025] FIG. 3 a shows a three-dimensional top sectional view of the muffle furnace 105 in accordance with the present invention;

[0026] FIG. 3b shows a sectional view of the muffle furnace 105 along the horizonal plane in accordance with the preferred embodiment of the present invention; and FIG. 3c shows a sectional view of the muffle furnace 105 along the vertical plane in accordance with the preferred embodiment of the present invention.

[0027] DESCRIPTION OF THE INVENTION:

[0028] The present invention relates to a system for utilizing the thermal energy from flue gases generated by waste incineration for the purpose of steam or hot water generation.

[0029] References in the specification to "one embodiment" or "an embodiment" means that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

[0030] References in the specification to “preferred embodiment” means that a particular feature, structure, characteristic, or function described in detail thereby omitting known constructions and functions for clear description of the present invention.

[0031] The foregoing description of specific embodiments of the present invention has been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed and obviously many modifications and variations are possible in light of the above teaching. The pharmaceutical waste contains a significant number of hydrocarbons that exhibit good combustion properties, leading to unutilized energy when burned in an incinerator. The present invention aims at harvesting this heat energy derived from such combustion. The system of the present invention is a waste-to-energy setup that incorporates a dual combustion chamber design, referred to as a muffle furnace, to optimize energy recovery from the combustion of biomass fuel and pharmaceutical waste.

[0032] Further, the muffle furnace is characterized by a unique four-pass system that operates to neutralize the dioxins and furans from the flue gases. The hot flue gases are then passed through a waste heat recovery unit and treated via air pollution control systems before releasing them into the environment. Overall, the setup offers a comprehensive and environmentally conscious solution for converting hazardous waste into both energy and clean exhaust, minimizing environmental impact.

[0033] Accordingly, the present invention discloses a system for utilizing the thermal energy from flue gases generated by waste incineration for the purpose of steam / hot water generation.

[0034] Referring to FIG. 2, a system (100) for steam or hot water generation by utilizing thermal energy from flue gases generated by waste incineration (herein after referred to as “system 100”) is described. The system (100) includes a muffle furnace (105), a waste heat recovery unit (WHRU) (110), a wet scrubber (115 a), an absorber system (115 b), a chimney (120), a venturi (125) and an ash chamber (130). The muffle furnace (105) further includes an incinerator chamber for pharmaceutical waste combustion (105 a), a biomass briquette combustion chamber (105 b), and a four-pass holding chamber (105 c).

[0035] The pharmaceutical waste is fed to the incinerator (105 a), and the biomass briquettes are fed to the combustion chamber (105 b) of muffle furnace (105), where the pharmaceutical waste and biomass briquette undergo separate combustion to generate hot flue gases.

[0036] The hot flue gases generated from the incinerator (105 a) and the combustion chamber (105 b) mix at the venturi (125) and are then passed to the holding chamber (105 c) of the muffle furnace (105). The flue gases are inactivated in the holding chamber (105 c) by subjecting the flue gases to a four-pass procedure at a predefined temperature for a predefined residence time. The combustion of the biomass briquettes generates ash that is collected in the ash chamber (130) below the combustion chamber (105 b).

[0037] The waste heat recovery unit (WHRU) (110) in accordance with the present invention is installed after the muffle furnace (105) to recover the heat energy generated after combustion. The thermal heat energy generated through combustion is passed to the waste heat recovery unit (110) for generating steam / hot water. The waste heat recovery unit (110) includes a waste heat recovery condenser (110 a) and a boiler (110 b). The waste heat recovery condenser (110 a) receives the thermal heat energy, which is further passed to the boiler (110 b). The flue gases further undergo additional treatments through air pollution control system (115). Accordingly, the flue gases are passed through the wet scrubber (115 a) and absorber system (115 b) that remove particulate matter, acidic gases, and trace pollutants from the exhaust stream and reduces their temperature to a level suitable for release into the atmosphere. The flue gases are further released via the chimney (120).

[0038] In accordance with the present invention, the boiler (110 b) is selected from a fire tube type boiler, a water tube type boiler, a hot water generator and the like.

[0039] Now, referring to FIG. 3a, 3b and 3c, the four passes of the four-pass holding chamber (105 c) in accordance with the preferred embodiment of the present invention are described. The holding chamber (105 c) is divided into four passes wherein the flue gases are held for a predefined residence time. The four-pass holding chamber (105 c) is characterized by a first pass (105 cl) located in the horizontal plane above the incinerator (105 a).

[0040] The first pass (105 cl) merges with the second pass (105 c2) vertically located in the plane adjacent to the incinerator (105 a). The second pass (105 c2) further merges with the third pass (105 c3) that is located centrally in the horizontal plane below the incinerator (105 a). The third pass (105 c3) further splits into two channels forming the fourth pass (105 c4) that is located in the same horizontal plane below the incinerator (105 a) on either side of the third pass (105 c3).

[0041] In accordance with a preferred embodiment of the present invention, the pharmaceutical waste is selected from chemical ingredients, oil, gelatine, active pharmaceutical ingredients and excipients and the like. The flue gases are inactivated in the holding chamber (105 c) by subjecting the flue gases to a four-pass procedure at a predefined temperature of 900 - 1100°C for a predefined residence time of 3.1 seconds to 3.8 seconds.

[0042] The volume of gas that flows through the first pass includes 0.85 m3(3.4 x 0.6 x 0.42). The volume of the gas flowing through the second pass includes 0.35 m3(1.3 x 0.46 x 0.6). In the third pass, the volume of the gas is 1.56 m3(2.9 x 0.6 x 0.9). In the fourth pass, the volume of the gas is 1.82 m3(2.9 x 0.35 x 0.9 x 2). The flow rate of gas is maintained at 1.29 m3 / s.

[0043] A residence time greater than 2 seconds at a temperature of 900 - 1100°C in the holding chamber (105 c) is maintained as per the norms of the Central Pollution Control Board (CPCB) to achieve proper neutralization of Dioxins and Furans present in the flue gas generated from waste incineration.

[0044] In accordance with the preferred embodiment, the boiler (110 b) is a Fire tube type boiler. The specification of the fire tube type boiler is around 30 m2, HSA in Semi IBR boiler generating around 500 kg / hr at 7 kg / m2.

[0045] In another embodiment, any alternative waste with good combustion properties in liquid, solid, molten form and having high calorific value after combustion is utilized as fuel for steam / hot water generation.

[0046] Now, the process flow of the flue gases though the system (100) in accordance with the preferred embodiment of the present invention is disclosed. The pharmaceutical waste is fed in the incinerator (105 a), and the biomass briquette is fed in the combustion chamber (105 b) of muffle furnace (105), where the waste and briquette undergo combustion to produce hot flue gases. These hot flue gases from the incinerator (105 a) and the combustion chamber (105 b) meet and mix at the start of the venturi (125) and further pass through the holding chamber (105 c). The thermal energy is recovered from the flue gases in the waste heat recovery condenser (110 a) and passed to the boiler (110 b).

[0047] The flue gases are further passed to the wet scrubber (115 a) and absorber system (115 b) where they are scrubbed of particulate matter, acidic gases, and trace pollutants from the exhaust stream and the temperature of flue gases is gradually reduced, and the gases are further released through the chimney (120).

[0048] Now, the operation of the system (100) in accordance with the preferred embodiment of the present invention is described. The biomass briquette is fed in the combustion chamber (105 b) of muffle furnace (105). The biomass briquettes are ignited to start the combustion of the biomass. The flue gas temperature gauge at the end of the muffle furnace is continuously monitored during this starting phase.

[0049] When the flue gas temperature gauge indicates that a flue gas temperature of 900 - 1100°C is reached; the pharmaceutical waste is then fed in the incinerator (105 a) of the muffle furnace (105). If the flue gas temperature gauge indicates a flue gas temperature of <900°C, the feeding of the biomass briquette in the combustion chamber (105 b) is continued till the flue gas temperature gauge shows a constant temperature of 900°C +.

[0050] Once the pharmaceutical waste is fed in the incinerator chamber (105 a) and is ignited, a phase change of the pharmaceutical waste takes place in the incinerator chamber (105 a) as it is already preheated to 1000°C. During the phase change, the solid phase of the waste gets converted into gaseous phase and latent heat is given out in the form of heat energy. As a result, the gaseous phase of waste is converted into hot flue gases that rise up in the incinerator chamber (105 a) and the heavy ash gets collected at the bottom of the incinerator chamber itself. The ash from the bottom of the combustion chamber (105 b) is collected in the separate ash chamber (130), whereas the ash from the incinerator chamber (105 a) is collected at the bottom of the incinerator chamber itself.

[0051] These flue gases from the incinerator (105 a) and the combustion chamber (105 b) of the muffle furnace (105) meet and mix at the start of the venturi. After entering the venturi, uniform combustion of the flue gases takes place in the first pass (105 cl) of the holding chamber (105 c) of the muffle furnace (105). The flue gases are further passed through the second (105 c2), third (105 c3) and the fourth (105 c3) pass of the holding chamber (105 c) of the muffle furnace (105).

[0052] The passage of the flue gases via the first (105 cl), second (105 c2), third (105 c3) and the fourth (105 c3) pass of the holding chamber (105 c) collectively maintains the flue gases at a uniform temperature of 900 - 1100°C for a period of 3.1 seconds or more. For example, in one case it is found to be 3.2 seconds, in another case it is found to be 3.54 seconds, and in one more case it is found to be 3.7 seconds.

[0053] In the holding chamber (105 c), as the flue gases are maintained at a uniform temperature of 900 - 1100°C for 3+ seconds; the dioxins and furans present in them are neutralized and converted into non-hazardous flue gases. The flue gases at 900 - 1100°C are made to pass through the fire tube type boiler (110 b) which generates steam. After the muffle furnace, the exhaust gases are fed into the waste heat recovery unit. Here, the actual heat transfer takes place via the fire tube type boiler system and the exhaust flue gas temperature falls from 900°C to 300°C. The boiler gives away steam / hot water as a by-product that is used for processes in the manufacturing system.

[0054] In the fire tube boiler, the water flows through the tube, and the thermal energy generated by the incineration process from the flue gases is passed to the outer wall of tube. This thermal energy is then transferred from the metal conduits to the water via heat transfer method thus converting it to steam / hot water. These flue gases are further made to pass through a water preheater system where their temperature is further reduced from 300°C to 130°C; and the water preheater system generates hot water or steam from this energy.

[0055] The feed water is heated in the boiler (110 b) from the heat transferred. In accordance with one embodiment, the boiler (110 b) generates hot water from the heat transferred. In accordance with another embodiment, the boiler (110 b) generates steam from the heat transferred. The steam generated is utilized for various purposes including HVAC, low pressure steam for pure steam generation, drying purpose, equipment sterilization and the like.

[0056] The cooled exhaust gases at 90°C are further made to pass through the wet scrubber (115 a) and absorber system (115 b) to remove any harmful remnants including sulphuric acid or particulate matter from them before releasing them into the environment via the chimney. The flue gases pass through the wet scrubber (115 a) and absorber (115 b) where the particulate matter is removed by capturing it in liquid droplets. The droplets are then collected, with the liquid dissolving or absorbing the pollutant gases.

[0057] The flue gases are finally passed through the chimney where they cool down and are finally let out into the environment. The steam is utilized for various purposes such as hot water generation processes as well as HVAC, low pressure steam for pure steam generation, drying purpose, and the like.

[0058] After the combustion of both biomass fuel and pharmaceutical waste, ash from the combustion chamber (105 b) gets deposited into the ash chamber (130) located below the combustion chamber (105 b). The ash from the incinerator chamber is collected at the bottom of the incinerator chamber (105 a) itself. The biomass fuel ash is non-toxic and can be easily used for landfill, red brick making, in agriculture process as a soil conditioner and alternate nutrient source. The pharmaceutical waste ash being classified as toxic, is handed over to government authorized agency for landfill purposes according to the government guidelines.

[0059] In accordance with an alternate embodiment, alternate waste material is fed to the incinerator (105 a) for incineration. The waste material is selected from hazardous and non-hazardous waste materials selected from chemical, paints, textiles, food and the like.

[0060] EXAMPLES: Only a few examples and implementations are disclosed. Variations, modifications, and enhancements to the described examples and implementations and other implementations can be made based on what is disclosed.

[0061] Examples are set forth herein below and are illustrative of different amounts and types of reactants and reaction conditions that can be utilized in practicing the disclosure. It will be apparent, however, that the disclosure can be practiced with other amounts and types of reactants and reaction conditions than those used in the examples, and the resulting devices various different properties and uses in accordance with the disclosure above and as pointed out hereinafter.

[0062] Example 1: Operation of the system for steam / hot water generation by utilizing pharmaceutical waste as a fuel

[0063] 1) Biomass briquettes were fed into the combustion chamber (105 b) of the muffle furnace (105) and the biomass briquettes were ignited to start the combustion process.

[0064] 2) The flue gas temperature was monitored by the flue gas temperature gauge present at the end of the muffle furnace and when the flue gas temperature of 900 °C was reached; 125 kg pharmaceutical waste including gelatin and liquid paraffin was fed in the incinerator (105 a) of the muffle furnace (105). The pharmaceutical waste was ignited, and the incineration process was initiated at a temperature of about 900 - 1100°C to generate the hot flue gases. 3) The hot flue gases were further passed via the venturi to the holding chamber (105 c). The hot flue gases were subjected to four passes at 900 - 1100°C for a residence time of 3.4 seconds to undergo inactivation of dioxins and furans present in them. 4) The heat energy generated after combustion was passed to the waste heat recovery condenser (110 a) and boiler (110 b). The hot flue gases were then passed through the wet scrubber (115 a) and absorber (115 b) and released into the atmosphere via the chimney (120) after the temperature was reduced to 90°C. 5) The water was allowed to flow through the shell of the fire tube type boiler and flue gases through the external tube and the thermal energy generated by the incineration process was passed to the tube's outer walls. This thermal energy converted the water into steam. Example 2: Calculation of residence time in the muffle furnace

[0065] The residence time of the exhaust flue gases in the four-pass passage is calculated as below:

[0066] Table 1: The dimensions of the 4 passages of the holding chamber

[0067] Flue Gases at 900 - 1100°C:

[0068] 1. For Pharma Waste Combustion

[0069] = [feed rate of gelatine waste / molecular weight of air] X [combustion rate in kg of air / fuel] X [gas constant] X [Ambient Temperature of Muffle Furnace / Absolute Temperature Constant]

[0070] = [40 / 29] x 10 x 22.4 x [1173 / 273]

[0071] = 1327 m3 / hr

[0072] 2. For Biomass Briquette Combustion

[0073] = [feed rate of gelatine waste / molecular weight of air] X [combustion rate in kg of air / fuel] X [gas constant] X [Ambient Temperature of Muffle Furnace / Absolute Temperature Constant]

[0074] = 100 / 29 x 10 x 22.4 x (1173 / 273)

[0075] = 3318 m3 / hr

[0076] 3. Total = 1327 m3 / hr + 3318 m3 / hr = 4645 m3 / hr

[0077] Residence Time = (4.58 / 4645) x 3600 = 3.54 seconds.

[0078] Example 3: Efficiency of the system for steam / hot water generation by utilizing thermal energy from flue gases generated by waste incineration

[0079] 1) Capital Cost (CAPEX)

[0080] The system (100) for steam / hot water generation by utilizing thermal energy from flue gases generated by waste incineration of the present invention provides a capital cost saving up to 51 % compared to a traditional boiler + incinerator setup. Some elements of a traditional boiler setup and a traditional incinerator setup are same, these are clubbed together in the system (100). These elements include absorber, wet scrubber and chimney; hence providing direct cost saving to the end user. Cost of New Boiler and Incinerator = Rs. 2,22,00,000 / -

[0081] Cost of Bin-cinerator = Rs. 1,08,00,000 / -

[0082] Capital Cost Savings = Rs. 1,14,00,000 / -

[0083] Capital Cost Saving in % =1,14,00,000pQO _ 5 %

[0084] 12,22,00,000

[0085] 2) Carbon Footprint: The traditional incinerator setup uses Diesel / PNG fired burner to directly incinerate the pharmaceutical waste. On the contrary, the system (100) of the present invention uses biomass briquette to indirectly heat the muffle furnace evenly up to 1000°C and hence achieve uniform combustion of pharmaceutical waste via vaporization. The carbon saving by not burning PNG is provided in table 2:

[0086] Table 2: Carbon saving yearly if PNG is not utilized for incinerator 3) Fuel:

[0087] The system (100) reduces the fuel consumption up to 50% based on the calorific value of waste generated in the manufacturing process. In the system (100), pharmaceutical waste having good calorific value is combusted to generate exhaust flue gases, that replaces the fuel required to achieve the desired quantity of steam / hot water.

[0088] Calorific Value of Briquette = 3800 kcal / kg

[0089] Calorific Value of Gelatine Waste = 4500 kcal / kg

[0090] Daily Generation of Gelatine Waste = 800 kgs

[0091] Present fuel expense in Rupees / day (as per table 3) = Rs. 35000 / day

[0092] Daily Fuel Requirement = (3 x 3800) - (0.8 x 4500)

[0093] = 11400 - 3600

[0094] = 7800 / 3800

[0095] = 2.05 Tonnes / day

[0096] Proposed expense on Briquettes = 2.05 x Rs.7200

[0097] = Rs. 14750 / day

[0098] Fuel Savings = Rs. 35000 / day - Rs. 14750 / day

[0099] = Rs. 20250 / day

[0100] 20250

[0101] Fuel Saving in % = X 100 = 57 %

[0102] 35000

[0103] 4. Operational Cost Saving (OPEX):

[0104] As compared to the operations of traditional Boiler + traditional Incinerator setup, the system (100) requires 30% less manpower to run the same setup as compared to running 2 setups separately.

[0105] CTC of Boiler Operator = Rs.22, 000 / month CTC of Fireman = Rs.18,000 / month

[0106] Manpower Requirement to run standalone Boiler = 4 Boiler Operator + 4 Fireman

[0107] = Rs. (22,000 x 4) +

[0108] Rs (18,000 x 4)

[0109] = Rs. 88,000 + Rs. 72,000

[0110] = Rs. 1,60,000 / month

[0111] Manpower Requirement to run standalone Incinerator = 4 Fireman

[0112] = Rs. (18,000 x 4)

[0113] = Rs. 72,000 / month

[0114] Total Manpower required to run standalone Boiler + incinerator

[0115] = Rs. 1,60,000 + Rs. 72,000

[0116] = Rs. 2,32,000 / month

[0117] Manpower required to run system 100 = 4 Boiler Operator + 4 Fireman

[0118] = Rs. (22,000 x 4) + Rs. (18,000 x 4)

[0119] = Rs. 88,000 + Rs. 72,000

[0120] = Rs. 1,60,000 / month

[0121] Manpower Saving = Rs. 2,32,000 - Rs. 1,60,000

[0122] = Rs. 72,000 / month

[0123] Manp

[0124] 1ower Saving in % =72000X 100 = 31 % 232000

[0125] Advantageously, the system (100) for steam / hot water generation by utilizing thermal energy from flue gases generated by waste incineration is highly efficient, economical, eco-friendly and utilizes heat energy for steam / hot water generation than the existing technologies. The system eliminates the need for additional disposal costs associated with pharmaceutical waste. The system of the present invention effectively neutralizes flue gases before their release into the atmosphere.

[0126] The system (100) provides a capital cost saving up to 50% compared to traditional boiler + incinerator setup. The system further saves precious floor space as compared to the traditional setup. The system reduces the carbon footprint by decreasing the CO2 generation by up to 1,14,000 kg than the traditional incinerator setup as PNG fired burners are not utilized. The system reduces fuel consumption by up to 50% based on the calorific value as the pharmaceutical waste utilized is of high calorific value.

[0127] The system (100) requires less maintenance due to negligible moving parts operating on the principle of thermal engineering, heat transfer and vaporization. The eco-friendly design of the system provides better compliance towards pollution control norms hence effectively contributing to better environment social governance.

[0128] The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated.

[0129] It is understood that various omissions and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the scope of the present invention.

Claims

CLAIMS:

1. A system (100) for generating steam or hot water by utilizing thermal energy from flue gases produced during waste incineration, the system (100) comprising: a muffle furnace (105) including an incinerator chamber (105 a) for combustion of pharmaceutical waste, a biomass briquette combustion chamber (105 b) for combustion of biomass briquettes, and a four-pass holding chamber (105 c) for thermal treatment of flue gases; a waste heat recovery unit (WHRU) (110) including a waste heat recovery condenser (110 a), and a boiler (110 b); an air pollution control system (115) including a wet scrubber (115 a), and an absorber system (115 b); and the pharmaceutical waste and biomass briquettes undergoing combustion together, producing hot flue gases such that the hot flue gases being passed through the holding chamber (105 c) to neutralize dioxins and furans; and the thermal energy being recovered from the flue gases in the waste heat recovery condenser (110 a) and being transferred to the boiler (110 b).

2. The system (100) as claimed in claim 1, wherein the flue gases being treated in the holding chamber (105 c) through a four-pass process including a first pass(105 cl), a second pass (105 c2), a third pass (105 c3), and a fourth pass (105 c4); and the flue gases being maintained at a temperature range of 900-1100°C with a residence time of 3.1 to 3.8 seconds to facilitate inactivation of pollutants.

3. The system (100) as claimed in claim 1, wherein the gas volumes and flow rates in the holding chamber (105 c) being maintained at a predefined volumes in respective passes such that the first pass (105 cl) having a volume of 0.85 m3(3.4 x 0.6 x 0.42), the second pass (105 c2) having a volume of 0.35 m3(1.3 x 0.46 x 0.6); the third pass (105 c3) having a volume of 1.56 m3(2.9 x 0.6 x 0.9) and the fourth pass (105 c4) having a volume of 1.82 m3(2.9 x 0.35 x 0.9 x 2); and the gas flow rate being maintained at 1.29 m3 / s.

4. The system (100) as claimed in claim 1, wherein the waste heat recovery unit (110) being installed downstream of the muffle furnace (105) and the thermal energy from combustion being transferred to the waste heat recovery unit (110) to generate steam or hot water.

5. The system (100) as claimed in claim 1, wherein the thermal energy captured by the waste heat recovery condenser (110 a) further being transferred to the boiler (110 b) for boiling water or converting it into steam.

6. The system (100) as claimed in claim 1, wherein the air pollution control system(115) including: a wet scrubber (115 a) for removing particulate matter, acidic gases, and trace pollutants from the exhaust stream; and an absorber system (115 b) for reducing their temperature to a level suitable for release into the atmosphere.

7. The system (100) as claimed in claim 1, wherein the pharmaceutical waste including chemical ingredients, oils, gelatine, active pharmaceutical ingredients, excipients, and similar materials.

8. The system (100) as claimed in claim 1, wherein the boiler (110b) being selected from a fire-tube type boiler, a water tube type boiler, a hot water generator and the like.

9. The system (100) as claimed in claim 1, wherein the system reduces carbon emissions by avoiding the use of fossil fuels in waste incinerators and boilers.

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