Modular Sludge Incineration Kit for Small Plants
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Solution Overview
Problem
Current sludge incineration solutions are costly and not economically viable for small treatment plants handling sludge volumes of around 500 kg/hour, as they require large-scale installations and high operational costs, and face challenges with agricultural spreading and landfilling due to environmental and regulatory issues.
Innovation Solution
A modular sludge incineration kit comprising a fluidized bed furnace, heat exchangers for energy recovery, and filtration units, allowing for on-site assembly and operation with reduced infrastructure needs, including water, electricity, and auxiliary fuels, to treat sludge efficiently and meet regulatory standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional incineration installation is constructed, then sludge treatment capability is improved, but installation cost and operational cost increase significantly
Solution Approach 1:
The incineration system is divided into three independent transportable modules: module A (furnace with fluidized bed), module B (cooling system with heat exchangers), and module C (filtration system with bag filter). These modules can be manufactured separately, transported to the site, and assembled on concrete slabs, significantly reducing installation complexity and cost while maintaining treatment capability for 500 kg/hour sludge volume.
2Productivity
If conventional incineration installation is constructed, then sludge treatment capability is improved, but operational cost increases
Solution Approach 1:
The system recovers thermal energy from the flue gases exiting the furnace. Module B cools these hot gases using heat exchangers, and the recovered heat can be utilized for preheating air or other process needs. This energy recovery reduces the overall operational cost by minimizing energy waste from the incineration process.
Solution Approach 2:
The modular design allows the system to be self-sufficient at the treatment plant location. Module A generates heat through combustion, which can be partially utilized by module B for cooling and heat recovery. The system requires minimal external infrastructure beyond basic utilities (water, electricity, auxiliary fuel), reducing operational dependencies and costs.
3Device complexity
If modular kit is assembled on-site, then installation cost is reduced, but assembly complexity may increase
Solution Approach 1:
The system is segmented into three standardized modules that can be manufactured independently using conventional fabrication techniques. Each module is designed to be transportable and assembleable on-site on concrete slabs with minimal infrastructure requirements, reducing installation cost while maintaining manageable assembly complexity through standardization.
Solution Approach 2:
The modular design creates universal components that can serve multiple functions. For example, module B serves both as a cooling system and a heat recovery system. The standardized interfaces between modules allow for flexible assembly and potential reconfiguration, simplifying the assembly process despite the segmented design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The modular system enables cost-effective and environmentally compliant sludge treatment for small plants, reducing transportation issues and achieving satisfactory profitability by utilizing heat recovery and compact installation design, while ensuring compliance with regulatory standards.
Implementation Method 1
module A comprising a furnace, means for supplying the furnace with sludge to be incinerated, thermal means for the furnace and means for evacuating the fumes
Implementation Method 2
the fluidized bed, formed from the mixture of the sludge to be treated and inert materials in the form of grains or particles (silica sand for example), ensures an optimal distribution of the sludge in the combustion zone
Implementation Method 3
module B comprising means for cooling the fumes coming from module A... The heat exchangers make it possible to reduce the temperature of the fumes evacuated by the oven while recovering the calories contained in the fumes to recover them
Implementation Method 4
module C comprising means for filtering the cooled fumes, means for evacuating the filtered fumes... the flue gas filtration means are in the form of a dust collector filter
Data Source
Figure 1A~1C
Figure 2
Figure 3
AI summary
Kit for the incineration of sludge comprising the following successive modules, each module comprising side walls, a ceiling and a bottom: - a module A (1) comprising a furnace (6), means for feeding (13) the furnace with sludge to be incinerated, heating means for the furnace and means for evacuating fumes (4), - a module B comprising means for cooling fumes (17,18) from module A; - a module C comprising means for filtering (31) the cooled fumes, means for evacuating (38, 39) the filtered fumes, means for storing and means for evacuating ash from filtration (36, 37), - removable connection means for connecting the means for evacuating fumes from module A with the means for cooling fumes from module B (2), - removable connection means for connecting the means for cooling fumes from module B with the means for filtering cooled fumes from module C (3).Installation achieved by assembling the kit components.