Vulcan 40 TPH Portable Thermal Desorption Plant in Moberly, MO
- Moberly, MO
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Vulcan 40 TPH Portable Thermal Desorption Plant - 42' long x 7' diameter direct fired rotary kiln with air pollution control devices. This equipment is designed to thermally purify petroleum/hydrocarbon contaminated soils. Particulate matter emissions are controlled by a multi-clone and baghouse. The volatile organic compounds and hazardous air pollutants emissions are controlled by a thermal oxidizer and an optional acid gas scrubber. The plant includes the following major components:
Material Feed System:
Feed hopper, trommel screen with over and under belts, live bottom feeder and a cleated weight belt conveyor
Primary Treatment Unit:
Direct fired rotary kiln with combustion chamber, burners and seals
Dry Material Discharge:
Cooling auger with spray manifold
Air Pollution Control Devices:
Multi-clone, thermal oxidizer, baghouse, evaporative cooling tower, and an optional acid gas scrubber
The Vulcan soil remediation plant has been refurbished and reengineered to effectively purify petroleum contaminated soils at a rate of up to 40 tons per hour. The system is designed to be both versatile and easily portable. A key design consideration is complete control of operational parameters in each component to tune the system for the most effective operation for a specified contaminate. Once this has been established, the system can be controlled automatically.
The system works on the premises of low-temperature desorption (LTTD), also known as low-temperature thermal volatilization, and thermal stripping, whereby contaminates are vaporized using heat. The temperature must be maintained above the boiling point range of the mixture, but under the auto-ignition temperature of the compounds and mixture as well.
The vaporized hydrocarbons are drafted into a high-temperature multi-clone to reduce dust and glass formation before entering into the thermal abatement unit, the thermal oxidizer. This direct fired thermal oxidizer or afterburner oxidizes the VOCs and HAPs to carbon dioxide and water at a minimum temperature of 1,500 degrees Fahrenheit.
Hot gases discharging from the thermal oxidizer are cooled by an evaporative cooling tower. There is no wastewater because the system operates well above the dew point. This unit cools the gases to a manageable temperature for the baghouse.
The baghouse is a traditional fabric filter collector which removes particulate matter greater than 1 micron with more than 99.99 percent efficiency. Cleaned gases are then discharged to the atmosphere by an induced draft fan. In special cases where high acid gas concentrations are present, the gases can be routed to a wet scrubber pollution control device to neutralize the acid gases into salts.
Material Feed System
Materials (typically soils contaminated with fuel oils and other similar hydrocarbon compounds) are prepared for treatment by the material feed system. This feed system preps the material by screening and clay shredding in a live bottom feeder. Then the material is belt fed into the rotary desorber.
Primary Treatment Unit (PTU)
The primary treatment unit is a reconditioned Direct Fired Vulcan 8442 Rotary Kiln. The rotary kiln is 42' long x 7' diameter, operating in a parallel flow. Lifting flights along the walls of the kiln veil the feed material, mixing it directly with the hot combustion gases from a Hauck 60 MMBtu/hr. Ecostar Multi-Fuel Burner. This direct contact mixing provides the energy for the moisture and volatile organic compounds (VOCs) to change phase from liquid form to gaseous form. By nature of the parallel flow arrangement, all solid particles, which become entrained in the vapor stream, are forced to travel the entire length of the drum. This ensures that the entrained materials rise to temperature and do not require further treatment. Materials can be brought to temperatures of 800 degrees Fahrenheit, the operating limit for the drum. The treated materials discharge from the drum, and the vapor stream continues for further processing.
Material Discharge System
The plant includes a material discharge system for spraying the processed soils with water for cooling and dust control in a screw conveyor. Controls are included to modulate the appropriate water flow rate.
Multi-Clone Dust Collector
Exhaust gases leaving the rotary kiln are drafted into a Vulcan Multi-Clone with 160 9" tubes. The unit can handle 50,000 SCFM flow, 118,900 ACFM at 800 degrees Fahrenheit. Collected fines are deposited with the processed material discharge system to be blended back into the treated soils before exiting the plant. The high operating temperature eliminates the potential for hydrocarbon condensation. Gas then travels to the thermal oxidizer.
Secondary Treatment Unit
A secondary treatment unit in the form of a thermal oxidizer is necessary to combust pollutants down to carbon dioxide and water. Satisfactory abatement is achieved by adequate temperature, turbulence, time and oxygen. Destruction removal efficiencies are generally in excess of 99 percent. The oxidizer itself has cast refractory, a 20.5 MMBtu/hr. Bloom Burner and an optional heat recovery unit. Preheated air boosts combustion efficiency, thereby reducing auxiliary fuel costs.
Evaporative Cooling Tower
Oxidized gases exiting the secondary treatment unit are cooled in an evaporative cooling tower. This direct contract spray tower can handle up to 80,000 CFM in its 11' diameter x 32' exterior. This two pass unit is trailer-mounted. A 200 hp fan provides the induced draft for the entire plant.
Baghouse Dust Collector
The 50,000 CFM pulse jet baghouse collects dust on 700 fabric filters, each 6" diameter x 8' long for a total of 8,800 sq. ft. of cloth. This dust is ejected by the pulsars into the hopper of the unit and then carried out via three (3) clean-out augers.
Optional Gas Scrubber
An optional final exhaust gas treatment is accomplished by a direct contact wet collector. This spray tower uses an atomized liquid mist to remove high levels of SOx or NOx. The scrubbing liquor is recirculated and monitored by a pH probe to determine when to add additional caustic. This option is determined on a case-by-case basis.
A climate controlled control room houses all the electrical cabinets for the plant. The unit sits on a single axle trailer with dual 10.00-20 tires. The trailer includes: manual landing jacks, air bag suspension, air brakes, storage rack underneath trailer, main door to control room, and rear access doors to electrics.
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