PROCESS ENGINEERING DESIGN OF TOBACCO WASTES INCINERATOR WITH UTILIZATION OF COMBUSTION GASES HEAT ENERGY

Abstract

The objective of this thesis is to develop an integrated incineration unit which is technically and economically capable for the efficient handling of tobacco-waste processing plant with the subsequent utilization of the heat content of combustion gases. The incinerator engineering design is based on the composition of solid wastes disposed from the tobacco processing plants of the Eastern Company in 6th October city. The basis of design depends on feeding the incinerator with 1 t/h of solid waste consisting of: 50% tobacco, 20% paper& cartons, 20%wooden boxes, and 10% plastic materials. The remaining ash after the incineration process does not exceed 5% of the original volume of feed stock. The overall material & energy balances reveals discharging combustion gases at mass flow rate of 25490 kg/h with heat content of 20 092 348 kJ. Flue gases energy is utilized either in generating saturated steam or producing hot water. An engineering design is given for: (i) a fired-tube boiler capable to generate 7 t/h saturated steam at 185 ºC & 10 bar, and (ii) 1- 4 shell and tube heat exchanger that produces hot water rated 80 t/h at 85 ºC. The temperature of the exhaust effluent combustion gases vented to the atmosphere is 200 ºC, that proves a highly efficient utilization of their original heat content. The calculated results are in excellent conformity with the data given in the fabricator incinerator manual already installed in the Eastern Company plants.