Process exploration for scale melting and solidifying of municipal solid waste incineration (MSWI) fly ash by horizontal cyclone melting furnace.

This study used the horizontal tubular heating furnace to explore the melting potential of circulating fluidized bed (CFB) incinerator fly ash and mechanical grate furnace (MGF) incinerator fly ash. The horizontal cyclone melting furnace was then built to explore further the feasibility of scale melting of MSWI fly ash. The melting characteristic temperature, amorphous content, and heavy metal leaching concentration characterized the melting potential and solidification effect of MSWI fly ash. The experimental results show that the amorphous content of CFB fly ash after melting is up to 92.37%, and the volatilization rate of heavy metals Zn, Pb, and Ni does not exceed 30%. MGF fly ash exhibits the "sintering into shells" phenomenon during heating, and the leaching concentrations of heavy metals Pb in the sintered products still exceed the standard limits. In addition, the volatilization rates of heavy metals Cu, Zn, Cd, Pb, Cr, and Ni in Slag II are above 50%, and the volatilization rate of Cr reaches 85%. So, slag's amorphous content also affects heavy metals' volatilization rate. The MSWI fly ash melting characteristic temperature decreases with the decrease of alkalinity value. When the alkalinity value drops to 0.6, the melting characteristic temperature reaches its lowest value. Mixing 80% CFB fly ash or 50% MGF bottom ash into MGF fly ash can significantly enhance the melting potential to reduce hazardous waste. When using the horizontal cyclone melting furnace to process MSWI fly ash on a large scale, MSWI fly ash achieves an excellent melting effect with an amorphous content of over 93% at the positions of the furnace middle section, inner tail cone, slag discharge outlet, and flue gas outlet. The fly ash particles are in motion in the melting furnace, so the particle size distribution affects the melting effect of MSWI fly ash.

Numerical simulation on the deposition characteristics of MSWI fly ash particles in a cyclone furnace.

In melting municipal solid waste incineration (MSWI) fly ash by cyclone furnace, the deposition characteristics of particles affect the slag flow and the secondary MSWI fly ash formation. In this study, the composition mechanism based on critical viscosity is selected as the particle deposition model to predict the deposition and rebound of particles on the furnace wall. The Riboud model with an accurate viscosity prediction performance is selected, then the particle deposition model is integrated into a commercial computational fluid dynamics (CFD) solver through the user-defined function (UDF) to realize the coupling of particle motion and deposition process. The results show that under the same case, the deposition rate decreases obviously with the increase of MSWI fly ash particle size. And the escape rate reaches a maximum at particle size 120 µm. Controlling the particle size of fly ash particles within 60 µm can effectively reduce the generation of secondary MSWI fly ash. During the forward movement of the fly ash inlet position, the escape of MSWI fly ash particles with large particle sizes has been significantly weakened. This measure not only lowers the post-treatment cost but also dramatically reduces the pretreatment step of MSWI fly ash before the melting and solidification process. In addition, the deposition rate and quality will reach the maximum values, respectively, along with gradually increasing MSWI fly ash input flow. Overall, this study has the guiding significance for reducing the pretreatment steps and post-treatment costs of MSWI fly ash by melting in the cyclone furnace.