Description:[0031] The exemplary embodiments described herein detail for illustrative purposes are subject to many variations in structure and design. It should be emphasized, however, that the present invention is not limited to a system for enabling access control of physical documents as described. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover the application or implementation without departing from the spirit or scope of the present invention.
[0032] The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. The terms “having”, “comprising”, “including”, and variations thereof signify the presence of a component.
[0033] To serve the various objectives described hereinabove, the present invention provides an advanced Moving Grit Incinerator with a multi zone combustion-based waste treatment system, designed for efficient combustion and disposal of Refuse-Derived Fuel (RDF) and grit materials collected from industrial and municipal waste treatment plants. The system ensures enhanced combustion efficiency, reduced emissions, and optimized energy utilization for heating oil used in the Rexine industry. Waste treatment plants generate significant quantities of RDF and grit, which require effective disposal to prevent environmental contamination. Traditional incinerators are stationary, limiting flexibility and operational efficiency. The Moving Grit Incinerator introduces a dynamic combustion process, optimizing heat transfer and material handling to improve incineration outcomes. The generated heat energy is further utilized to heat oil, which is employed in the Rexine industry.
[0034] Reference is made to Figure 1 illustrating a diagrammatic representation of components of a multi zone combustion-based waste treatment system with advanced Moving Grit Incinerator, in accordance with an embodiment of the present invention. The system comprises of:
• Conveyor Belt System (1): for transferring segregated RDF waste to the incineration unit.
• Moving Grit Incinerators (2): Attached to a refractory unit for controlled ash management during incineration.
• Preheated Tower (3): Enhances heat recovery by further heating the oil while acting as a fly ash collector.
• Air Preheater (APH) (4): At the time of incineration RDF burning produces few flue gas in incinerators itself and the Air Preheater recovers heat from flue gases to preheat combustion air, increasing fuel efficiency and reducing operational costs.
• Air Pollution Control Unit (5): Comprising a precipitator, lime mixture, and scrubber for effective emission control.
• Tube Control chamber (6): for regulates and directing the heated oil for utilization in ovens.
• Oil Storage Tank (7): During the process two pipes are connected to the moving grate incinerators: one carries hot oil from the incinerators to all ovens, while the other returns the cooled oil to the storage tank for recirculation. This process operates in a continuous cycle. Oil storage tank stored the cooled oil returning from the Rexine ovens, which is then recirculated for reheating.
• Rexine Industry Ovens (8): Utilizes the heated oil for controlled heating in different manufacturing stages.
[0035] The RDF is transferred from the conveyor belts (1) to moving grit incinerators (2). In (2), RDF is burned at temperature 800 to 12000C. The incineration tank is designed to achieve a maximum output efficiency of up to 2.5 million calories (25 lakh calories), depending on the fuel quality and operating conditions. Sensor is installed inside the incineration unit to control the temperature according to the oil temperature. A crucial component of this system is the coiled tube running along the ceiling of the incineration chamber, similar in design to automobile radiators. This tube contains Hi Tech Therm Oil 60, a specialized heat transfer fluid. The oil 60 is used in the Rexine industry for the production of Rexine. To ensure optimal combustion and temperature control, (3) and (4) a preheated section is connected to the tower. Preheated section is the location where temperature will be constant after burning the RDF. This section helps in maintaining a stable temperature range, ensuring complete combustion of the RDF. As a result, the combustion process is more efficient, and the risk of unburned material or incomplete combustion is minimized. This setup facilitates effective energy recovery while also addressing environmental concerns related to ash production. The tower is also equipped with mechanisms to manage the fly ash produced during combustion. Fly ash particles, along with other suspended matter, are largely settled within the tower, ensuring that the exhaust gases released have minimal particulate content. Additionally, bottom ash, which forms as a by-product in the incineration chamber, is collected separately from the base of the system. Both bottom ash and fly ash are crucial by-products of the industry. After passing through the tower, the heated tube, now at the desired temperature, is directed towards the tube control chamber (6). The tube control chamber plays a critical role in regulating and maintaining the temperature of the Hi Tech Therm Oil 60, ensuring that it is ready for utilization in the rexine manufacturing process.
[0036] Air pollution control units (5) consist of precipitator, lime mixture and scrubber. Meanwhile, the hot air generated during the combustion process is directed toward a scrubber. The scrubber performs an essential function in reducing the environmental impact of emissions by neutralizing the acidic gases present in the flue gas. In the scrubber, lime is added to the gas stream, which reacts with harmful components such as sulfur dioxide (SO2) to form neutral compounds, thus reducing the overall acidity and harmful content of the emissions. After the scrubber, the partially cleaned gas moves into the air filtration system. The air filtration device is designed to capture any remaining particulates and gaseous pollutants. This filtration system typically consists of bag filters or electrostatic precipitators, which remove fine dust particles and residual fly ash from the gas stream. As the gases pass through these filters, particulate matter is trapped, ensuring that only clean air is released from the system. Once filtered, the cleaned air is finally directed to the chimney, where it is safely released into the atmosphere. The chimney ensures that the gas is dispersed at a height that minimizes any local air quality impacts, thus completing the gas emission process. With the emissions now controlled and mitigated, the focus shifts to the energy transferred to the rexine manufacturing process, which is powered by the heat energy harnessed from the RDF combustion.
[0037] In the rexine industry, the heated Hi Tech Therm Oil 60, which has been maintained at a controlled temperature in the tube control chamber (6), is transferred to the ovens in the production line (8). The oil enters the system at temperatures ranging from 260°C to 280°C, depending on the operational requirements. The production line consists of four ovens arranged in sequence, each connected to a central oil supply tube originating from the tube station. Each oven has its own dedicated branch tube, which is coiled inside the oven in a radiator-like configuration, designed to transfer heat to the incoming air. Unlike typical radiators that dissipate heat, this system works in reverse: hot oil flows through the coiled tubes, raising the temperature of air drawn into the ovens. Just close to the moving grit incinerators there is refractory unit where hot air is passed from the incineration unit and from the refractory unit oil is heated. Initially, air is sucked into the ovens via ducts at a temperature of approximately 30°C to 40°C. As the air passes over the hot oil coils, its temperature is increased significantly, reaching up to 200°C. This hot air is then utilized to perform various heating functions required during the rexine sheet manufacturing process. The temp of all oven is almost same and oven is used for the Rexine production. Each oven in the production line serves a specific purpose: Oven 1 - Preheating the Paper Substrate: The heated air warms the paper substrate to ensure proper adhesion in subsequent stages. Oven 2 - Rexine-Paper Bonding: The hot air activates adhesive layers, ensuring strong bonding between the rexine material and paper. Oven 3 - Paint Application and Pressing: The high-temperature air assists in drying applied paint, enhancing the durability and aesthetic appeal of the rexine. Oven 4 - Finishing and Recovery: Hot air is used for final treatments, ensuring a smooth and glossy surface, after which the paper substrate is recovered for reuse. This process, powered by RDF-combusted heat, enables the production of up to 10,000 meters of rexine within a 12-hour cycle, demonstrating high efficiency.
[0038] Throughout this process, the controlled use of hot air generated by the heat from RDF-combusted oil ensures that each step is energy-efficient and optimized for productivity. The plant is capable of producing up to 10,000 meters of rexine within a 12-hour operational cycle, highlighting the system’s efficiency. After performing its task in the ovens, the hot air, now cooler, is expelled through an outlet. It is then directed to the exhaust system, where it passes through environmental control devices such as scrubbers and air filters to minimize particulate emissions before being released into the atmosphere via the chimney.
[0039] In an aspect the invention introduces an advanced Moving Grit Incinerator designed to enhance the combustion and disposal of Refuse-Derived Fuel (RDF) and grit materials collected from industrial and municipal waste treatment plants. This system ensures higher combustion efficiency, reduced emissions, and optimized energy utilization, particularly in heating oil for the rexine industry. Waste treatment plants generate significant amounts of RDF and grit, necessitating efficient disposal methods to mitigate environmental contamination. Traditional stationary incinerators limit flexibility and efficiency, whereas the Moving Grit Incinerator incorporates a dynamic combustion process to optimize heat transfer and material handling, thereby improving incineration outcomes. The heat energy produced is further utilized for heating oil used in the rexine industry.
[0040] RDF conversion to energy is achieved by combustion and/or pyrolysis. A combustion system designed for burning Refuse-Derived Fuel (RDF) typically includes several key components tailored to handle the unique characteristics of RDF, which is derived from municipal solid waste (MSW). The components may include but not limit to fuel preparation systems, fuel feed systems, combustion chamber or furnace or incinerators, air supply systems, heat recovery systems, Flue gas treatment system, Ash handling system, Control and monitoring system and certain optional add-ons including gasification units, pretreatment bio drying and co-generation systems. Incinerators are designed to maximize waste burnout and heat output. Combustion essentially a chemical reaction which utilizes oxygen in the air to convert carbon hydrogen and other elements of the waste to energy. Incinerators are designed to maximize waste burn out and heat output, while minimizing emissions by balancing the oxygen (air) and the three “Ts”, i.e., time, temperature and turbulence. The temperature reached in the incinerator is 900 to 11000C. Utilization of heat produced in RDF combustion needs it optimization to the levels being needed by the industry. The utilization of heat produced in RDF (Refuse-Derived Fuel) combustion is a critical step to maximize energy efficiency while optimizing the heat to levels suitable for industrial needs. This process involves converting the high-temperature energy released during combustion into forms that are practically usable for various industrial applications, such as steam, hot water, or lower-temperature heat. RDF combustion systems generate high-temperature heat, typically exceeding the levels directly usable in many industrial processes. To address this certain component such as waste heat boilers, waste heat exchangers are needed to be integrated with the incinerators in order to achieve the desired temperature levels.
[0041] A non-limiting embodiment of present invention is depicted in fig 1 wherein the muti stage temperature reduction system is depicted as “S” invention
[0042] In an aspect this invention provides for a moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit, comprising: a heat-resistant moving Conveyor Belt (1) for transporting RDF and grit at adjustable speeds;
at least an incineration chamber (2) constructed from high-temperature-resistant refractory-lined stainless steel and equipped with multiple burners for controlled combustion of the RDF and grit, the incinerator chamber being attached to a refractory unit for controlling and managing ash during incineration, wherein, at least a coiled tube heat exchanger is provided along the ceiling of the incineration chamber containing Hi Tech Therm Oil (60);
at least a Preheated Tower (3) arranged at the side of the incineration chamber (2) providing enhanced heat recovery by further heating the oil while acting as a fly ash collector,
at least a temperature sensor is provided within the incineration unit to regulate combustion,
at least a Air Preheater (APH) (4) arranged at the bottom of the Preheated Tower (3)for recovering heat from flue gases and preheating the combustion air;
at least a Air Pollution Control Unit (5) arranged at the side of the Preheated Tower (3) including electrostatic precipitators, lime mixture chambers, emission filtration units and scrubbers for controlling emissions;
at least one or more Rexine Industry Ovens (8);
at least a tube Control chamber (6) arranged at the top of the Preheated Tower (3) having at least two ducts for regulating and directing the heated oil into the one or more Rexine industrial ovens (8) for controlled heating;
at least an Oil Storage Tank (7) for storing and recirculating cooled oil used in the incineration process from the Rexene industrial ovens, wherein the oil storage tank is connected with the tube Control chamber (6) and Rexine Industry Ovens (8) via the at least two ducts transferring the oil; and
at least a PLC-based automated control system, wherein the PLC-based automated control system comprises of programmable logic controllers, corresponding sensors and actuators for temperature and oil heating control, a mechanism for feed rate adjustment and integrated remote monitoring interface.
[0043] In an aspect this invention the Conveyor Belt System is a heat-resistant stainless steel roller system and the Conveyor Belt System is provided with an automated chain conveyor.
[0044] In an aspect this invention the Conveyor Belt System is provided with adjustable speeds to continuously move RDF waste and grit through the combustion zone at the desired speed.
[0045] In an aspect this invention the incineration chamber is ranging from 4.5m to 6m in length and 2m to 3m in diameter,
[0046] In an aspect this invention within the incineration unit is provided with at least a Temperature sensor to regulate combustion based.
[0047] In an aspect this invention the incineration chamber is provided with a refractory lining and the refractory lining provides resistance to high-temperature.
[0048] In an aspect this invention a collection furnace is arranged at the bottom of the incinerator (2) for collecting the bottom ash.
[0049] In an aspect this invention the Preheated Tower (3) is provided with at least one duct each for transferring hot oil and hot air respectively from the incineration chamber. In another aspect the Preheated Tower (3) provides additional heating to the oil.
[0050] In an aspect this invention the Preheated Tower (3) is provided with at least a fly ash collector at the bottom and an oil heating system with an integrated heat exchanger and regulated oil tank for industrial applications.
[0051] In an aspect this invention the system is provided with an air control mechanism with primary and secondary air injection for combustion efficiency enhancement.
[0052] In an aspect this invention the emission filtration unit is provided with a cyclonic separator, electrostatic precipitator, and catalytic converter to minimize pollutants.
[0053] In an aspect this invention the cyclonic separator provided with the emission filtration unit is wet or dry cyclone.
[0054] The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 1, wherein the electrostatic precipitator is for precipitation of ions in the ash.
[0055] In an aspect this invention the emission filtration unit is provided with electrostatic precipitator. The ions present in the ash interact with each other and in turn precipitate out in turn providing a clean emission.
[0056] In an aspect this invention the emission filtration unit is provided with the catalytic converter.
[0057] In an aspect this invention the tube Control chamber is provided with ducts for transferring hot oil from the tube chamber to the oven.
[0058] In an aspect this invention the Oil Storage Tank is provided with tubes for circulation of the oil through the system.
[0059] In an aspect this invention the system is provided with a PLC-based automated control system for temperature regulation, oil heating, combustion monitoring, and remote operation.
[0060] In an aspect this invention the system is provided with a air pollution control system comprising a precipitator, lime mixture chamber, and scrubber for effective pollutant removal and clean air production. (Yes)
[0061] In an aspect this invention provides a method for RDF-based incineration in a waste-to-energy plant using the moving grit incinerator system, comprising of transporting the RDF waste and grit via a Conveyor Belt (1) at adjustable speeds into an incineration chamber (2); followed by burning the RDF waste and grit between 800°C and 1200°C with controlled oxygen supply in the incineration chamber (2) and transferring heat energy to Hi Tech Therm Oil (60) through a coiled tube exchanger provided along the ceiling of the incineration chamber; thus in turn ensuring complete combustion of the RDF and grit by transmitting heat via transferring of hot oil and hot air from the incinerator chamber to a Preheated Tower (3); followed by transmitting additional heat from flue gases and pre-heating the combustion air by an Air Preheater; and transferring hot oil from the Preheated Tower (3) to a tube control chamber (6) having at least two ducts for regulating and directing the heated oil into the one or more Rexine industrial ovens (8) for controlled heating; followed by storing and recirculating cooled oil used in the incineration process from the Rexene industrial ovens to an Oil Storage Tank (7); and in turn controlling emissions by transferring the hot air from the Preheated Tower (3) to an Air Pollution Control Unit (5) having electrostatic precipitators, lime mixture chambers, emission filtration units and scrubbers for air filtration.
[0062] In an aspect this invention lime is added in the scrubber to neutralize the acidic gases present in the flue gas.
[0063] In an aspect this invention after the scrubber the partially cleaned gas moves into the air filtration system for capturing any remaining particulates and gaseous pollutants.
[0064] In an aspect this invention the air filtration system contains bag filters or electrostatic precipitators to remove fine dust particles and residual fly ash from the gas stream.
[0065] In an aspect this invention the cleaned air from air filtration system is finally directed to the chimney, where it is safely released into the atmosphere

System Methodology:
[0066] The Moving Grit Incinerator system integrates a dynamic conveyor-based feeding system, a modular incineration chamber, an air control mechanism, an oil heating system, and an emission filtration unit. Designed for continuous RDF and grit incineration, its automated movement ensures uniform heat distribution, reducing unburned residues and maximizing energy recovery. The key components of the system include:
[0067] Moving Conveyor System (1): A heat-resistant stainless steel roller system with an automated chain conveyor that continuously moves RDF and grit through the combustion zone at adjustable speeds.
[0068] Incineration Chamber (2): A high-temperature-resistant, refractory-lined chamber constructed from stainless steel (Grade 310/316), measuring 4.5m to 6m in length and 2m to 3m in diameter. It operates at 800°C to 1100°C, equipped with multiple burners for controlled combustion.
[0069] Air Control and Combustion Optimization Unit (3): A forced air and exhaust management system with adjustable oxygen supply and secondary air injection for enhanced combustion.
[0070] Oil Heating System (4): A heat exchanger unit that transfers combustion heat to oil, with a regulated flow rate of 50-200 L/hr, ensuring effective industrial applications.
[0071] Emission Filtration and Air Pollution Control Units (5): the unit comprises of Electrostatic precipitators for particulate matter removal; Lime mixture chambers to neutralize acidic gases; Scrubbers to capture residual pollutants and An 8m to 12m tall stack for proper air dispersion.
[0072] Tube Control Units (6): for regulating and directing the heated oil for utilization in ovens.
[0073] Oil Storage Tank (7): for storing cooled oil returning from the Rexene ovens, which is then recirculated for reheating.
[0074] Rexine Industry Ovens (8): Utilizes the heated oil for controlled heating in different manufacturing stages.
[0075] Control System: A PLC-based automated system for temperature, oil heating, and feed rate regulation, with sensors for combustion efficiency, emissions, and oil temperature monitoring, and remote monitoring capabilities. The PLC-based automated control system comprises of programmable logic controllers, corresponding sensors and actuators for temperature and oil heating control, a mechanism for feed rate adjustment and integrated remote monitoring interface.
[0076] In the operational methodology of the RDF-based waste-to-energy plant, the transportation of RDF into the incineration chamber is carried out through a well-structured conveyor system. Initially, the RDF is loaded onto a conveyor belt via a crane or lifting system, which ensures efficient handling of the pre-processed RDF. The lifting system is designed to streamline the feeding process, minimizing manual intervention, and optimizing the flow of material. Once on the conveyor belt, the RDF is transported to a moving pusher belt that propels the material into the incineration chamber. The pusher belt operates at a speed of 5 meters per second (m/s), ensuring a steady and controlled feed of RDF into the combustion area. This consistent feeding rate is critical to maintaining the optimal burn rate within the incineration chamber, which in turn maximizes energy recovery and ensures smooth plant operation. The incineration process in the rexine plant, powered entirely by Refuse-Derived Fuel (RDF), is initiated by feeding RDF into the incineration chamber via a conveyor belt.
[0077] Inside the incineration chamber, the temperature ranges from 600°C to 1200°C. During combustion, RDF burns at temperatures between 800°C and 1200°C, with an incineration tank designed for a maximum output of 2.5 million calories, depending on fuel quality and operational conditions. Temperature sensors within the incineration unit regulate combustion based on oil temperature. A crucial component of this system is the coiled tube running along the ceiling of the incineration chamber, similar in design to automobile radiators. This tube contains Hi Tech Therm Oil 60, a specialized heat transfer fluid. The Hi-Tech Therm Oil 60 enters the tube system at an average temperature of 200°C, absorbing heat directly from the incineration flames. As the oil circulates through the coil, it gradually heats up due to the intense thermal energy within the chamber. By the time it exits the system, the oil has reached a temperature of approximately 315°C. This heated oil is then transferred for further applications, making it a highly efficient method for harnessing waste heat generated during RDF combustion.
[0078] A preheated section connected to the tower ensures stable combustion, minimizing unburned material and maximizing energy recovery while addressing environmental concerns related to ash production. The system collects bottom ash separately, while the tower manages fly ash, ensuring minimal particulate content in exhaust gases. The characteristics of bottom ash and fly ash are analysed to assess their environmental impact.
[0079] Post-incineration, the heated oil is directed to a tube station that regulates its temperature before it is transferred to the rexine manufacturing process. The oil, maintained between 260°C and 280°C, enters the production line, which consists of four ovens arranged in sequence. Each oven receives hot oil through a radiator-like configuration that raises incoming air temperature to approximately 200°C, facilitating various heating functions in the rexine sheet manufacturing process.
[0080] The production line includes: Oven 1 - Preheating the Paper Substrate: In the first oven, the preheated air at 200°C is used to heat the paper substrate. This preheating step is crucial for ensuring proper adhesion and quality in the subsequent stages. The uniform heating conditions provided by the controlled airflow ensure that the paper reaches the necessary temperature without deformation or degradation. Oven 2 - Rexine-Paper Bonding: In the second oven, the rexine material is laminated onto the preheated paper. The hot air, again at 200°C, facilitates the bonding process by activating the adhesive layer between the rexine and the paper. This step is critical to ensure a firm and durable bond, forming the base of the final product. Oven 3 - Paint Application and Pressing: In the third oven, hot air is used to assist in pressing and drying the paint applied to the rexine sheet. The high temperature allows the paint to dry quickly and evenly, ensuring that it adheres properly and forms a uniform surface. This step also enhances the durability and aesthetic appeal of the rexine product. Oven 4 - Finishing and Recovery: The final oven is dedicated to the finishing process. Hot air at 200°C is used to apply finishing treatments to the rexine sheet, ensuring a smooth and glossy surface. In this stage, the paper substrate, now fully processed, is separated from the rexine and recovered for reuse. The final product, a continuous roll of rexine, is prepared for further packaging and distribution.
[0081] This process, powered by RDF-combusted heat, enables the production of up to 10,000 meters of rexine within a 12-hour cycle, demonstrating high efficiency. Exhausted hot air passes through environmental control devices such as scrubbers and filters before being released into the atmosphere. (5) are air pollution control units which consist of precipitator, lime mixture and scrubber. Meanwhile, the hot air generated during the combustion process is directed toward a scrubber. The scrubber performs an essential function in reducing the environmental impact of emissions by neutralizing the acidic gases present in the flue gas. In the scrubber, lime is added to the gas stream, which reacts with harmful components such as sulfur dioxide (SO2) to form neutral compounds, thus reducing the overall acidity and harmful content of the emissions. After the scrubber, the partially cleaned gas moves into the air filtration system. The air filtration device is designed to capture any remaining particulates and gaseous pollutants. This filtration system typically consists of bag filters or electrostatic precipitators, which remove fine dust particles and residual fly ash from the gas stream by interacting with the ions and in turn precipitating it. As the gases pass through these filters, particulate matter is trapped, ensuring that only clean air is released from the system. Once filtered, the cleaned air is finally directed to the chimney, where it is safely released into the atmosphere. The chimney ensures that the gas is dispersed at a height that minimizes any local air quality impacts, thus completing the gas emission process. With the emissions now controlled and mitigated, the focus shifts to the energy transferred to the rexine manufacturing process, which is powered by the heat energy harnessed from the RDF combustion.

Examples:
[0082] In this study, Refuse-Derived Fuel (RDF) is collected from a nearby landfill and processed in a dedicated RDF processing facility located in proximity to the plant. RDF (Refused derived fuel) waste is collected from various waste disposal facility in U.P., India. The RDF was collected in segregated form which contains plastic 43%, rubber 7%, paper and cardboard 41% and organic 9%. The calorific value was 5660.7 KJ/Kg. The waste from the landfill is segregated and treated to remove non-combustible materials such as metals, glass, and inert matter. This process ensures that only high-calorific-value waste materials such as plastics, paper, and textiles are retained for energy conversion. Once processed, the RDF is transported to the waste-to-energy (WtE) plant using trucks and other heavy-duty vehicles. The transportation logistics are critical in maintaining the supply chain's efficiency, and careful planning is employed to ensure that approximately 75 to 80 tonnes per day (TPD) of RDF are delivered to the plant. The RDF is received in its final form, pre-shredded and prepared for direct use in the combustion chamber, which optimizes the plant’s operational efficiency by minimizing additional on-site pre-processing.

[0083] Advantages:
1. Efficient RDF and Grit Incineration: The moving mechanism improves heat transfer, reducing incomplete combustion.
2. Energy Optimization: Waste heat recovery integration enhances fuel efficiency.
3. Industrial Application: Heated oil can be effectively used in the rexine industry.
4. Environmental Compliance: Advanced filtration system ensures minimal emissions.
5. Clean Air Production: The combination of a precipitator, lime mixture chamber, and scrubber effectively removes pollutants, ensuring purified air output.
6. Flexible Operation: Modular design allows adaptability to different plant capacities.
7. Clean Air Production: The combination of a precipitator, lime mixture chamber, and scrubber effectively removes pollutants, ensuring purified air output.
8. Improved Thermal Efficiency: The inclusion of an Air Preheater (APH) recovers heat from flue gases to preheat combustion air, improving fuel efficiency and reducing operational costs.
9. Flexible Operation: Modular design allows adaptability to different plant capacities.
[0084] Since other modifications and changes varied to fit particular operating requirements and environments are apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.
[0085] Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as herein described.
[0086] As one of ordinary skill in the art may appreciate, the example system and method described herein can be modified. For example, certain steps can be omitted, certain steps can be carried out concurrently, and other steps can be added. Although particular embodiments of the invention have been described in detail, it is understood that the invention is not limited correspondingly in scope, but includes all changes, modifications and equivalents coming within the spirit and terms of the claims appended hereto.
[0087] The foregoing descriptions of specific embodiments of the present invention have 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 embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, and 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. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the spirit or scope of the present invention.
, Claims:I/we Claim
1. A moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit, comprising:
a heat-resistant moving Conveyor Belt (1) for transporting RDF and grit at adjustable speeds;
at least an incineration chamber (2) constructed from high-temperature-resistant refractory-lined stainless steel and equipped with multiple burners for controlled combustion of the RDF and grit, the incinerator chamber being attached to a refractory unit for controlling and managing ash during incineration, wherein, at least a coiled tube heat exchanger is provided along the ceiling of the incineration chamber containing Hi Tech Therm Oil 60;
at least a Preheated Tower (3) arranged at the side of the incineration chamber (2) providing enhanced heat recovery by further heating the oil while acting as a fly ash collector;
at least a temperature sensor is provided within the incineration unit to regulate combustion,
at least a Air Preheater (APH) (4) arranged at the bottom of the Preheated Tower (3) for recovering heat from flue gases and preheating the combustion air;
at least a Air Pollution Control Unit (5) arranged at the side of the Preheated Tower (3) including cyclonic separator, electrostatic precipitators, catalytic converter, lime mixture chambers, emission filtration units and scrubbers for controlling emissions;
at least one or more Rexine Industry Ovens (8);
at least a tube Control chamber (6) arranged at the top of the Preheated Tower (3) having at least two ducts for regulating and directing the heated oil into the one or more Rexine industrial ovens (8) for controlled heating;
at least an Oil Storage Tank (7) for storing and recirculating cooled oil used in the incineration process from the Rexine industrial ovens, wherein the oil storage tank is connected with the tube Control chamber (6) and Rexine Industry Ovens (8) via the at least two ducts transferring the oil; and

at least a PLC-based automated control system, wherein the PLC-based automated control system comprises of programmable logic controllers, corresponding sensors and actuators for temperature and oil heating control, a mechanism for feed rate adjustment and integrated remote monitoring interface.
2. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 1, wherein the Conveyor Belt System is a heat-resistant stainless steel roller system.
3. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 2, wherein the Conveyor Belt System is provided with an automated chain conveyor.
4. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 2, wherein the Conveyor Belt System is provided with adjustable speeds to continuously move RDF waste and grit through the combustion zone at the desired speed.
5. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 1, wherein at least a Temperature sensor is provided within the incineration unit to regulate combustion based.
6. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 5, wherein the incineration chamber is provided with a refractory lining.
7. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 5, wherein the refractory lining provides resistance to high-temperature.
8. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 1, wherein a collection furnace is arranged at the bottom of the incinerator (2) for collecting the bottom ash.
9. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 1, wherein the Preheated Tower (3) is provided with at least one duct each for transferring hot oil and hot air respectively from the incineration chamber.
10. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 10, wherein the Preheated Tower (3) provides additional heating to the oil.
11. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 10, wherein the Preheated Tower (3) is provided with at least a fly ash collector at the bottom.
12. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 1, wherein the system is provided with an air control mechanism with primary and secondary air injection for combustion efficiency enhancement.
13. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 1, wherein the Preheated Tower (3) provides an oil heating system with an integrated heat exchanger and regulated oil tank for industrial applications.
14. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 1, wherein the emission filtration unit is provided with a cyclonic separator, electrostatic precipitator, and catalytic converter to minimize pollutants.
15. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 1, wherein the cyclonic separator provided with the emission filtration unit is wet or dry cyclone.
16. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 1, wherein the electrostatic precipitator is for precipitation of ions in the ash.
17. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 1, wherein the emission filtration unit is provided with the catalytic converter.
18. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 1, wherein the tube Control chamber is provided with ducts for transferring hot oil from the tube chamber to the oven.
19. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 1, wherein the Oil Storage Tank is provided with tubes for circulation of the oil through the system.
20. The moving grit incinerator system for continuous incineration of Refuse-Derived Fuel (RDF) and grit as claimed in claim 1, wherein the system is provided with A PLC-based automated control system for temperature regulation, oil heating, combustion monitoring, and remote operation.
21. An air pollution control system comprising a precipitator, lime mixture chamber, and scrubber for effective pollutant removal and clean air production.
22. A method for RDF-based incineration in a waste-to-energy plant using the moving grit incinerator system, comprising
a. transporting the RDF waste and grit via a Conveyor Belt (1) at adjustable speeds into an incineration chamber (2);
b. burning the RDF waste and grit between 800°C and 1200°C with controlled oxygen supply in the incineration chamber (2);
c. transferring heat energy to Hi Tech Therm Oil 60 through a coiled tube exchanger provided along the ceiling of the incineration chamber;
d. ensuring complete combustion of the RDF and grit by transmitting heat via transferring of hot oil and hot air from the incinerator chamber to a Preheated Tower (3);
e. transmitting additional heat from flue gases and pre-heating the combustion air by an Air Preheater;
f. transferring hot oil from the Preheated Tower (3) to a tube control chamber (6) having atleast two ducts for regulating and directing the heated oil into the one or more Rexine industrial ovens (8) for controlled heating;
g. storing and recirculating cooled oil used in the incineration process from the Rexine industrial ovens to an Oil Storage Tank (7); and
h. controlling emissions by transferring the hot air from the Preheated Tower (3) to an Air Pollution Control Unit (5) having electrostatic precipitators, lime mixture chambers, emission filtration units and scrubbers for air filtration
23. The method for RDF-based incineration in a waste-to-energy plant using the moving grit incinerator system as claimed in claim 22, wherein lime is added in the scrubber to neutralize the acidic gases present in the flue gas.
24. The method for RDF-based incineration in a waste-to-energy plant using the moving grit incinerator system as claimed in claim 22, wherein after the scrubber the partially cleaned gas moves into the air filtration system for capturing any remaining particulates and gaseous pollutants.
25. The method for RDF-based incineration in a waste-to-energy plant using the moving grit incinerator system as claimed in claim 22, wherein the air filtration system contains bag filters or electrostatic precipitators to remove fine dust particles and residual fly ash from the gas stream.
26. The method for RDF-based incineration in a waste-to-energy plant using the moving grit incinerator system as claimed in claim 22, wherein the cleaned air from air filtration system is finally directed to the chimney, where it is safely released into the atmosphere