High Temperature, Extremely Heavy-Duty Shaftless Screw Conveyors for Pyrolysis Process

General Description

Pyrolysis is the thermochemical decomposition of material at elevated temperatures in the absence of oxygen. It is a proven and commercially viable technology used in the recycling and waste-to-energy industries to convert waste plastic and trash into fuel oil through processes that are scalable, flexible and environmentally positive. In general, pyrolysis of various substances produces gas and liquid products and leaves a solid residue called char that is rich in carbon content. Pyrolysis converts waste materials into sustainable biofuels and is in great demand because it is an environmentally friendly technology.

KWS partners with many different technology providers to design mechanical conveying systems for injecting waste materials into the pyrolysis process and convert the waste to usable gases and liquids. Typically, the mechanical conveying system are subjected to temperatures up to 1700-degrees F. KWS has developed solutions to satisfy the unique needs of the pyrolysis industry.

Design Parameters

1. Product Type: Waste Materials
2. Material Density: Varies per Application
3. Capacity: Varies per Application
4. Duty: 24 Hours per Day, 7 Days per Week

KWS Advantages

When a project requires highly engineered bulk material handling equipment for high temperature and abrasive environments, no company is more qualified than KWS. KWS has a large staff of degreed engineers with experience designing equipment for severe duty. Since the pyrolysis process requires heating materials to extreme temperatures, KWS has successfully chosen high-nickel alloys such as Inconel 625 and Nitronic 60 for the conveying systems.

KWS has the ability to design and manufacture complete conveying and processing systems eliminating the need for third-party engineering firms or consultants on small-to-medium size projects. Working directly with KWS drastically reduces the cost and timeline of the project. Utilizing the latest 3D modeling software, sharing information and working together in virtual on-line real-time design sessions, KWS significantly reduces the normal engineering time required for difficult and unique projects. KWS also has manufacturing capabilities that are unique. All KWS welders are AWS and ASME certified to weld high-nickel alloys such as Inconel 625 and Nitronic 60.

Special Features

For the pyrolysis process with operating temperatures up to 1,700-degrees F, KWS uses Inconel 625 and Nitronic 60. These high-nickel alloys maintain high yield strengths at elevated temperatures and are also corrosion and abrasion resistant. The conveyor housings and spirals are constructed from dissimilar metals to prevent seizing and galling under these harsh conditions. Extended pedestal drive bases with special shaft couplings are required to keep the drive components away from the extreme heat. No fugitive air can be allowed to leak into the process. Conveyor housings are constructed from Inconel 625 pipe with Class 150 flanges at every connection point. Non-compressible Mica gaskets and purgeable flanged gland seals can handle the high temperatures and prevent leaks. Conveyors are designed to operate at very slow speeds to reduce abrasion. KWS Shaftless Screw Conveyors are the best option to convey abrasive and sluggish waste materials as well as char after the pyrolysis process. Hydraulically driven gear reducers provide high torque and allow the power source to be in a safe area at ambient temperature.