KWS Manufacturing

High Temperature Kiln Injection Screw Conveyor

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Plant Name and Location

Calgon Carbon Corporation
Pittsburgh, PA

General Description

Calgon Carbon Corporation is a global leader in the manufacturing of granular, powdered, and extruded carbon. These products are used as purification solutions for drinking water, wastewater, pollution abatement, and a variety of industrial and commercial manufacturing processes.

The Calgon Carbon facility in Santa Fe Springs, CA reactivates carbon and as part of the process, ash is generated and injected back into the furnace. The current system blew the ash back into the furnace using steam and an eductor but did not work well due to rapid wear on the pneumatic conveying components. Calgon contacted KWS to find a solution to convert the existing process to a mechanical system using an injection screw conveyor.

Design Parameters

  1. Product Type: Ash
  2. Material Density: 3 Lbs. per Cubic Foot
  3. Conveyor System Capacity: 50 Cubic Feet per Hour
  4. Design Temperature: 1,600-Degrees F
  5. Design Pressure: -0.04-psig
KWS Screw Conveyor Injects Ash into Furnace

KWS Screw Conveyor Injects Ash into Furnace

Furnace Temperatures Range Up to 1,600-Degrees F

Furnace Temperatures Range Up to 1,600-Degrees F

KWS Advantages

Engineers from Calgon Carbon and KWS collaborated to design a high temperature screw conveyor to fit the eductor’s existing footprint without major modifications to the surrounding area. KWS provided 3D models and AutoCAD drawing to Calgon engineers to use for field measurements to ensure proper layout and fit-up before arrival of equipment on-site. In doing so, potential design issues were eliminated that could have proved costly in the field.

KWS Special Features

The new KWS injection screw conveyor needed to mate directly to the furnace and withstand elevated kiln temperatures up to 1,600-degrees F. KWS designed and manufactured the conveyor using 316 and 304 stainless steel to withstand the high temperature during the conveying process.

The KWS drive pedestal protects the gear reducer and motor from heat and shock loads. Since the gear reducer and motor could only withstand 210-degrees F of constant heat before failures would begin to occur, KWS located the gear reducer and motor several feet away from the heat source. The KWS drive pedestal allows the gear reducer and motor to operate at ambient temperature.

Most notably, the injection screw conveyor utilized a KWS custom-designed 316 stainless steel hanger bearing with Stellite bearing inserts and coupling shaft with Stellite sleeves. Stellite provides excellent wear resistance and can withstand extreme temperatures. KWS incorporated a cantilevered screw section at the discharge end to create additional space between the hanger bearing assembly and heat from the furnace.

Testimonial

"The KWS screw conveyor is running great and has been the reliable solution we were after."

Ryan Accetta, Process Engineer – Calgon Carbon Corporation

Cantilevered Screw Conveys Ash Directly into Furnace

Cantilevered Screw Conveys Ash Directly into Furnace

KWS Drive Pedestal Protects Gear Reducer and Motor from Heat and Shock Loads

KWS Drive Pedestal Protects Gear Reducer and Motor from Heat and Shock Loads

Activated Carbon

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