Injection Screw for Renewable Energy

General Description

A renewable energy plant located in the southeast is a state-of-the-art facility focused on converting swine waste into usable renewable natural gas (RNG), renewable electricity, and biochar, which can be used as fertilizer. The facility captures methane generated from swine waste and processes it into pipeline-quality natural gas, helping reduce greenhouse gas emissions while providing a sustainable energy source. The plant initially has the potential to generate renewable energy sufficient to power more than 5,000 homes and businesses throughout eastern North Carolina and support Duke Energy in meeting its swine waste requirement under the Renewable Energy Portfolio Standard law in North Carolina.

KWS Injection Screw Meters Swine Manure to Reactor

Design Parameters

Product Type: Swine Waste
Material Density: 44 Lbs. per Cubic Foot
System Capacity: 75 Cubic Feet per Hour
Duty: 24 hours a day, 7 days a week

KWS Advantages

KWS understands the unique challenges associated with high-temperature, continuous-duty renewable energy applications. Handling pyrolyzed material requires specialized engineering to accommodate thermal expansion, prevent leakage of gases, and ensure long-term reliability under extreme operating conditions.

The KWS engineering team worked closely with the customer to design six heavy-duty pyrolysis injection screw conveyor systems capable of performing reliably in a high-temperature environment. From initial design through final commissioning support, KWS provided expert application guidance to ensure optimal equipment selection and integration into the overall plant process.

With over 30 years of experience in designing and manufacturing bulk material handling systems, KWS brings unmatched expertise to complex energy applications. All equipment was manufactured in our ISO 9001-certified facility in the United States, ensuring the highest standards of quality, precision, and durability. Our ability to meet demanding schedules and expedite production when required helped keep the project on track and aligned with the customer’s operational goals.

KWS Special Features

To ensure safe and reliable operation in a high-temperature pyrolysis environment, KWS incorporated several advanced design features into the injection screw conveyor system. The heart of the system is the KWS-designed pyrolysis injection screw. Engineered specifically for high-temperature service, the screw features heavy-duty construction to withstand thermal stresses and continuous operation. The flighting and pipe were designed to maintain structural integrity and consistent material flow, even under extreme thermal conditions.

A Stasskol high-temperature seal was provided at the drive shaft to prevent gas leakage while accommodating elevated temperatures. This specialized sealing solution is designed for severe service applications and provides reliable containment of process gases, enhancing both safety and environmental compliance.

To address thermal growth, KWS incorporated a thermal expansion base into the conveyor design. This engineered base allows the conveyor to expand and contract freely as temperatures fluctuate, preventing structural stress, misalignment, and premature component wear. By allowing controlled movement, the expansion base significantly increases equipment longevity and ensures proper alignment with upstream and downstream equipment.