KWS Manufacturing

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

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Plant Name and Location

R-Gen Systems, LLC
White Pines, CO

General Description of the Application

R-Gen Systems is a recycling company that uses pyrolysis, a proven and commercially viable technology to convert waste plastic and trash into fuel oil through a process that is scalable, flexible and environmentally positive. Pyrolysis is the thermochemical decomposition of material at elevated temperatures in the absence of oxygen. 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. R-Gen Systems partnered with KWS to help them design a mechanical conveying system for injecting waste sludge into the pyrolysis process and convert the waste to usable gases and liquids. The mechanical conveying system would be subjected to temperatures up to 1700-degrees F. KWS worked in tandem with R-Gen Systems to develop a solution to satisfy their unique needs.

Design Parameters of Application

  1. Product Type: Waste Sludge (sluggish, sticky, abrasive)
  2. Material Density: 55 Lbs. per Cubic Foot
  3. Conveyor System Capacity: 67 Cubic Feet per Hour
  4. Duty: 24 Hours per Day, 7 Days per Week

Advantages Provided by KWS

R-Gen Systems contacted KWS after trying unsuccessfully to work with several other equipment manufacturers. When a project requires highly engineered bulk material handling equipment for high temperature and abrasive environments, no one is more qualified than KWS. KWS has the largest staff of degreed engineers in the industry. R-Gen was impressed with KWS’ engineering qualifications and previous experience in the pyrolysis and biofuels industries. Since the pyrolysis process requires heating the product to extreme temperatures, KWS and R-Gen chose to design and construct the conveying system from high-nickel alloys such as Inconel 625 and Nitronic 50.

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 reduced the cost and timeline of the project. KWS engineers and design team worked hand-in-hand with R-Gen Systems to develop a workable solution to this difficult application. Utilizing the latest 3D modeling software, sharing information and working together in virtual on-line real-time design sessions, KWS was able to significantly reduce the normal engineering time required for a project as detailed and unique as this one. KWS also has manufacturing capabilities that are unique to the industry. All welders at KWS are AWS certified. The top-level welders are also ASME certified to weld carbon steel, stainless steel and high-nickel alloys such as Inconel 625 and Nitronic 50.

Special Features of KWS Design

With operating temperatures up to 1,700-degrees F, KWS chose to design and manufacture the equipment from Inconel 625 and Nitronic 50. These high-nickel alloys maintain high yield strengths at elevated temperatures and are also corrosion and abrasion resistant. The housings and spirals were constructed from dissimilar metals to prevent seizing and galling under these harsh conditions. Extended pedestal drive bases with special shaft couplings were required to keep the drive components away from the extreme heat. No fugitive air could leak into the process so the housings were constructed from pipe with Class 150 flanges at every connection point. Non-compressible Mica gaskets and purgeable flanged gland seals were selected to handle the high temperatures and eliminate leaks. The conveyors ran at very slow speeds to reduce abrasion. KWS Shaftless Screw Conveyors were the best option to convey the damp, abrasive and sluggish material as well as the char after the pyrolysis process. Hydraulic motors were utilized to provide high torque and allow the power source to be located in a safe area at ambient temperature.


"The KWS staff has been great to work with and their engineers have been second to none in response and quality of work."

Martin Redeker – Co-Founder and Owner, R-Gen Systems, LLC

Biosolids / Sludge

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