Rotary kiln

Opportunities must be taken! Rotary kiln technology enables environmentally friendly energy production by the combustion of various by-products and waste materials.

Rotary kiln technology

With rotary kiln technology, Werkstätten heating-systems GmbH provides future-proof answers to pressing questions facing agriculture, industry and local authorities today. We develop holistic thermal concepts with the rotary kiln for the independent and efficient recycling of material flows such as foliage, fermentation residues, seed stock or sewage sludge. Easy to use, self-cleaning and fully automatic, the combustion technology offers maximum efficiency in times of great political and economic pressure.

Under the umbrella of the Werkstätten Group, Werkstätten heating-systems GmbH participates in the combined experiences and competences. Our customers can rely on our professional planning and execution, our high level of ambition and our personal commitment. We provide comprehensive services and always think a little bit further ahead for each project. Rotary kiln technology also has great potential which must be exploited jointly with smaller and medium-sized local authorities, associations and businesses.

Rotary kilns at a glance:

  • Modular design and container solution offer flexibility in terms of location
  • Flexible PLC control for regulating the boiler and integrating upstream and downstream components
  • Oxygen and load-controlled automatic charging and combustion via dynamic PLC control system
  • PLC control with clear visualisation and the option of remote monitoring and manufacturer support
  • Water-cooled, rotating combustion zone with divided ventilation zones for supplying fuels with combustion air
  • Energetic use of a wide variety of biomasses
  • Slag-free combustion of the most difficult fuels
  • Very low CO content in the flue gas prevents caking in the heat exchanger
  • Almost stoichiometric combustion in innovative rotary kiln
  • High efficiency due to constant material circulation
  • Automatic ignition
  • Automatic ash removal

Rotary kilns at a glance:

  • Modular design and container solution offer flexibility in terms of location
  • Flexible PLC control for regulating the boiler and integrating upstream and downstream components
  • Oxygen and load-controlled automatic charging and combustion via dynamic PLC control system
  • PLC control with clear visualisation and the option of remote monitoring and manufacturer support
  • Water-cooled, rotating combustion zone with divided ventilation zones for supplying fuels with combustion air
  • Energetic use of a wide variety of biomasses
  • Slag-free combustion of the most difficult fuels
  • Very low CO content in the flue gas prevents caking in the heat exchanger
  • Almost stoichiometric combustion in innovative rotary kiln
  • High efficiency due to constant material circulation
  • Automatic ignition
  • Automatic ash removal
  • Rated heat output: 500 — 5.000 kW
  • Partial load: 150 — 1.500 kW
  • Approval according to 4th + 17th BlmSchV possible
  • Permissible water temperature: 105 °C
  • Permissible Thermal oil temperature: 400 °C
  • Steam, saturated steam + superheated steam

The user-friendly, self-cleaning and fully automatic combustion technology has an innovative, water-cooled rotary tube technology with a number of advantages:

  • Suitable for fuels with low ash melting point and high ash content
  • Combustion extends over the entire length of the rotating tube with a turbulent flame vortex
  • All boiler components exposed to wear and/or high heat loads are lined with refractory and wear-resistant concrete
  • In an insulated post-combustion chamber, the flue gases are completely burnt out before they enter the heat exchanger
  • Emission values according to the 4th and 17th BImSchV, depending on the fuel, are significantly undercut.
  • The powdery ash is low in carbon and free of slag; the nutrient salts it contains are available to plants and can be used as fertiliser Possible forms of energy are
  • hot water, steam and/or thermal oil

Examples of decentralised energy concepts

  • Digestate drying and incineration for nutrient concentration and mass reduction
  • Chicken manure utilisation for heat generation for stables and properties
  • Steam generation or thermal oil for industrial and drying plants by using industrial by-products
  • Sewage sludge drying and incineration

This combustion technology can use the following biofuels, for example, for energy with a high degree of efficiency and low emissions:

  • Landscape maintenance material, screening of woodchips, roadside greenery
  • Straw, coffee substitute, seed clippings, nut shells, cherry pits, coffee/cocoa residues
  • Digestate from biogas plants, leaves, horse manure, chicken manure

FAQ

What makes the new technology so special and sets it apart from other boilers?

The rotary kiln stands out from conventional boilers as, in addition to wood chips and wood pellets, even the most difficult fuels can be combusted without slagging and with good emission levels. With the fully automatic technology, it is also possible to energetically heat biogenic waste residues with a low ash melting point, a low calorific value or with a lot of minerality optimally as fuel. The plant allows the plant operator the flexibility of using low-cost and low-quality input materials.

How long is the delivery time?

The delivery time depends on the status of the pre-planning and the scope. In the case of detailed pre-planning and a “standard scope” (bunker system, rotary kiln, ash disposal, flue gas cleaning, chimney), the delivery time is approx. 6 months.

How much effort will I need to put in as the plant operator?

The flexibility in the choice of fuel, the low emissions and the high operational reliability are decisive criteria for the purchase of the rotary boiler. Furthermore, the low operating costs are crucial. Thanks to the fully automatic technology, the operator only has to ensure that the bunker is filled and the ash container emptied. For this purpose, he/she will receives an electronic message in order to be able to plan the filling and emptying in good time. The combustion process and the heat supply run fully automatically.

What are the maintenance requirements?

Since the rotary kiln has no movable grate elements or ash slides with high wear rates, in addition to one or two annual maintenance operations, no additional downtimes are required. The cleaning of the heat exchanger tubes takes place fully automatically by compressed air. Additional manual cleaning is not required.

Contact persons

Nils Moggert

Nils Moggert

+49 (0) 5921 / 8076 — 32
n.moggert@werkstaetten-gmbh.de

Alfred Moggert

Alfred Moggert

+49 (0) 5921 / 8076 — 0
a.moggert@werkstaetten-gmbh.de

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