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FLUIDFIRE thermal incineration with fluidized bed system


Fluidized bed systems for waste recycling

The decentralized recycling concept FLUIDFIRE K³ offers reliable thermal recycling of waste by means of fluidized bed incineration.

The compact thermal recycling plant FLUIDFIRE K³ treats waste of various types, grain sizes and strength levels and can be easily integrated into the existing site due to its small footprint. The smart process combination offers optional economic efficiency through the production of district heating, steam and electricity. The decentralized thermal recycling plant and controlled exhaust air treatment form the basis for sustainable resource recovery and a high, stable level of environmental friendliness.

Advantages of the fluidized bed system FLUIDFIRE K³ at a glance

Fuel flexibility enables a wide range of fuels and simultaneous use of different fuels

Cost-effective ash recycling and disposal through classification and removal of pollutants during and after the combustion process (= heating cyclone)

Competent service, in-house large-scale component production and decades of experience in plant engineering ensure long travel times and high availability. 

Compact system design with furnace integrated into the boiler saves valuable space for the waste processor

Low Nox exhaust gas values thanks to controlled combustion chamber temperature control, staged combustion and locally adapted asphyxiation system

Local waste recycling reduces transportation and reduces the footprint of waste incineration.

Lower nitrous oxide values (emissions) due to the cooling function after the burnout zone reduces emission costs.

No costs for CO2 certificates and reliable compliance with emission values in accordance with the 17th BImSchV and the BAT Directive.

By adding the P-XTRACT process, the plant availability of phosphorus can be maintained and a higher separation of pollutants can be achieved. This favours the popularity of phosphorus ash among fertilizer producers.

Through the sale of district heating, steam and electricity. (feasibility depends on the fuel supplied)

fluidized bed system for thermal waste incineration - 3D Model of WEHRLE FLUIDFIRE

Areas of application for FLUIDFIRE systems

The FLUIDFIRE K³ fluidized bed incinerators are not only suitable for use in classic waste management for the incineration of production waste, production sludge, substitute fuels and screen overflows with very different calorific values, but are also very well suited for use in the mono-incineration of municipal sewage sludge.

FLUIDFIRE K³ sludge – decentralized sewage sludge mono-incineration for phosphorus recovery

With the FLUIDFIRE fluidized bed system, sewage sludge is used to generate energy in a mono-combustion process and quality ash is produced from raw materials such as wood. Phosphorus made easier to use. The process is used to increase the quality ash content in particular. At the same time, pollution (e.g. from heavy metals) is significantly reduced. An increased concentration of phosphorus in the ash can facilitate the recovery of phosphorus.

Further information about the fluidized bed system FLUIDFIRE

  • FLUIDFIRE K³ sludge: WEHRLE's sewage sludge mono-incineration plants increase the quality of the phosphorus ash produced through targeted ash fractionation and enable sustainable phosphorus recovery with significantly reduced costs.
  •  FLUIDFIRE K³ industry: The smart and stable process control relieves the burden on regular plant operation, withstands process fluctuations and enables material recovery. Depending on the dimensions of the thermal recycling plant, the economic efficiency of the plant can be further increased by accepting external waste. 
  •  FLUIDFIRE K³ waste: The thermal waste recycling plant reliably treats mixed domestic waste and hazardous waste. Thanks to its compact design, the system only requires a small footprint and can be easily integrated into the existing site.

P-XTRACT® is an add-on for future K³ fluidized bed systems or can be retrofitted to existing systems. P-XTRACT® is a thermal process for recovering phosphorus from phosphorus-containing fuels such as sewage sludge. The addition of certain (earth) alkali additives to the combustion process reduces heavy metals and increases the availability of phosphorus to plants. Subsequently, a high-quality fertilizer can be produced as directly as possible from the ashes and applied regionally.

The fluidized bed system in standardized design is available from a thermal output of 1 MWth to approx. 10 MWth. In addition, individually planned systems of up to approx. 30 MWth can be realized with partners.

Depending on the size, the fluidized bed furnace offers a variable use of fuel grain sizes from pulverized to 300 mm edge length. This allows a wide range of fuels to be used. The high impurity tolerance is made possible by the open nozzle base with smooth air pockets and special ash discharge system.

The FLUIDFIRE system produces additional energy once its demand has been met. Depending on the mixing ratio and water content of the fuel, more or less surplus energy can be produced. This enables the plant operator to feed district heating, steam and electricity into the local grid as an energy producer.

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