Rotary kilns Both solid and liquid wastes are introduced into the rotary kiln, in which the temperature is typically above 1800°F.
Temperature is maintained at this level by using the heat content of the liquid wastes or by introducing supplemental fuels into the chamber, such as natural gas.
Liquid wastes generally are pumped into the kiln through nozzles, which atomize the liquids into fine droplets-as small as one microgram (one millionth of a gram)-for optimal combustion. Solid wastes may be fed into the kiln in bulk or in containers, using either a conveyer or a gravity feed system. The kiln slowly rotates so that the solid wastes are tumbled, to assure that they are exposed on all sides to the high temperature in the kiln, much as the rotation of a clothes dryer maximizes the exposure of the clothes to the hot air in the dryer. A large fan draws excess air (containing oxygen) into the system to increase combustion efficiency.

The flame and high temperature in the kiln cause the organic and some of the metal wastes to be converted from solids or liquids into hot gases. These hot gases pass into the afterburner. Any inorganic materials (metals, such as zinc or lead) that have not been converted into gases drop out as ash at the end of the kiln, into a container, for further management. (See "Residue Management," below).

Afterburner Atomized liquid wastes and/or supplemental fuel are injected into the afterburner, where temperatures are typically maintained at 2000°F. or higher. These atomized liquids and the hot gases entering the afterburner from the kiln are mixed with air and passed through the hot flame in the afterburner. The heat and flame break down the chemical bonds of the gaseous and atomized organic compounds into atoms. These atoms recombine with oxygen from the air in the chamber to form stable
compounds primarily composed of non-hazardous chemicals such as carbon dioxide and water (i.e., steam).

The gases exiting the secondary chamber are cooled and cleaned in the APCS. The APCS removes particulates (small solid matter) and the remaining hazardous constituents-such as metals which were not destroyed by the incineration process-down to levels established as safe by the regulations and the facility's permits. These levels are already more stringent than the risk standards established by the Clean Air Act of 1990 for future controls of emissions from manufacturing processes.

Controls and monitoring Operation within the key parameters of the combustion process are assured by systems of monitors and computer controls. These systems make automatic adjustments to key functions as necessary. For example, if temperatures begin to drop below desired levels, supplemental waste fuels are automatically injected. Conversely, if temperatures rise above the desired range, waste feeds are reduced.

All regulated incinerators have waste feed cut-offs (WFCOs) to assure protective operations. WFCOs automatically stop the feeding of waste into the incinerator if any of the key parameters even momentarily falls outside the narrow range of operating requirements.

There is also continuous monitoring and recording of key indicators, so that a permanent record is maintained, verifying operation of the incinerator within these parameters. Frequently, as many as twenty sCPCBrate parameters are monitored and recorded.

Rotary kilns Both solid and liquid wastes are introduced into the rotary kiln, in which the temperature is typically above 1800°F.

Temperature is maintained at this level by using the heat content of the liquid wastes or by introducing supplemental fuels into the chamber, such as natural gas.
Liquid wastes generally are pumped into the kiln through nozzles, which atomize the liquids into fine droplets-as small as one microgram (one millionth of a gram)-for optimal combustion. Solid wastes may be fed into the kiln in bulk or in containers, using either a conveyer or a gravity feed system.

The kiln slowly rotates so that the solid wastes are tumbled, to assure that they are exposed on all sides to the high temperature in the kiln, much as the rotation of a clothes dryer maximizes the exposure of the clothes to the hot air in the dryer. A large fan draws excess air (containing oxygen) into the system to increase combustion efficiency.

The flame and high temperature in the kiln cause the organic and some of the metal wastes to be converted from solids or liquids into hot gases. These hot gases pass into the afterburner. Any inorganic materials (metals, such as zinc or lead) that have not been converted into gases drop out as ash at the end of the kiln, into a container, for further management. (See "Residue Management," below).

The rotary kiln discharges an inorganic ash into a large container. The ash, and any residue from the APCS, is analyzed to assure that it does not contain any hazardous organic constituents above concentration levels specified in CPCB's regulations as safe for land disposal. These concentration levels are almost always less than one part per million for any organic hazardous constituent.

This inorganic residue is further treated by mixing it with chemical stabilizers to chemically bind the constituents. The chemically stabilized inorganic residue is analyzed to assure that the metals cannot leach out of the residue above the low levels specified in CPCB's rules. Finally, the stabilized and certified inorganic waste residue, which now meets all required treatment standards, is placed in a hazardous waste landfill meeting CPCB's Minimum Technology Requirements (MTR). MTR landfills have two liners, with a leachate collection system between the two liners. Groundwater monitoring is also provided, outside the landfill, to supplement the protection provided by the double-liner, leachate collection and leak detection systems of the MTR landfill itself.

The entire process at Toshi Group of Industries is driven tightly with testing and compliance of specifications, also called TQM – Total Quality Management. Quality is relative and quantitative but better managed during and while manufacturing rather than simply testing the end-products. We have instituted a TQM process where at every step (or stage) the sample and catalysts are immediately tested on the spot using portable/mobile test equipment or in our lab (in many cases, prior to performing next stage). Toshi Group of Industries employees are fully trained on the quality process and are empowered to make decisions on the spot based on test results along with the Lab/QA Management. The Lab/QA reports directly to the R&D Director and/or Chief Operating Officer and serves as an independent & responsible unit ensuring consistent quality all the time to our customers.

In addition to measurement equipment, Toshi Group of Industries has setup small mini laboratory size plants to conduct tests prior to going live on the plant. We do that to ensure process parameters, quantitative analysis of catalyst/solvent addition, thorough/complete distillation in vacuum columns.

R&D at Toshi Group of Industries is based on a matrix organization, perfectly adapted to the multidisciplinary projects conducted by Toshi Group of Industries. Our research & development includes following active areas:

Toshi Group of Industries actively conducts research in discovering newer ways to improve product extraction and quality with the following goals: