Failure Analysis and Thermo-Structural Design Simulation of a Cylindrical Dual-Chamber Solid Waste Incinerator

Abstract

The generation of municipal solid waste (MSW) is rapidly increasing. This has worsened environmental pollution and public health hazards, especially in places with poor waste management policies. This research employs finite element simulation techniques to investigate the thermo-structural response and failure behaviour of a cylindrical dual-chamber MSW incinerator. The study's objectives were to assess the structural stability and operational reliability of the system under various service situations. A three-dimensional computer-aided model of the incinerator was developed using CATIA CAD modelling. Finite Element simulations were used to analysed various operational fault conditions like over-heating, refractory deterioration, chamber deformation, cracking, corrosion, chimney blockage, seal leakage and ash accumulation. The main structural material was mild steel, with refractory linings used mainly to improve insulation and also to prevent the combustion chambers from high temperatures. The numerical analysis was performed with tetrahedral meshing and appropriate thermal boundary conditions. The simulation results showed that the combustion chambers and connecting duct had the highest temperature distribution, and the major thermal stresses were concentrated around the welded joints and support regions. During normal operation, the secondary chamber temperatures ranged from 995°C to 1050°C, and the maximum Von Mises stress ranged from 145 MPa to 180 MPa. The results indicated that repetitive thermal cycling, corrosion, inadequate airflow circulation and excessive heat loading increased the likelihood of deformation and structural collapse. The study showed that the cylindrical dual-chamber design had better heat distribution, lower stress concentration and better combustion performance when compared to the conventional rectangular incinerator.