Incineration of Waste

Permanent Security for the Environment

Responsibility for the World

Effectivity for the Future

→ The logical Consequence for Ecology with Economy

→ Respencting the Demands of Human Ressources

I P H

The specialist – worldwide experienced since 30 years

How we do it...

We offer a state-of-art thermal treatment

system, complete with a soffisticated air

pollution control system. Since more than 30

years, permanently developed and improved to

more than nowadays standards. Working

today already for the future.

The Situation

Thermal Power Plant

With the worldwide growth of environmental awareness,

contaminated sites have become a major issue. Public

perceptions, new loss and regulations, ongoing monitoring

costs, health and safety risks, depressed land values and

potential ground water as well as seawater contamination

are causing to seek new solution for tomorrow.

With laws increasingly excluding landfill options, as well as

future liability associated with ecological deposits,

permanent treatment has become the one and only option

for going on with the enhancing amounts of waste

produced by industry, households and tourism.

Details and specification for the Thermal Oxidizer (rotary kiln),

for the treatment and disposal of waste. 16 Million cal/hour

It consists of a rotary Primary

Combustion Chamber, an air mixing

section, and a Secondary

• A controlled-air, dual atmosphere,

counter current rotary kiln furnace

(replacing conventional concurrent,

• Pyrolysis operation in the kiln

which limits the velocity of the

flue gas in the kiln, thus

Combustion Chamber (Figures 1 excess air kilns) that achieves minimizing the particulate carry

and 2). The waste material enters greater energy efficiency, higher over and loading on the air

the primary rotary pyrolysis unit throughput capacity, reduced flue gas

through a screw conveyer system. volume, and superior ash quality

cleaning system;

This unit operates at 700-800°C at compared to conventional • Operation of the kiln at lower

which temperature hydrocarbons

are vaporized and reacted under

incineration systems; temperatures compared to

conventional incinerators to

starved oxygen conditions to • Vertical, side-fired Secondary minimize the volatilization of

produce combustible gases. This Combustion Chamber (replacing heavy metals, which makes this

low operating temperature conventional horizontal chambers) unit one of the few to meet

minimizes heavy metal volatilization

and carry over. The gases then

enter through a cyclone section to

the afterburner where 50 to 100%

excess air is added and oxidation

takes place at 1000-1200°C. The

residence time for the gases in the

that is self-cleaning of entrained ash

and slag and capable of oxidizing the

range of chemical substances

produced in the kiln;

• An emergency relief system that

would safely release the hot flue

stringent new heavy metal

emission criterion;

• Versatility and flexibility, i.e., its

capability of destroying an array

of organic substances in forms

that range from lightly

oxidation sections is 1-2 seconds. gases when the waste thermal contaminated soils to

The residence time for the solid oxidizer system experiences a water

material is anticipated to be in the failure to the scrubber system;

range of 15-20 minutes depending

concentrated liquids and sludges;

• High capacity (65 million

on the availability of the organic

hydrocarbons for combustion and

• Central Control System (CCS) with

a battery powered Uninterruptible

Btu/hr), which when combined

with the waste destruction

through-put as adjusted by the Power Supply (UPS), and extensive technology enhances the

speed of kiln rotation. safety interlocks to ensure safe destruction of the waste in an

The Thermal Oxidizer is controlled

by a fully automated control system

which will keep process upsets to a

operation of the plant;

• Continuous Emissions Monitoring

efficient and cost effective

manner;

minimum. The kiln itself is system (CEM) made up of stack gas • A gas cleaning system capable

operating under negative pressure probes, sample conditioning of removing very high loadings of

minimizing the possibility of gases

escaping from the system.

Mechanical seals are provided to

systems, gas analyzers, and

interface with the Central Control

System (CCS) to control the plant,

sub-micron

(characteristic

decontamination); the

particulate

of waste

further prevent such escape. The

gases would exit the afterburner

and enter the air pollution control

equipment from the top of the unit.

and produce correctly formatted data

for regulatory agencies

• Extensive system of process control

performance criteria for the gas

cleaning system are based on

stringent emission limitations that

currently exist in British

Specific design features of the

thermal oxidizer provide an

optimum system for incinerating

hydrocarbon type wastes. The

important features are:

• Modular construction and

transportability;

to automatically control system Columbia.

operating parameters within optimum

range and ensure complete

combustion of the waste material;

• CAM system interlock to the main

CCS to ensure uninterrupted

measurement of stack gases and

discontinuation of waste feeds if

emission levels exceed permit

condition limitations

DESCRIPTION

The following paragraphs provide a more detailed description of the Thermal Oxidizer system.

Process Flow Diagrams, design information and heat and mass balances will be provided

once the initial proposal is accepted.

Rotary Kiln (Primary Combustion Chamber)

To maximize the waste handling capacity, the kiln is operated in a controlled air mode. Infiltration of

ambient air is minimized by the use of special seals, and by air locks on the feed and ash discharge

chutes. Air infiltration into the kiln reacts with the hot fuel gases to form larger volumes of

combustion products thereby significantly increasing the size of all downstream equipment (which is

sized according to the volume of flue gas). Combustion air is controlled at the burner end (also the

ash discharge end) of the kiln to oxidize the auxiliary fuel and a limited quantity of waste

hydrocarbons to generate the required temperatures. Fuel for the burners is natural gas, but diesel

or waste oil may be substituted. The proposed burners will be multi-fuel type and be capable of

handling waste oil, diesel fuel, and natural gas. It will be the client's responsibility to supply clean

pressurized fuel to the burners.

The organics vaporized from the waste feed form a low quality fuel gas that flows to the secondary

combustion module, where oxidation and destruction are completed in a high efficiency burner

system. The ash flows counter-current to the combustion gases in the kiln and passes through a

"soaking zone" where high temperatures and radiant heat from the burner flame and the controlled

introduction of air completes the removal and destruction of any residual organics. The temperature

within the rotary kiln is maintained between 600-1000°C depending on the chemical composition of

the waste and its availability for combustion.

Secondary Combustion Chamber

The kiln exit gases are directed to the

Secondary Combustion Chamber (SCC).

The SCC module consists of a high

efficiency side-fired burner system, a

vertically oriented retention chamber, and

a bottom ash removal conveyer. The

complete destruction of hazardous

wastes is achieved in this unit by

maintaining the combustion gas at

elevated temperatures (1000-1200°C) for

residence times of 1 to 2 seconds.

Controlled secondary air injection is used

to closely control combustion and to

minimize NOxformation. Heat is provided

by oxidizing the low quality fuel gas from the kiln and/or by firing natural gas or

liquid fuel in the SCC.

The specially designed combustion gas

inlet manifold, side-fired burner, and

bottom ash exit prevent the solids

Gas Cleaning Module

The gas cleaning module is a uniquely designed

dry scrubber system consisting of a gas quench

section, two high temperature bag-filter houses,

a variable speed ID fan, and a stack. The

cleaned exhaust gases are discharged through

the stack complete with a Continuous Emission

Monitoring (CEM) system. The key premise

used in selecting and integrating these

components was that the system had to have

high scrubbing efficiency, high on-stream

reliability, and low maintenance. The gas

cleaning module removes sub-micron particulate

from the quenched combustion gases.

The hot combustion gases from the SCC exit

directly into the air conditioning section where a

controlled quantity of water is sprayed to cool the

gases to a temperature typically about 150°C.

Spray nozzles in this section spray finely

atomized water provided by the water pump.

accumulation problems typically Dry activated lime is injected into the gas stream

associated with horizontal secondary

chambers, when solids are carried over

from processing waste in a kiln. Any

solids that are carried into the SCC will be

subjected to the high temperatures and

completely detoxified.

Ancillary Modules

A control building contains the Central

Control System (CCS), and the Motor

Control Centre. The CCS provides

centralized monitoring and control for the

Thermal Oxidizer.

The exhaust stack gases are continuously

analyzed by the CEM for oxygen, carbon

dioxide, and carbon monoxide. The CEM

consists of extractive sampling and

analysis systems, made up of a probe,

particulate filters, a sample cooler, and

analyzers. Corrected values from the CEM

are displayed in the CCS and are used for

control and shutdown of the waste feeds.

to react with acid gases in the flue gases. Two

bag houses with appropriate temperature

resistance are provided to remove the lime and

particulate matter from the flue gas stream.

Cleaned combustion gases that exit the filter

houses are discharged to the atmosphere

through an ID fan and stack. The ID fan's

variable inlet vane is used for start-up and for

optimizing the fan's energy consumption for the

actual gas handling requirements of each waste

type.

Thermal oxidizer Dimensions

The following are normal dimensions:

Primary Combustion Chamber Outside Diameter

Inside Diameter Length

Material of Construction: Refractory Lined Carbon Steel

8'‐6„ 7'‐0"

Secondary Combustion Chamber:

Material of Construction:

Quench Tower:

Material of Construction:

Bag Houses:

Material of Construction:

Stack:

Material of Construction:

Outside Diameter

Inside Diameter Length Refractory Lined Carbon Steel

Outside Diameter

Inside Diameter Length Refractory Lined Carbon Steel

Dimensions

Height A‐36 Steel

Diameter

Length Carbon Steel

10'‐0“

8'‐6“

45'‐0"

12'‐0“ 11'‐4“ 50'‐0"

12'‐0" x 12‐0“ 38'‐6"

4'‐0“

60'‐0"

Auxiliary Fuel Burners: The auxiliary fuel burners are natural gas or diesel fuel burners with

independent pilot and external fans. The primary burner is Maxon Multifire with an output of 4 million cal/hr and the secondary burner is Maxon Kinemax C with an output of 2 million cal/hr.

Operating Parameters

Parameter

Feed rate

Organic Content (up to 0.5% sulphur)

Moisture

Inert material

Temperature

Rotary Kiln (Feed End)

Rotary Kiln (Burner End)

Afterburner

Stack

Design

Up to 20

1,500

3,500

15,000

600 700

800 1000

1000 1200

150 200

Unit

tons/hr

Kgs/hr

Kgs/hr

Kgs/hr

C

C

C

C

Electrical Components

Motor Control Centre to include:

• Two (2) only banks of electrical panels housing all necessary electrical switch gears, variable

frequency drives (for the waste feed auger, lime metering auger and kiln drive), incoming service

switch, low voltage (220 volts) transformer, low voltage distribution panel, control voltage (24 volts)

transformer;

• One (1) only current transformer to measure current draw of the ID fan motor and digital read out

displayed on the ID fan motor panel door;

Electrical Motors to Include:

The motors described herein are

TEFC, class F, 1.15 service factor,

standard efficiency electric motors

suitable for operation with 380/3/60

power supply applied from the motor

control centre.

Modulating Motor List to Include:

The Modulating motors described

herein are, modulating motors

adapted for operation with 120/1/60

power supplied from the motor

control centre.

COMPONENT

Induced draft fan drive

Air compressor drives

Kiln drive

Waste feed auger drive

Primary combustion fan drive

Secondary combustion fan drive

Primary air fan drive

Secondary air fan drive

Gas conditioning chamber air lock drive

Fabric filter air lock drives

Water pump drives

Main ash conveyor drive

Fabric filter ash storage auger drive

Secondary combustion chamber auger drive

Gas conditioning chamber auger drive

COMPONENT

Primary Burner Actuator (Modulating) Motor

Primary Air Actuator (Modulating) Motor

Secondary Burner Actuator (Modulating) Motor

Secondary Air Actuator (Modulating) Motor

ID Fan VIV Modulating Motor

QTY

1

2

1

1

1

1

1

1

1

2

2

1

1

1

1

QTY

1

1

1

1

1

MOTOR

SIZE

250 KW

56 KW

16 KW

10 KW

26 KW

35 KW

11 KW

22 KW

.75 KW

.75 KW

7.5 KW

5 KW

2.25 KW

2.25 KW

2.25 KW

MOTOR

24 VOLTS AC

24 VOLTS AC

24 VOLTS AC

24 VOLTS AC

220 / 1 / 50

Control System

A totally integrated control system based

on a Siemens master Programmable Logic

Controller (PLC), will be provided for the

optimum monitoring, interlocking and

automatic control of the entire system. The

PLC constantly monitors position, on/off

status, temperature, pressure, level, flow,

and alarm signals from the various

Control Console

• One (1) only free standing control console

complete with Siemens PLC, computer, keyboard,

19" video screen, Allan-Bradley motor starter push

buttons and an Emergency Shut-down Switch.

• The primary and secondary burner flame

safeguard units based on the Honeywell series

digital unit with continuous readout of flame

subsystems and field devices intensity. The system is fully engineered and hard

approximately every 30 milli-seconds.

Upon reading the proper signals the PLC

starts the next sequence of operation or

maintains the proper operation of the

system through the appropriate PID control

loops.

The main control panel is designed for the

operator to easily check the status of the

entire system. The main control panel

contains push buttons, selector switches,

status indicators, temperature and

pressure indicators on the main video

panel.

Instrumentation

wired according to the regulatory requirements and

includes main fuel and pilot interlocks, combustion

fan air pressure interlocks, and UV flame scanner

interlocks. The flame safeguard units are mounted

in the control console.

• Continuous Emission Monitoring (CEM) unit for the

measurement of CO, Oxygen, and CO2. The CEM

unit includes the gas conditioning unit and the analyser as a stand alone unit.

Meters and instrumentation for monitoring the thermal plant operating and control parameters;

Temperature Sensors:

Temperature Control Loops:

TI – 1

TI – 2

TI – 3

TI – 4

TI – 5

TI – 6

PCC (Burner End)

PCC (Feed End)

SCC (Burner End)

SCC (Exit end)

Fabric Filter Entrance

Stack Temperature

TIC – 1

TIC – 2

TIC – 3

TIC – 4

TIC – 5

TIC – 6

Main Burner (PCC Burner end temperature)

Primary Air (PCC Feed end temperature)

Waste Feed (SCC temperature)

Secondary Burner (SCC temperature)

Secondary Air (SCC temperature)

Quench Water (GCC exit temperature)

Flue Gas Analyser:

S‐1 Oxygen

Pressure Control Loops:

S‐2

S‐3

CO

CO2

PIC‐1

PIC‐2

I.D. Fan (PCC Burner end pressure)

Bag filter blow back (Filter pressure differential)

Pressure Indicators:

PI‐1

PI‐2

SCC Pressure Differential

Fabric Filter Pressure Differential

System Interlocks

There are several safety and operational interlocks of the kiln and burner systems:

- Burner interlock: This interlock is activated to shut off the fuel flow to the burners in

case of the following;

• failure of combustion air,

• absence of fuel pressure, and

• flame failure.

-Interlock 1: This interlock is activated to shut off the waste stream to the thermal

oxidizer in case of the following;

• Kiln high temperature,

• Kiln low temperature,

• After-burner high temperature,

• After-burner low temperature,

• Low O2level, (under 5%), and

• High CO level, (over 100 ppm).

-Interlock 2: This interlock is activated to shut off the waste stream and open the

emergency door on top of the after-burner in case of the following;

• Quench water failure,

• Main thermal oxidizer fan failure, and

• High quench exit temperature.

-Interlock 3: This interlock is activated to shut off the waste stream to the thermal

oxidizer in case of the following;

• Low O2level, (under 5%).

Equipment Supply

The Thermal Oxidizer consists of:

I. Primary Combustion Chamber (rotary kiln) to include:

• 8'-6" O.D. x 40'-0" long refractory lined steel drum complete with refractory lining and

lifters, driven by a chain mechanism, and supported on heavy duty trunnions;

• Endboxes and mechanical seals to enclose both ends of the drum;

• Waste feed hopper with the capacity of one cubic yard, and 16"f screw feed

mechanism including the drive gear box;

• Primary air fan (5,000 m3/hr) and multi-fuel burner (4 MM cal);

• Sub-frame and end platform.

II. Secondary Combustion Chamber to include:

• 10'-0" diameter x 50 foot long vertical free standing vessel with conical bottom

sections for particulate and slag removal;

• Venturi transition section from the kiln to the afterburner including air inlet ports and nozzles;

• Secondary air fan (24,000 m3/hr) and burner (4 MM Btu);

• Emergency Dump Cap for bypassing scrubber systems during emergency conditions;

• Cross over ducting complete with refractory lining;

• Necessary ladders and access platforms.

III. Air Conditioning Chamber and Reactor to include:

• 12'-0" diameter x 50 ft long vertical free standing vessel complete with partial

refractory lining, water atomization nozzles, and lime and recycle introduction nozzles;

• Necessary ladders and access platforms.

IV. Bag Houses to include:

• Two free standing pulse type baghouses, each sized for 60% of the flow with air to cloth ratio

of 4.2:1. Baghouse access is through roof plenum. The baghouse is insulated with hopper wall

heaters;

• One set of filter bags made of woven fibreglass with teflon coating;

• Ladder and access platform for the pulse and solenoid valves and access to the roof door of the

baghouse.

V. I.D. Fan and Motor to include:

• Backward inclined fan and motor sized for 80,000 m3/hr at 150°C and 23 inch W.G. static

pressure. Fan motor is 250 HP TEFC 3/50/560;

• Inlet box and damper, etc.

VI. Stack to include:

• 4'-0" diameter x 60 ft high free standing stack complete with vortex breakers;

• Ladder and access platform for emission monitoring;

VII. Control Room, MCC, and instrumentation to include:

• All necessary electrical switch gear in the motor control centre including the varidrives for

the auger and kiln drives;

• All necessary meters and instrumentation for the thermal oxidizer control centre, including

the console, mimic diagram, annunciation panel, PID logic controllers, and chart recorders,

etc.;

• The control room to consist of a 8'-6" x 20'-0" trailer with the MCC and control console

prewired and installed.

VIII. Miscellaneous items to include:

• Ductwork from the ACC to the baghouses and from the baghouse to the ID fan and stack;

• All refractory linings for the appropriate sections.

The company will shop install the thermal oxidizer refractories. All necessary pipe, fittings,

wire, conduit, brackets, and burners required to complete the installation will be installed in our

shop in Vancouver. Protruding items will be shipped loose for site installation. Site installation

will be conducted by the Client.

Drawing and Instruction Manuals

The company will supply the purchaser with three (3) complete sets of operating and instructions

manuals with spare parts lists, etc. at the time of shipment of the thermal oxidizer.

IPH GmbH Pretschgasse 12

A-1110 Wien

Tel: 0043 664 3389195

Fax: 0043 1 768 31 42

Email: iph-gmbh@aon.at

Web: www.environment-waste.com