The Incinerator units shall be designed to last in operation in a tropical environment for a minimum period of 10 years if the specified maintenance schedule is followed. All metal surfaces (except combustion chamber internal fittings) shall be either galvanized, enameled, painted or otherwise treated against atmospheric and process induced corrosion
The incinerator combustion chamber(s) should be designed for easy maintenance of all internal parts including the refractory and insulation. Materials used in the individual parts of the incinerator shall be heat resistance and also be protected against oxidation, corrosion, etc.
The incinerator shell shall be made of mild steel with an adequate thickness for small units of between 3-6mm and larger units 5-10 mm depending on the construction part and painted externally with heat resistant aluminum paint suitable to withstand 250° C. The outside surface temperature of the incinerator casing should not exceed 50° C above ambient temperature and shall include a safety mesh around all hot surfaces. Cold face refractory lining of calcium silicate or superior material, minimum thickness 100 mm.
The incinerator units shall include a temperature based electronic combustion control system that utilizes temperature and other data to inform automated or programmed cycling through the standard burn cycle: pre-heat, burn with waste addition, burn completion, cool-down. The system shall be capable of varying auxiliary fuel and air supply in both combustion chambers to achieve optimum combustion conditions. As far as practicable, the incinerator shall be of a plug and play type for ease of installation and commissioning in remote locations.
“The control system shall have a separate push button-based work station, which shall be located adjacent to the loading bay and protected from weather and impact damage. The system shall allow for rapid and straightforward intervention by the operator if the automatic system is not achieving the desired results during a burn cycle.
”
The control system shall include an electronic performance monitoring and logging system. The system shall be capable of monitoring and logging chamber temperatures at regular intervals (not less than once per minute, with the capacity to vary the logging frequency). The system shall include the capacity to download the performance data by USB connection.
All the measuring devices attached with the incinerator should have digital display and should have provision of connecting to the recording system, which should include fuel meter and separate energy meter.
The temperature shall be determined against the inside wall of the combustion chambers. An audible and visible alarm shall be installed to warn the operator when the secondary temperature drops to below the required temperature.
The primary chamber must meet or exceed the following criteria:
“• Heavy steel construction.
• Fixed hearth geometry and starved air gasification operational mode.
• Hot face refractory concrete-ceramic suitable for thermal shock up to 1400 Celsius and abrasion. Minimum thickness 150mm.
• Cold face refractory lining of calcium silicate or superior material, minimum thickness 100mm.
• Refractory lining of all the ducts shall be done with refractory castings. Superior quality ceramic wool shall be used at all hot duct flanges and expansion joints.
• Multiple electric ignition fuel burners designed to use automotive diesel fuel.
• Flame of the primary burner shall be oriented towards the center of the unit which does not impinge directly on the refractory floor or wall. The secondary burner shall be positioned in such a way that the flue gas passes through the flame.
• The unit shall prevent leakage of the hot flue gas and any backfire.
• An electrically powered fan forced air supply, with the capacity for variation by the operator.
• Digital thermometers connected to electronic dataloggers. The thermometers shall be located on the chamber walls away from the fuel burner.
• A differential air pressure gauge connected to an electronic datalogger
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The secondary chamber must comply with the following minimum criteria:
“• Heavy steel construction
• An excess air and high temperature operational mode.
• Sufficient size and appropriate geometry to achieve a gas temperature of at least 1000 Celsius for a retention time of at least 2 seconds when pre-heated and correctly operated.
• Sufficient forced air inflow and airflow and fuel supply controls to ensure an exhaust gas oxygen content range of 6-12% at all times.
• Hot face refractory concrete-ceramic suitable for thermal shock up to 1400 Celsius and abrasion. Minimum thickness 150mm.
• Cold face refractory lining of calcium silicate or superior material, minimum thickness 100mm.
• Refractory lining of all the ducts shall be done with refractory castings. Superior quality ceramic wool shall be used at all hot duct flanges and expansion joints
• An electrically powered fan forced air supply, with the capacity for variation by the operator.
• One or more fuel burners designed to use diesel fuel type 2 (vehicle standard) equipped with a spark igniter.
• A digital thermometer with connected to an electronic datalogger. The thermometer shall be located on the chamber wall away from the fuel burner.
”
A heat exchanger to pre-heat air destined for the primary chamber is not compulsory but recommended.
The combustion air systems and fans shall be designed to ensure high combustion efficiency and avoid a reducing (corrosive) atmosphere, incomplete burnout of the flue gases and related problems. It should also be possible to heat the primary air from 10°C to approximately 145°C, depending on the waste composition and moisture content.
“The incinerator shall be designed and equipped to be installed, commissioned and operated in such a way as to prevent emissions into the air giving rise to significant ground-level air pollution; in particular, exhaust gases shall be discharged in a controlled fashion by means of a stack the height of which is calculated in such a way as to safeguard human health and the environment.
All incinerators shall meet the following emission and operating standards:
• Combustion efficiency (C.E.) shall be at least 99.0%
• The combustion efficiency shall be computed as follows:
o C.E = (CO2 X 100) / (%CO2 +%CO)
Suitably designed pollution control devices such as scrubbers, filters or electrostatic precipitators, shall be installed/retrofitted with the incinerator to achieve emission limits.”
“Each unit shall include a complete vertical exhaust and stack system, including the following features:
• Steel construction.
• Refractory lining in the lower section.
• The exit height of the stack shall be not less than a range of 3-12 metres above ground level depending on the capacity of the incinerator unit.
• The diameter of the stack shall be selected by the Contractor to deliver an exhaust exit velocity of not less than 10 metres per second vertically upwards when at full scale operation.
• An emission stack sampling port shall be included immediately above the secondary chamber.
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Controlled hygienic, mechanical or automatic feeding methods must not negatively influence the air supply and temperature in the primary and secondary chambers of the incinerator.
“Each unit shall include a diesel fuel storage tank of sufficient capacity to enable operation of the unit for 5 working days of 10 hours each.
• The unit shall include a pumping system and lines to supply the burners from the tank and the diesel-electric generator. The pumping system will have two pumps in parallel for redundancy.
• The supply lines will be fabricated from steel tubing and adequately protected and supported against damage during operations and include shutoff valves for each line.
• The unit shall be equipped with a fuel meter.
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| Items/Model | TS10(PLC) | TS20(PLC) | TS30(PLC) | TS50(PLC) | |
| Burn Rate (Average) | 10 kg/hour | 20 kg/hour | 30 kg/hour | 50 kg/hour | |
| Control Mode | PLC Auto. | PLC Auto. | PLC Auto. | PLC Auto. | |
| Combustion Chamber | 100L | 210L | 330L | 560L | |
| Internal Dimensions | 50x50x40cm | 65x65x50cm | 75x75x60cm | 100x80x70cm | |
| Secondary Chamber | 50L | 110L | 180L | 280L | |
| Smoke Filter Chamber | Dry Scrubber | Dry Scrubber | Dry Scrubber | Dry Scrubber | |
| Feed Mode | Manual | Manual | Manual | Manual | |
| Voltage | 220V | 220V | 220V | 220V | |
| Power | 0.75Kw | 0.83Kw | 0.99Kw | 1.2Kw | |
| Diesel Oil Consumption (kg/hour) | Ave.8.4 | Ave.10.9 | Ave.13.3 | Ave.16.9 | |
| Natural Gas Consumption (m3n/hour) | Ave.10.1 | Ave.13 | Ave.16 | Ave.20.2 | |
| Temperature Monitor | Yes | Yes | Yes | Yes | |
| Temperature Protection | Yes | Yes | Yes | Yes | |
| Items/Model | TS100(PLC) | TS150(PLC) | TS300(PLC) | TS500(PLC) | |
| Burn Rate (Average) | 100 kg/hour | 150 kg/hour | 300 kg/hour | 500 kg/hour | |
| Control Mode | PLC Auto. | PLC Auto. | PLC Auto. | PLC Auto. | |
| Combustion Chamber | 1200L | 1500L | 2000L | 3000L | |
| Internal Dimensions | 120x100x100cm | 150x100x100cm | 170x120x100cm | 210x120x120cm | |
| Secondary Chamber | 600L | 750L | 1000L | 1500L | |
| Smoke Filter Chamber | Dry Scrubber | Dry Scrubber | Dry Scrubber | Dry Scrubber | |
| Feed Mode | Manual | Manual | Manual | Manual | |
| Voltage | 220V | 220V | 220V | 220V | |
| Power | 1.38Kw | 1.69Kw | 2.57Kw | 4.88Kw | |
| Diesel Oil Consumption (kg/hour) | Ave.20.4 | Ave.24.2 | Ave.33 | Ave.44 | |
| Natural Gas Consumption (m3n/hour) | Ave.24.5 | Ave.29 | Ave.39.6 | Ave.52.8 | |
| Temperature Monitor | Yes | Yes | Yes | Yes | |
| Temperature Protection | Yes | Yes | Yes | Yes | |
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