Large Unit Incinerator to handle an average waste production of 2,000kg/day

a.    be based on common, well-proven and clean technology – both as a complete unit and in terms of its individual components

be suitable for modular application including shipping and transport

 

b.    be very robust, sturdy and capable of installation in remote locations subject to severe conditions

d. flexible and mobile to allow for on-site treatment/operation – must be containerized.

e.    generate residual incinerator ash conforming to <10% by volume and <25% by weight of the waste incinerated

f.     achieve a Total Organic Carbon (TOC) content in the slag and bottom ashes of less than 3%,

g.    be user friendly, easy to use and operable by trained but mostly unskilled operators,

h.    include clearly readable system operation panels;

i.      include an operator’s manual (in English);

j.      require minimal pre-processing i.e. there shall be no/very limited need for prior sorting, crushing or shredding (unless stated otherwise in the SOR),

k.    be capable of handling mixed solid waste streams and incinerable hazardous wastes as indicated below,

l.      can accommodate large variations in waste composition and calorific value,

m.  allow for batch loading,

n.    incorporate an Air Pollution Control System suitable for basic emission control,

o.    have a thermal efficiency of not less than 85%

p.    primary and secondary chambers shall preferably have rounded inside corners to avoid the formation of dead zones or cold pockets,

q.    have very low levels of unburned material in the slag,

r.     include a supplement fuel source and storage unit (e.g., diesel tank),

s.     be economical to operate and maintain and have a low and efficient fuel consumption; proposals shall include the fuel consumption at the rated capacity

 

 

2.4.2 Incinerator unit completeness, size and efficiency

 

The proposed incinerator units must be complete and include all of the key features listed below and all of the associated support services and interconnections.

 

The forecasted feedstock loads, and daily loading rates are generally summarized as:

·        Mixed general and incinerable hazardous wastes with a wide range of calorific values and densities. The majority of the wastes will be of a general municipal nature, with up to 20% by volume of medical wastes and up to 5% by volume of hazardous wastes. The content of the combustible matter will be above 60% and moisture content below 30%. The wastes will be crudely pre-mixed by selective loading from different waste streams prior to incinerator loading.

·        Wastes either small enough to fit within a 60-litre waste sack or broken up or shredded to less than 300mm in size.

·        Operation on a daytime shift basis, 5 days per week.

·        An 8 hour daily operating cycle of ash removal, pre-heat and burn with continuous loading. The automated burn completion and cool down cycle will take place overnight.

The incinerators shall be capable of using AC power and diesel oil, both. If no AC power, can use local power generator

 

·        Should also consider provision for meeting international emission standards.

 

The incinerators to be procured will conform the following size capabilities to manage the forecast feedstock loads and daily loading rates and must be efficient in its demand for fuel and other utilities;

 

Large Unit – to handle an average waste production of 2,000kg/day and meet the capacity as herein below indicated:

Minimum load capacity: 2,000 kg

 

·        Maximum load capacity : 3500 kg

·        Nominal burning rate: 250 – 300 kg/hr (= 2,000 – 2,400 kg per 8hour day)

 

 

Items/Model	TS300
Picture
Principle	Waste Incineration Treatment
Door Opening	Front
Burn Rate	Average 300 kg/hour
Feed Capacity	Average 2400 kg/day
Control Mode	PLC(Programmable Logic Controller Incinerator)
Combustion Chamber	1800L
Internal Dimensions	150x120x100cm
Secondary Chamber	900L
Smoke Filter Chamber	Yes
Feed Mode/Ash Remove Mode	Manual
Voltage	380V 3P 50/60Hz
Power	2.5Kw
Oil Consumption (kg/hour)	Average 38.0(Full ignition)
Gas Consumption (m3/hour)	***
Temperature Monitor	4 Digital Display
Temperature Protection	Yes
Oil Tank	300L
Feed Door	60x50cm
Chimney	12.0 Meter
Chimney Type	Stainless Steel
1st. Chamber Temperature	800℃–-1000℃
2nd. Chamber Temperature	1000℃-1200℃
Residency Time	2.0 Sec.
Gross Weight	Around 11,000kg(Inc.Container)
External Dimensions	Around 300x160x220cm(Inside Main Body)

 

2.4.4  Containerization

 

The proposed incinerators shall be built into standard 20ft ISO containers or alternatively built into similar footprint complete with ISO load handling facilities (hooks, eyelets, etc). The number of containers/container sized modules required for each unit is at the discretion of the Contractor.

Each container shall be painted white with the “UN” logo painted in black.  We will provide the precise specifications for painting prior to contract award.

 

 

 

2.4.5 Spare parts, consumables and maintenance service

 

The proposed incinerator system shall include all of the necessary spare parts, PPE, and consumables required for 1 year of operation. The Contractor is to provide a proposed a list of spare parts for the incinerators.

Mandatory spare parts, for all the incinerators as a minimum, are as follows:

·        thermocouple

·        temperature gauge

·        fire rope

·        burner

·        induction air fan

·        digital temperature display panel

 

 

Optional maintenance service: The contractor shall deploy an expert, fully equipped with all required tools and equipment, to us to provide maintenance service of the installed waste incinerators, including all the parts and components (e.g., burners, ignitors, temperature gauges) when required. This will be at additional cost to this contract. This should be included in the technical support proposal and will be evaluated separately.

 

2.4.6 Corrosion resistance and weather proofing

 

The Incinerator units shall be designed to last in operation in a harsh arid 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 as well as extremely high temperatures and harsh winds.

 

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 (minimum 15 mm) and painted externally with heat resistant aluminium 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.

2.4.7       Combustion control system

 

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 in order 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.

 

 

 

 

2.4.8         Primary combustion chamber

 

The incinerator must have two discrete combustion chambers. 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. 

2.4.9       Secondary combustion chamber

 

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. total 2 sets burner for 1 set incinerator

·        A digital thermometer with connected to an electronic datalogger. The thermometer shall be located on the chamber wall away from the fuel burner.

 

 

2.4.10  Exhaust and stack

 

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 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.

 

 

 

 

2.4.11  Electrical supply, generation and wiring

 

The waste incinerators shall be designed for the following electricity supply:

   —380V ±10%, 50-60HZ

 

 

The primary power supply shall be a diesel electric generator. The secondary power supply shall be a plug for connection to an externally supplied power source, such as the local grid or a compound scale mini-grid.  Power will be provided by us.

 

All electrical connections attached with the incinerator and other machinery should be provided with suitable and necessary safety devices and be protected by steel conduits, cable trays, and supports.

 

 

The manufacturer should permanently mark on the incinerator indicating: (i) manufacturer’s name or trademark (ii) style, type, model or, date of manufacture of the incinerator (iii) capacity in terms of net designed heat release in heat units per timed period (i.e., British Thermal Units per hour, mega joules per hour, kilocalories per hour).