Technical Spesification for Incenerator Boiler

PROJECT
WASTE TO CHEMICAL

TECHNICAL SPECIFICATION
DOCUMENT

SPECIFICATION FOR INCENERATOR BOILER

Doc. No. : 001-SPEC-WTC -Rev0

0 26 Oct 2023 ALL Issued for Technical Proposal

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 Technical Spesification for Incenerator Boiler

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INCENERATOR BOILER
1. Fuel Analysis (Assumed)

2. Incenerator Boiler Data sheet

 Number of Boiler : 1 (One)
 Superheater Outlet Pressure : 40 BarA
 Maximum Continuous Rating Per Boiler : 95,000 Kg/hr (Net)
 Outlet Steam Temperature : 400 oC +/- 5 oC (Superheated)
 Fuel Composition : 100% RDF
 Exhaust Gas Temperature : 200 oC
 Grate Type : Reciprocating with 3 Zone ( Drying,
Pyrolysis and burn out)
 Boiler Efficiency Based on LHV : 85,38 %
 Boiler Efficiency Based on GCV : 76,92 %
 Fuel Consumption : +- 553 TPD RDF
 Feed Water Inlet Deaeator : 30 oC
 Condensate Inlet Deaerator : 60 oC
 Feed Water Outlet Deaeator : 105 oC

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3. MSW /RDF Combustion

Grate incinerators are widely applied for the incineration of mixed municipal wastes,
particularly low calorific (LCV) waste. The scheme of MSW combustion in a Grate
furnace in an idealized scheme is shown in Figure 2.2b. The waste is slowly and
continuously propelled through the combustion chamber by a mechanically actuated
grate.
The waste on the grate moves through different temperature zones as it procedes, and
its thermal destruction occurs through subprocesses: drying, volatilization (pyrolysis and
gasification), combustion and burnout of the residue. These processes may be
superimposed on each other because of mostly insufficient mixing of the waste bed
moving on the grates. It is preferable to have the waste spread out evenly to maximize
combustion. Hence, the grate systems are designed to have speed adjustments. The
grate is sped up when highly combustible waste is fed, and slowed down when waste is
wet or lower heat-value.

Drying volatile content is evolved (hydrocarbons and water) at temperatures generally

between 100 and 300◦C. The drying zone, the front area of the grate, is

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important of the process since it influences the location of the combustion area on the
grate. The onset timing of the combustion, which depends on the temperature
distribution in the furnace, residence time of the flue gases, and the level of the
material stress
of the combustion bed grate, if too soon or too late, then the temperature distribution
in the furnace may not be homogeneous, affecting the drying process which is strictly
related to the heat transfer in the waste bed. As the waste bed on the grates is like a
quasi-homogeneous bulk streamed by a fluid, the heat transfer (and hence the drying)
is a function of the fluid velocity and its heat capacity, density, heat conductivity and
viscosity.
Pyrolysis and gasification (Volatilization) – As the waste gets dried, the
temperature of the waste increases, and at a particular value, the combustion under
deficit oxygen (λ < 1, i.e., gasification) starts. In a shortwhile pyrolysis starts occurring
under no oxygen when the higher hydrocarbons, CxHyOz, are cracked into gaseous
species such as CH4, CO and H2 at high temperatures.
Therefore, the primary airflow through the waste bed is kept below stoichiometric
levels. This is the area of the grate with greatest carbon conversion. The energy for the
pyrolysis is supplied by the high temperature reactions between oxygen and some of
the
volatile hydrocarbons and solid components. Now, a mixture of gasified hydrocarbons,
water from the oxygen-hydrogen reaction and the remaining nitrogen leave the waste
bed and undergoes homogeneous secondary combustion above the waste bed.
The final composition of the pyrolysis gases and the volatilization
ratio depend on the composition and temperature of the waste, and the residence time
of the hot gas in the waste bed. After volatilization, the residual carbon called char
starts combusting through a series of heterogeneous reactions followed by ash burnout
at high temperatures. The complete process can best be explained as follows: the fuel
(waste) forms a bed on top of the grate, and the primary combustion air is injected
through the multiple

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inlets or ‘plenums’ in the grate by a forced-draft fan. The primary air supply must
be adequate to cool the grate, and to sustain the combustion.
Normally, the former quantity is the larger. By partly cooling the grate by water
(water-cooled grate), it is Combustion technology 27 possible to adjust the primary air
supply precisely to the flow needed for the primary combustion process only. The
primary air is generally taken from the storage pit to bring down the air pressure and
eliminate odour emissions from the storage area. At this point, the waste is burned in
sub-stoichiometric conditions, where the
available oxygen is about 30 to 80% of the amount required for complete combustion,
which results in the formation of pyrolysis gases.
These gases are combined with excess air (secondary air) introduced into the
combustion chamber through rows of high pressure-nozzles located in the side-walls of
the chamber above the waste bed. The secondary air flow facilitates complete
combustion of the flue gases by introducing turbulence for better mixing and by
ensuring surplus of oxygen. Optimizing the
direction of the secondary air jets also assists turbulence. The secondary air can be
fresh air, or alternately, the flue gas can be mixed with air and recirculated.
Approximately 10–20% by volume of the usually cleaned flue gases replaces the
secondary
air and the mixture recirclated (FGR). This technique is reported to reduce heat losses
with the flue-gas, and to increase the process energy efficiency by around 0.75–2%
. Also it reduces the nitrogen oxide content in the flue gas by another 20% . It is also
important whether the entire gas flow through the furnace is counter flow, centre flow
or parallel flow as explained in the later pages. Thus, the air supply and the volumetric
mixing of primary flue gases with secondary air is a delicate design feature. It is
pertinent to note that air injected below the grate (underfire air) enhances drying and
primary combustion of the waste; and air injected above the grate (overfire air) assists
in secondary combustion of gaseous volatilized organic compounds and ‘products of
incomplete combustion (PICs)’ released by the waste burning on the grate. Air and
waste delivery rates synergistically determine combustion chamber temperatures. A

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properly operating facility maintains combustion temperatures between

800◦ and 1100◦C. When excess air is introduced into the combustion chamber,
temperatures fall resulting in carbon monoxide emissions. Excessive waste flow also
decreases
temperature, and results in incomplete combustion of the waste. Therefore, continuous
emissions monitoring facility is used to control/regulate waste delivery rates and air
flow to the combustion chamber to optimize the performance.

4. Grate Design
Grate performance is critical to the entire plant performance; therefore the grate type,
design and dimensioning should be carefully selected. The design should be suitable to
accept a wide variation and possible changes in the calorific value and composition of
the input waste. Furthermore, regardless of the specific properties and varying ‘quality’
of the waste, the grate should be able to meet all requirements for waste capacity,
operational reliability, combustion efficiency, and operation at partial load.
An important aspect of the incineration grate design is to ensure a proper and sufficient
distribution of the incineration air into the furnace for complete combustion to occur.
Generally, a primary air blower introduces air through the holes in the burning grates
into the fuel bed. The primary combustion air also cools the grate itself (if it’s air-cooled
grate) as cooling is important for reducing thermal stress of the grate. The influence of
the waste composition and parameters such as primary air, temperature etc. on
combustion on the grates of different geometry and the related technological issues are
very vital and are discussed elsewhere .
The grates are made of special alloys to withstand the high temperature and to
avoid corrosion. Globally, high quality moving grates, the most expensive part of
the Plant equipment, are manufactured.

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Reciprocating grate type with Grate Material : ZG35Cr24Ni4SiN Alloy(1200 oC)

.Required grate area, in a conservative design, is normally determined by limiting

the burning rate to between 60 and 70 lb/ft.2 hr (290–340 kg/m2 hr) of grate area.2 This is
based on limiting the heat release rate loading on the grate to 250,000–300,000 Btu/ft.2 of
grate per hr (2.8–3.4 GJ/m2/hr

5. Furnace Design
The basic design factors which determine furnace capacity are grate area and furnace volume.
Also,the available capacity and method of introducing both underfire and overfire air will
influence,to a lesser extent, furnace capacity. Furnace volume required is established by the
rate of heat release from the fuel.Thus,furnace volume is generally established by using heat
release rates ranging from 12,500to20,000Btu/ft.3/hr (450–750 MJ/m3/hr), with the lower heat
release rate being more desirable from the standpoint of developing a conservative design. A
conservative approach to design in this area is desirable because of probable periodic operation
above design capacity to meet short-term higher than normal refuse
collections and possible receipt of high heat-content waste.

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Subsequent to the combustion of the waste on the grate, the resultant gases of combustion are
completely burnt in the upper combustion chamber. It is therefore essential that the grate and
furnace are designed as a fully integrated unit and not regarded asseparate supply
items.Depending on grate design, the furnace geometry and the method of injectingsecondary air
are very vital for optimizing combustion.The requirements that determine the design are: form
and size of the incinerationgrate, vortexing and homogeneity of waste gas flow, sufficient
residence time for thewaste gasses in the hot furnace, and partial cooling of waste).In order to
avoid fusion of the flying ash at the boiler, the waste gas temperaturemust not exceed an upper
limit at the incineration chamber’s exit

6. BOILER TYPE
The mass burn boiler types use membrane Water wall with protected by a resistant refractory
material such as Castable with Thickness around 50 mm complete with anchor material SUS 304.
Normally Membran water wall boilers are most often have four passes: 3 vertical radiation passes
and a convection pass. The first of the radiation passes is integrated in the furnace as the post
combustion chamber. The convection pass, in which the evaporators, superheaters and
economizers are located, may be vertical or horizontal.
Corrosion problem: When designing a boiler for waste incineration it is important to examine
the risk of corrosion arising mainly due to the presence of corrosive substances such as
alkalines, chlorine, sulfur, and heavy metals, zinc and lead, to an extent of nearly 1%. During
combustion of waste, these are released as HCl, NaCl, KCl, ZnCl2, PbCl2 and so on. These
contribute to a highly corrosive atmosphere that shortens the life of the heat exchanger tubes
in the water wall section due to the deposition, and especially in the steam superheater
sections where the tube temperature is at its maximum. HCl is highly corrosive at temperatures
>450◦C as well as at <110◦C. Therefore, as a general accepted limit for a sufficient lifetime of
boiler tubes, steam parameters of 40 bar/400◦C are widely used. That is, the maximum steam

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temperature in the present WtE plants is an economic compromise between the acceptable
corrosion rate and maximum power generation. Actually, various types of corrosion processes
exist in WTE power plants such as initial corrosion, high temperature corrosion, O2-deficient
corrosion, molten salt corrosion, chloride-high temperature corrosion, electrochemical
corrosion, dew point corrosion and so on. The corrosion process, although extensively studied
during the last few years, it is not fully understood yet. In addition to the concentration of
corrosive content, particularly chlorine in the municipal waste, other factors that affect the rate
of corrosion in the boilers are the operating temperature in the chamber, temperature
fluctuations at a particular location that may disrupt the protective oxide layer, the method
used for periodic cleaning of the process gas side of the tubes, and the design of the boiler. To
prevent the corrosive attacks on the furnace boiler system, the heating surfaces in the radiant
part is protected by a resistant refractory material such as Castable with Thickness around 50
mm complete with anchor material SUS 304.

7. Air Pollution Control

7.A Spray Drying Absorption (SDA)
The SDA process is a semi-dry flue gas desulphurization process. The process uses slaked lime
Ca(OH)2 as absorbent and results in a stable and dry end product, mainly consisting of fly ash
and various calcium compounds. SDA is a precise, effective system to remove multiple
pollutants in one common process. Hot, raw flue gas is fed into a ‘spray drying absorption’
chamber where it comes into contact with a fine spray of alkaline slurry (usually slaked lime).
Virtually all the acidic components in the flue gas (HCl, HF, SO2, and SO3) are absorbed into the
alkaline droplets, while the water is evaporated simultaneously. Precise control of the gas
distribution, slurry flow rate and droplet size ensures droplets are converted into a fine powder.
The injection of activated carbon into the flue gas can be used to enhance the removal of
mercury and dioxins. Some fly ash and reaction products drop to the bottom of the absorber
and are discharged. The treated flue gas continues on to a dust collector, where any remaining
suspended soli/ds are removed. The cleaned gases then exit through the stack. The chemistry of
SDA process can be represented as:
2HCl + Ca(OH)2 CaCl2 + H2O
2HF + Ca(OH)2 CaF2 + H2O
SO2 + Ca(OH)2 CaSO3 / CaSO4 + H2

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SDA is a self-adapting system to changes in flue gas flow rate, temperature and composition,
and is suitable for incinerators of all types and sizes, requiring only a single absorber and a
single rotary atomizer per incineration line. In addition, the SDA process can be easily integrated
with other flue gas cleaning technologies. The basic SDA process can be enhanced by additional
process options in order to meet the specific needs of incinerators with a very high
concentration of pollutants and/or very strict emissions requirements.

Schematic of Spray Drying Absorption process

7.B Particle Removal

The first step in the flue gas treatment is to remove the solid particles of sizes, 1 µm to 1 mm
applying the common practice of using cyclones, fabric filters or electrostatic precipitators
(ESP). Inside the cyclone, the gas entering a cylindrical chamber swirls around an immersed tube
and due to inertia, the particulates are carried to the cylinder wall. From there they exit through
the conical section on the bottom while the clean gas exits through the tube (Figure 3.1) .
Electrostatic precipitators utilize high voltage to electrically charge the particles contained in the
flue gas by hanging wires vertically in the gas stream; and the charged particles move toward
the electrode forming a dust layer on it. The electrode is shaken to push the dust particals
down. The ESP is robust and simple to operate. It is very effective in removing larger

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particulates but has limited efficacy at removing small particles. Fabric filter contains a large
number of filter bags. As the raw flue gas passes through the filter bags, the particle material is
retained on the walls and the cleaned gas flows through and exit at the top. The particles
remain until compressed air is blown in the opposite direction, cleaning the filter and causing
the dust to fall down where it is collected. Electrostatic precipitators and fabric filters have a
similar operational area, with the latter showing a high particulate removal efficiency and a
better performance for removing particles smaller than 1 µm (see Figure 3.2). As the fabric
filters also provide a surface for the reactions to occur to neutralize acid gases, they are usually
located at the back of the APC system downstream of the scrubber. Due to these advantages,
fabric filters are preferred in all modern waste incineration plants. But, in plants operating in
areas with stringent emission limits, both fabric filter and ESP are installed. Cyclones, due to
their limited removal efficiency, are not applied currently to modern waste incinerators.
However, they are utilized as a complement with other flue gas treatment stages .

Figure 3.1 Schematics of three common solid particle removers: Cyclones, ESP, Fabric filter

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Operational Areas of Dust Removing Processes

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