Professional Documents
Culture Documents
INCINATOR
INCINATOR
INCINATOR
OPERATING MANUAL
OF
INCINERATOR
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INDEX
SECTION I INTRODUCTION
1.0 Generalities
1.1 Equipment List
3.1 Incinerator
3.2 Refractory 3.3
Burners
3.4 Equipment and instrument
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I N D E X(cont ‘ d)
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SECTION 1
1.0 INTRODUCTION
1.1 GENERAL
The Incinerator system has been designed and erected by KINETICS TECHNOLOGY INTERNATIONAL. The operating manual covers the
design and operating instructions for the incinerator of the high vacuum bitumen blowing unit as well as the auxiliary and ancillary
equipment for the incinerator.
The main equipment related to the package is included in the following list :
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SECTION II
2.0 BASIS OF DESIGN
2.1 INCINERATOR
The incinerator H-1 has been designed to handle the waste stream listed below.
Case A Case B
- Waste stream Acid Gas Acid Gas
- LHV (Kcal/kg) 50 240
- Max. flow rate (kg/hr) 13158 12853
- Residence time greater than 1 sec.
- Operating temperature 800oC
- Operating pressure -7 to 10 mm WC
The incinerator has been designed considering both the thermal density (volumetric) and the residence time of fuel gas in order to
guarantee perfect combustion of the waste.
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BASIS OF DESIGN
c) Combustion air
- Composition (% vol.):
N2 72
O2 19.3
H2O 8.7
- Max flow rate (kg/hr) 7411 Case A 8109 Case B
- Operating pressure (mm WC) 380
o
- Operating temperature ( C) ambient (Case A and B)
d) Fuel gas
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- Composition (% vol.):
C1 89.6
C2 5.55
C3 1.33
C4 0.15
CO2 3.9
- AV.MW 18.3
- LHV (kcal/kg) 10350
- Flow rate (kg/hr) 372 Case A 135 Case B
- Pressure norm. (kg/cm2g) 3.5
o
- Operating temperature ( C) 20
BASIS OF DESIGN
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The summary of the utilities available for the incinerator is given below:
a) Instrument air
Dewpoint - 15oC
Purity oil free
Pressure norm. 10.0/7.0 bar g
Temperature 5-40oC
b) Electric power
Instruments 110 V/1 ph/50 Hz
Power 415 V/3 ph/50 Hz
BASIS OF DESIGN
c) Fuel gas
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SECTION 3.0
3.1 INCINERATOR
The incinerator is of the vertical cylindrical type with one burner. The burner is located at the bottom. Main characteristics of the incinerator
are as follows:
Dimensions:
Internal diameter 2100 mm
Height 6000 mm
- Wall material carbon steel
- Heat capacity 5.0 MMkcal/h
- Combustion temperature 800oC
- Residence time greater than 1 sec.
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3.2 REFRACTORY
Refractory is as follows:
a) Bottom
- 100 mm insulating castable type GIBCRETE K17
- 100 mm refractory castable type GIBCRETE 1350
b) Wall
- 100 mm insulating castable type GIBCRETE K17
- 100 mm refractory castable type GIBCRETE 1350
c) Roof
- 100 mm insulating castable type GIBCRETE K17
- 100 mm refractory castable type GIBCRETE 1350
d) Duct
- 62 mm insulating castable type GIBCRETE K17
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3.3 BURNER
Burner is suitable for forced draft operation with specified combustion air.
The burner is provided with gas firing ignitor (forced draft type), flame UV scanner and airtight peephole.
a) Burner
Model H.T.I. Type B11 GT
Heat Value 5,000,000 Kcal/h
Adjustment range 1 – 10
(on fuel gas basis)
The burner plenum is a high energy combination of fuel gas, waste gas and combustion air.
Burner plenum lining is as follows:
- 90 mm high refractory type GIBCRETE 1450.
For details of refractory specification, respective mechanical book is
referred.
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For equipment and instrument description and specifications corresponding mechanical book and drawings are referred.
SECTION 4.0
INSTALLATION INSTRUCTION
The incinerator is completely prefabricated in the KTI work shop with refractory and instruments installed. The stack was shipped in four
separate sections ready to assemble.
The dimensions and weights are according to the drawing FI 36.302.00.257. The lines at the battery limits were connected ensuring that the
lines were self-supporting, jointed and did not produce stress on the burner and instruments.
SECTION 5.0
The outlet gas temperature control maintains at 800oC the outlet gas temperature by adding or reducing the combustion activity of the
burner.
The loop includes the following items:
- Temperature measuring element 60 TE 1917
- Temperature recorder 60 TR 1917
- Temperature controller 60 TIC 1917
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The combustion activity is controlled in such a way that the air is leading the fuel during the load increase; and the fuel is leading the air
during the load decrease. This control is achieved with the combination of the low selector signal 60-FY-1915-3 and the high selector signal
60-FY-1917 associated with the fuel gas controller 60-FIC-1915 and the burner air flow controller 60-FRC-1916.
The air/fuel ratio is controlled by the combined action of the divider 60-FY-1916-2 and the multiplier 60-FY-1915. Both signal conditioners
are remote set from one manual station HIC-X.
The concept is to adjust the ratio by acting on the set point of the fuel gas flow controller through the divider and on the second input of the
high selector signal through the multiplier. The output of the high selector signal is the set point of the air-flow controller.
The fuel gas flow controller 60-FIC-1915 is cascaded by the temperature control via the low select signal and the divider of the air ratio. The
input is the gas flow coming from the transmitter 60-FT-1915 and 60-FY-1915-1 square root extractor. The controller modulates the control
valve 60-FV-1915 via the I/P 60 FY 1915.
The air-flow controller 60-FRC-1916 is cascaded by the load signal or gas flow through the high selector signal and the multiplier 60-FY-
1915. The input is the actual air-flow coming from the transmitter 60-FT-1916 and 60 FY 1916-1 square root extractor. The controller
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The process gas is controlled manually via the remote station 60-HIC-1920 and the I/P 60-HY-1920. The process gas flow is measured with
the flow transmitter 60-FT-1914 and recorded with the 60-FR-1914.
This loop controls the combustion air for the combustion of the process gas and for the burner. The control includes the air flow transmitter
60-FT-1919, the square root extractor 60-FY-1919, the controller 60-FIC-1919, the I/P 60-FY-1919 and the control valve 60-FV-1919. The
operator will adjust the set point of the controller 60-FIC-1919 according to the process gas flow 60-FT-1914.
The stack temperature is maintained at 350oC with the mixing of the exhaust gas from the incinerator with the quench air coming from the
fan F-02.
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SECTION 6.0
INTERLOCKS SYSTEM
The interlocks system provides the overall protection of the incinerator to ensure safe start-up, normal running and shut-down.
1) Pilot gas low pressure 60 PSL 1918 closes pilot gas valve 60 XV 1922
2) Fuel gas low pressure 60 PSL 1919 closes fuel gas valve 60 XV 1921,
process gas valve 60 HCV 1920 and trips combustion air fan F01.
3) No flame switch 60 BS 1905 closes main gas valve 60 XV1921, pilot gas
valve 60 XV 1933, process gas valve 60 HCV 1920 and trips
combustion air fan F01.
4) Combustion chamber high pressure 60 – PSH 1925 as point 3
5) Flue gas high temperature 60 TSH 1919 as point 3
6) Low pressure combustion air 60 PSL 1921, 60 PSL 1926 as point 3
7) Emergency trip (by push button) as point 3
8) Pilot trip (by push button 60 HS 1923) closes fuel gas valve to pilot 60
XV 1922.
9) Combustion chamber low temperature 60 TSL 1920 closes process gas valve 60 HCV 1920.
10) Hand switch 60 HS 1920 pushed closes gas valve 60 HCV 1920.
11) Low air pressure to pilot 60 PSL 1930 closes fuel gas valve to pilot 60
XV 1922
The process gas valve 60 HCV 1920 can be opened under these conditions:
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SECTION 7.0
SAFETY
Employees should be thoroughly informed of the hazards that can result from improper operation of high temperature equipment. They
must be familiar with the emergency steps, regarding various equipment.
SECTION 8.0
START-UP PREPARATION
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The information and procedures detailed below cover the preliminary operations required before the initial start-up of the unit. After completion of
construction each equipment must be inspected for the internal cleaning. When all piping is connected, all pressure parts shall be checked ‘ for
tightness’.
All parts of the equipment must be free of dirt, sand and all foreign matter left during the construction. In all cases where this is possible,
foreign matter must be removed by hand, as for example inside the incinerator, burner and other accessible equipment.
The cleaning of all pipe by air blowing must be performed before the start-up.
Special precautions must be taken to prevent injury to personnel by debris flying from the exhaust opening. It must be impossible for any
person to enter the area of the exhaust blast, allowing ample distance in the direction of the blast and, particularly observing a possible
deflection of the blast. To air-blow the lines, the system can be filled with air at high pressure whereafter the air can be realized successively
through the various lines. In other cases special connections can be made from compressed air tank. Blowing in both directions is often
advisable. Before the air blowing all valves, orifices, connections for instrument must be disconnected in order to avoid accumulation of dirt
in those spots. After cleaning all equipment, the unit is ready for commissioning, operational inspection and testing.
8.3 TIGHTNESS
The purpose of the tightness test is to demonstrate the adequacy of the assembly and the absence of defects in workmanship, before
combustible or hazardous materials are admitted to the unit. If possible, the leak test shall be carried out with air at a pressure not
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exceeding 100% of the operation pressure. In performing the test the following precautions must be observed:
a) Open all the section valves except those at the battery limits; pull temporary blinds out; reinstall control valves, pressure gauges,
etc.; reassemble broken flanges and install orifice plates.
b) Open all connections to instruments, pressure gauges, gauge glasses, etc. Close all drains, bleeders vents, sample connections
etc. Close block valves between sections of different operating pressures. Raise the pressure to the test value. Check for leaks. The
pressure should hold for half an hour. All joints, flanges, packing glands etc. must be checked for leaks by means of a sensitive
detector, for example by using soap solution. The final pressure test shall be done with air and the flanges and joints broken since
the proceeding pressure test shall be checked for leaks by, for example, putting masking tape over the gap between flanges and
testing a hole tape with soap solution to detect leakage.
a) Orifice plates
Following completion of air blowing, orifice plates should be installed in the proper locations and should face the correct direction.
SECTION 9.0
START-UP PROCEDURE
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1. Purge cycle.
2. Lighting pilot.
3. Starting burner (firing the heater)
4. Follow the start-up drying curve or successive start-up heating procedure.
5. Process gas ignition.
Override the interlock and start combustion air fan to have a minimum flow 60 FSL 1919. If the following conditions are satisfied a lamp will
indicate that purge is possible:
a) No high temperature after air quench 60 TSH 1919.
b) No flame detection 60 BS 1905.
c) No fuel pressure to pilots 60 PSL 1918.
d) No fuel pressure to main burner PSL 1919.
e) No process gas pressure 60 PSL 1917.
f) No high combustion chamber pressure 60 PSH 1905.
g) Total air flow higher than 60 PSL 1919.
By pushing the “purge start” push button a timer starts for purge time. During this operation a lamp “purge running” lights up.
When the purging timer elapses, the “purge running” lamp will go off and the “purge end” lamp will illuminate.
The “purge end” function permits the ignition of the pilot.
Open combustion air to pilots in order to have air pressure higher than minimum 60 PSL 1930. By pushing the pilot ignition push button the
60XV 1922 valve opens and the 60 XS 1935 ignition transformer energizes. After 15 seconds the ignition transformer is de-energized and if
the flame is detected and pilot gas pressure is okay (PSL 1918), then 60 XV 1922 is maintained open. If the flame is not detected or the 60
PSL 1918 is not okay, then 60 XV 1922 closes and another ignition is required. If all purge conditions are maintained, re-purge is not
necessary but a waiting period of at least one minute shall elapse before attempting a retrial.
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Open the manual block valve upstream of the shut off valve.
Open 60 FV 1916 to have air pressure higher than minimum.
The 60 FV 1919 is open. (Air pressure higher than minimum).
Press the “burner start” push button.
If the 60 XV 1922 is energized and if the fuel gas pressure is okay (PSL 1918), then 60 XV 1921 will be energized.
Slowly open the block valve downstream and light the burner. (During this operation open the fuel gas control valve 60 FV 1915 in order to
maintain the fuel gas pressure above the minimum (60 PSL 1919).
If the flame is okay, shut off the pilot by the push button, so that 60 BS 1905 will detect only on the burner flame.
If within 3 minutes after the pushing of “Burner start” push button there is no low fuel gas pressure to pilot (60 PSL 1918) and detection of the
flame, both gas valves 60 XV 1922 and 60 XV 1921 will shut and a new purge is required.
Castable are undergoing to considerable loss of water during initial heating and controlled heating ensures maximum strength. The
suggested heating schedule is as follows. The temperature is referred to the incinerator outlet 60-TE-1917. After the start up the firing
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rate should be adjusted in order to control the temperature increase according to the start up drying curves.
If it is difficult to control the minimum firing rate, adjust the cold air from the secondary air control FV-1919 in order to quench the gas of the
burner.
Successive start up can be with a temperature increase rate of 50oC per hour until 700oC. At 700oC the process gas can be taken gradually
in the incinerator. The outlet temperature 60 TE 1917 raised slowly up to 800oC.
During the heating, when the flue gas temperature reaches 350oC, start the quench air fans F 02 in order to maintain the temperature of the
flue gas to the stack at 350oC.
During the main burner ignition the 60 FIC 1915 and 60 FRC 1916, fuel gas and relevant combustion air controllers are in normal mode.
The 60 FV 1915 and 60 FV 1916 valve must be opened in order to have combustion air (pressure 60 PSL 1921) and fuel gas pressure (60
PSL 1919) above the minimum. The total air controller 60 FIC 1919 is in automatic mode set at 8200 kg/hr or air.
After the main burner ignition at minimum firing, if the flame is stable, the fuel gas and combustion air can be increased following the heating
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Sufficient instrumentation and alarms have been provided to visually indicate important readings necessary to evaluate the entire plant
performance and the performance of the individual pieces of equipment.
In addition to the remote instruments included in the control panel, field mounted instruments should indicate all important parameters, such
as temperatures, pressures, at proper points for easy plant operation.
Dismount and clean periodically gas pilot and UV scanner to avoid any scaling.
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Periodically check :
Incinerator temperature, waste stream flow-rate, flue gas outlet temperature, air flow rate, burner flame.
SECTION 10
SHUT-DOWN PROCEDURE
- Decrease the waste gas feed by HIC 1920 until the valve is completely closed.
- Decrease the incinerator temperature according to the refractory manufacturer’s
instructions.
- Initially 50oC/h decrease rate of temperature, can be sufficient.
- When the combustion chamber temperature is 350oC stop the quenching fan F 02.
- As soon as the temperature reached 200oC shut down the burner.
- Stop the combustion air fan F 01.
- Check temperature decreasing.
Close all manual valves.
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