Technical Proposal: N°: 20180919
Hafner Energy from Waste Srl
Via G. di Vittorio N°16
39100 Bolzano
ITALY
Phone: 0039 (0)471566300
Fax: 0039 (0)471566300
email:info@hafner.it
www.hafner.it
Date: 19/09/2018
Osal Group
K.Bakkalköy Mah.Kayışdağı Cad.
Kayaoğlu Plaza No:119/1
Ataşehir/İstanbul/TÜRKİYE
Tel :+90 216 575 04 61/53
Fax:+90 216 575 04 64
Email: info@osalgroup.com
www.osalgroup.com
Technical Proposal:
MSW – Incineration Plant
“Waste to Energy”
Waste throughput: 750,000 ton/year – 3 Facilities each 250,000 ton/year
RECIEVER:
State of QATAR - Doha
Osal Group
K.Bakkalköy Mah.Kayışdağı Cad.
Kayaoğlu Plaza No:119/1
Ataşehir/İstanbul/TÜRKİYE
Tel :+90 216 575 04 61/53
Fax:+90 216 575 04 64
Email: info@osalgroup.com
www.osalgroup.com
Hafner Energy from Waste Srl
Via G. di Vittorio N°16
39100 Bolzano
ITALY
Phone: 0039 (0)471566300
Fax: 0039 (0)471566300
email:info@hafner.it
www.hafner.it
Date: 19/09/2018
Dear Sir,
We sincerely thank you for your RFQ and for considering working with us. We are pleased to submit our
technical proposal under reference N°20180919 in date 19/09/2018.
Hafner is a global provider with a long history of successful installation and a technological innovation
leader in the “waste to energy” industry.
The following is an executive summary of our technical proposal for your project:
Type of supply:
Technical Facility - Waste to Energy Plant
Turn-Key – Waste to Energy Plant
Component Supplier
Type of Waste:
MSW
Biomass
Tot. Waste throughput:
750,000 ton/year
Tot. Thermal Capacity:
180 MW/h
Configuration:
3 facilities
Hazardous Waste
Hospital Waste
For this technical description, assumptions were made for the design if no specifications were defined by
the Client.
We do look forward to receiving your acceptance of our proposal. We are avaiable to discuss it with you
in more details. We thank you very much for giving us th opportunity to quote.
Best regards
Hafner Heinrich
Osman ALİOĞLU
CEO
President
Hafner Energy from Waste Srl
OSAL Group
TECHNICAL PROPOSAL
MSW – Waste to Energy 750,000 ton/year
with “Drinking Water Treatment Station”
CONTENT
1.
2.
3.
4.
INTRODUCTION – PRESENTATION ............................................................................. 7
1.1
Company Profile ...................................................................................................... 7
1.2
Our Works & References ......................................................................................... 9
TECHNICAL - MAIN PARAMETERS ............................................................................ 10
2.1
Facility capacity...................................................................................................... 10
2.2
Waste Characteristics Client .................................................................................. 11
2.3
Scope of supply & services .................................................................................... 12
2.3.1
Services .......................................................................................................... 12
2.3.2
Supply ............................................................................................................. 13
2.3.3
Civil works....................................................................................................... 14
2.3.4
Exlusions ........................................................................................................ 14
2.3.5
Terms of Delivery ............................................................................................ 14
2.3.6
Facility – process flow diagram ....................................................................... 15
2.4
Project BENEFITS ................................................................................................. 16
2.5
Construction Principles .......................................................................................... 17
2.6
Environmental conditions ....................................................................................... 18
2.7
Plant locating ......................................................................................................... 19
CIVILWORKS & INFRASTRUCTURE ........................................................................... 20
3.1
Production/Working area ........................................................................................ 20
3.2
Plant front area ...................................................................................................... 20
3.2.1
Plant road ....................................................................................................... 20
3.2.2
Transportation ................................................................................................. 21
TECHNICAL PLANT DESCRIPTION ............................................................................ 22
4.1
Feeding system...................................................................................................... 22
4.1.1
4.2
Acceptance and feeding of solid waste - Bunker ............................................. 22
Grate furnace ......................................................................................................... 26
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MSW – Waste to Energy 750,000 ton/year
with “Drinking Water Treatment Station”
4.2.1
Grate Drive ..................................................................................................... 27
4.2.2
Combustion air ................................................................................................ 27
4.3
Ash removal system ............................................................................................... 28
4.4
Combustion chamber (part of boiler) ...................................................................... 29
4.4.1
Burner ............................................................................................................. 30
4.4.2
NOx reduction system – SNCR + SCR ........................................................... 32
4.5
Steam generator – Boiler ....................................................................................... 33
4.5.1
Boiler overview................................................................................................ 33
4.5.2
Constructional features of the generator ......................................................... 33
4.5.3
Components making up the boiler ................................................................... 33
4.5.4
Natural circulation ........................................................................................... 34
4.5.5
Radiant chambers ........................................................................................... 34
4.5.6
Drum – level in the drum ................................................................................. 35
4.5.7
Superheater .................................................................................................... 36
4.5.8
Desurrerheater ................................................................................................ 36
4.5.9
Economizer ..................................................................................................... 36
4.5.10
Superheater function ....................................................................................... 37
4.5.11
Boiler cleaning system .................................................................................... 37
4.5.12
Boiler feed water treatment system ................................................................. 37
4.6
Energy Recovery (thermal cycle) - functional description ....................................... 38
4.7
Steam Turbine & electrical Generator – Turbo unit ................................................ 38
4.7.1
General requirements for steam for turbine functioning ................................... 38
4.7.2
Construction details of the turbine ................................................................... 39
4.7.3
By-pass turbine ............................................................................................... 42
4.7.4
Oil system for lubrication and regulation ......................................................... 42
4.7.5
Electro-hydraulic turbine adjustment system ................................................... 42
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MSW – Waste to Energy 750,000 ton/year
with “Drinking Water Treatment Station”
4.7.6
Instrumentation and control devices ................................................................ 43
4.7.7
Turbine accessories ........................................................................................ 43
4.7.8
Alternator ........................................................................................................ 44
4.8
Air condenser with vacuum unit and hot well .......................................................... 44
4.8.1
Air condenser .................................................................................................. 44
4.8.2
Steam distribution pipelines ............................................................................ 45
4.8.3
Axial fan units ................................................................................................. 46
4.8.4
Sound-absorbing protection wall ..................................................................... 46
4.8.5
Steam Ejector system ..................................................................................... 46
4.8.6
Hot well – condensate collection tank ............................................................. 47
4.8.7
Air condenser control ...................................................................................... 48
4.8.8
Semi-automatic condenser cleaning system ................................................... 49
4.9
Deaerator & Feedwater Tank ................................................................................. 49
4.9.1
4.10
Boiler feed pumps ........................................................................................... 50
Demineralize water production system ................................................................... 51
4.10.1
Process description ......................................................................................... 51
4.10.2
Pre-treatment .................................................................................................. 51
4.11
Flue gas cleaning system ....................................................................................... 53
4.12
Cyclone .................................................................................................................. 53
4.13
Reactor 1+2 ........................................................................................................... 54
4.14
Bag filter 1+2.......................................................................................................... 54
4.15
DeNOX catalyst (catalytic system for the reduction of dioxins and furans) ............. 56
4.16
ID fan ..................................................................................................................... 57
4.17
Chimney................................................................................................................. 57
4.17.1
Protection against atmospheric discharges ..................................................... 57
4.17.2
Analysis at the chimney .................................................................................. 57
4.18
Additives- and Residues storage & feeding systems .............................................. 59
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with “Drinking Water Treatment Station”
5.
4.19
Storage silo sodium bicarbonate and dosing with Mill ............................................ 59
4.20
Storage silo and dosage of activated carbon .......................................................... 60
4.21
Storage tank and dosage of urea ........................................................................... 60
4.22
Storage of ash........................................................................................................ 60
4.23
Storage residual sodium products .......................................................................... 61
4.24
Steel structures, platforms, ramps, stairs ............................................................... 62
4.25
Piping and Valve .................................................................................................... 62
MATERIAL RECOVERY SISTEM ................................................................................. 63
5.1
Location and logistics of the recovery material plant .............................................. 64
5.2
Slag/Ash Treatment ............................................................................................... 65
5.2.1
Ferrous metals ................................................................................................ 65
5.2.2
No ferrous Metals............................................................................................ 66
6.
DRINKING WATER TREATMENT PLANT .................................................................... 67
7.
Electrical parts & process control system ...................................................................... 68
7.1
PCS - Process control system (DCS) ..................................................................... 68
7.1.1
Philosophy of automation ................................................................................ 68
7.1.2
SCADA - Supervisory Control and Data Acquisition ........................................ 70
7.1.3
PLC- Programmable Logic Controller (SPS) ................................................... 72
7.1.4
Instrumentation in the field .............................................................................. 73
7.2
Electrical part ......................................................................................................... 74
7.2.1
Main distribution and general wiring diagram .................................................. 74
8.
PROCESS CHARACTERISTICS .................................................................................. 77
9.
PROPERTY / CONFIDENTIALTY ................................................................................. 82
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MSW – Waste to Energy 750,000 ton/year
with “Drinking Water Treatment Station”
1. INTRODUCTION – PRESENTATION
Thank you for your interest and your trust in Waste to Energy solutions of Hafner Energy from
Waste. Srl.&Osal Group.
Hereby you receive our technical description for the realisation of a MSW Municipal solide
Waste to Energy Plant – total throughput 750,000 ton/year in your country Qatar.
1.1
Company Profile
The Hafner company will provide a multi-disciplinary team with expertise in each of the areas
critical to the success of the design and construction of the speciall waste incinerator and the
training of its staff.
Upon careful analysis of the technical specifications in the tender, the Hafner management has
a clear understanding of the requirements and full ability to provide an effective solution that
can match the expected requests.
The hereby proposed solution will be based on proven engineering technologies that have been
field-tested in nearly thirty years of company activity, using a combination of advanced design
along with tried and tested systems.
The Hafner group was established in 1979 in Bolzano (pictured in photo below), in the beautiful
northern Italian region of South Tyrol, to design, construct and manage Waste to Energy plants.
Located at the foothills of the Alps, only one hour south of the Austrian border, the Hafner
company ensures a tradition of experience in the field of environmental protection.
At its core, the company has always
followed the ecological values that have
made this European region a famous
tourist destination; an innate, sacrosanct
respect for nature, widespread protection
of the environment, and strong traditions.
Fig. 1 Bolzano,South Tyrol- Italy
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TECHNICAL PROPOSAL
MSW – Waste to Energy 750,000 ton/year
with “Drinking Water Treatment Station”
For nearly thirty years, with office subsidiaries in
Germany and Austria, the company has
developed a technology aimed at exploiting the
value of waste and biomass by generating
thermal and electric energy in full compliance
with the requirements of European waste
directives.
The company provides turn-key industrial knowhow for the treatment of municipal waste, special
waste (such as toxic wastes), medical waste,
liquid waste, sludge, and biomass. Over the
years, the Hafner facilities have allowed the safe
disposal
of
waste
while
simultaneously
contributing to climate protection.
Since its inception, the company has been
striving to be at the forefront of technological
Fig. 2 Hafner Tower at Bolzano City
innovation. It was one of the first to propose the
concept of “mobile waste to energy plant”, offering an important factor of flexibility to those
entities in need of small, mobile plants for managing waste in diverse and remote locations.
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1.2
Our Works & References
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TECHNICAL PROPOSAL
MSW – Waste to Energy 750,000 ton/year
with “Drinking Water Treatment Station”
2. TECHNICAL - MAIN PARAMETERS
The following is a technical description of process of Municipal Solid Waste Incineration and
Energy Generation Facility (named “Waste to Energy Plant”) that the Hafner Company
envisions to be the most suitable for the safe disposal of the waste described on page 11. The
system is guaranteeing the lowest emission values possible, as listed in the table on page 80.
Incineration Technology:
Grate Incinerator (the mechanical reciprocating
grate incinerator);
Waste Characteristics
Type of Waste:
MSW - Municipal Solide Waste
Waste Consistency:
solid
Waste caloric value:
2.1
pasty
liquid
the Design low heat value of the MSW is 1,650 kcal/kg
Facility capacity
The amount of waste:
2,250 tons/day
Facility total capacity:
750,000 tons/year – 3x Lines 250,000 tons/year
Facility Line Number:
3 Lines
Single facility capacity:
250,000 tons/year – 750 tons/day
Single facility thermal power:
59.97 MWt/hour
The Hafner Incineration system can work 24 per day hours, 8,000 hours per years and is
planned to guarantee a throughput rate in excess of 31,250 kg waste per hour for the single
facility line. The heating power of one facility is 215.9 GJ per hour – approx. 59.97 MWt per
hour. The facility consist of 3 independen parallel line which have the equal capacity and the
same technical design.
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TECHNICAL PROPOSAL
MSW – Waste to Energy 750,000 ton/year
with “Drinking Water Treatment Station”
2.2
Waste Characteristics Client
This waste-to-energy plant was dimensioned for a MSW waste mix according to the following
table*:
WASTE DESIGN MIX*
GfuelMax
31,250 kg/h
6.91 MJ/kg
LCV*
Maximum rate of mass flow of fuel
Low heating value
C
17.12 % weight
H
2.18 % weight
Hydrogen content
0.26 % weight
Sulfur content
O
9.62 % weight
Oxygen content
N
1.12 % weight
Nitrogen content
Cl
0.96 % weight
Chlorine content
Carbon content
H2O
46.50 % weight
Water content
Ash
22.25 % weight
Ash content of fuel
Total Comp.
100 % weight
Total percentage all components
*This table must be approved by the customer
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MSW – Waste to Energy 750,000 ton/year
with “Drinking Water Treatment Station”
2.3
Scope of supply & services
Engineering, construction and delivery of a Hafner Waste to Energy plant (W2E).
2.3.1 Services
The process- and plant related basic engineering includes all general arrangement and
workshop drawings, plans, calculations regarding the scope of supply. The proposal-related
engineering also includes the elaboration of all technical specifications for the components
and installations which connect to the on-site limit of supplies of the plant.
Basic engineering:

Combustion calculation of the relevant load cases.

Process description.

Creating of the process & instrumentation diagrams

Creating the energy- and mass balance.

Evaluation of the consumption figures including the electric power consumption.

Evaluation of the production figures.

Data sheets, revision 0, for instruments and machines with weight specification.

Project of lay-out with load specifications for the construction engineering.

Basic engineering for the location of platforms, ramps, stairs for our scope of supply.
Detail engineering:

Process & instrumentation diagrams with a list of changes for the particular revision.

Data sheets (corresponding with the example documentation).

Legwork for the operation charts of the process control.

Creation of the program flow charts for the combustion control.

Engineering drawings of the primary components.

Creating the layout plans.

Construction information drawings.

Pipe diagram.

Piping specification.

Pipework list.

Controls and instruments list.

Data sheets special controls and instruments
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MSW – Waste to Energy 750,000 ton/year
with “Drinking Water Treatment Station”

Material certificates for the tubing material (where necessary).

Details over heat loses.

Details about the protection against corrosion.

Acceptance documentation for instruments and machines.

Documentation for authorities-liable pressure vessels.

Operating and maintenance manual.
Documents for authorities:

Principle schematic diagram.

Description of the authorities-inspected components (primary pressure and
technical specification).

Construction plans for the building project.

Description of the safety equipment and devices.

Process flow images (simplified) for the safety equipment and devices.
2.3.2 Supply
Hafner Waste to Energy plant (W2E) system consists of treatment system main equipment,
treatment system auxiliary equipment, automatic control systems and flue gas online monitoring
system.
Treatment system main equipments for
one facility line
each facility line including:

Waste lifting & feeding system

Waste incineration system (grate furnace with combustion chamber),

Vertical/horizontal Boiler (water-steam cycle)

Slag and fly ash treatment system

Flue Gas Cleaning –System,

Flue gas waste heat utilization system

Storage and transportation systems for consumptions materials
served for each single facility line
serviced for all of the facility line
including:

Turbine power generation system,

Air Condenser & hot well with condensate relaunching sistem,
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
Water supply system
Auxiliary equipments:
serviced for each single facility line
serviced for all of the facility line
Including:

Air supply, exhaust system

Automatic ignition and auxiliary burning system

Process pipeline and maintenance platform

Instrumentation and control equipment;

DCS control system and flue gas online monitoring system:

Incineration equipments operation control system

Electrical system -Electrical facilities for technical part of the plant,

Flue gas online monitoring system
2.3.3 Civil works

Civil works and design of all necessary foundations,

Building services

Waste management buildings (bunker of solid wastes)

Alarm system

Fire Extingushing System

Noise control system.

Safety and fire protection system
2.3.4 Exlusions
The following is excluded from this proposal:

Land provide

Wastewater treatment system
2.3.5 Terms of Delivery
Terms of delivery for our scope of supply is: “CIF” Cost Insurrance Freight port Qatar.
(Incoterms 2010).
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Example of Hafner process flow diagram for 3x facilities - tot. 750,000 tons/year (250,000 tons/year x 3):
-
Red Zone: Combustion – for one facility line
-
Blue Zone: Flue gas cleaning system – for one facility line
-
Yellow Zone: Energy Recovery – for four facility lines
-
Green Zone: Material Recovery – Independent facility
-
Pink Zone: Drinking Water Treatment Station – Independent facility
TECHNICAL PROPOSAL
MSW – Waste to Energy 750,000 ton/year
with “Drinking Water Treatment Station”
2.3.6 Facility – process flow diagram
Fig. 3 Process Flow Diagram
OsalHafner Energy from Waste
In this process flow diagram are illustrated the different Hafner technologies and the plant components.
TECHNICAL PROPOSAL
MSW – Waste to Energy 750,000 ton/year
with “Drinking Water Treatment Station”
2.4
Project BENEFITS
In addition, due to the implementation of the Project, it is planned to achieve the following
objectives:

Reducing the emissions (CO2) by 218,250 t/year.

The possibility of producing and providing the population with heating and hot water in
the amount of approx. 737 GW/y or

production of more than approx. 339 GW/y per year of electric power or

the possibility of placing a "Drinking Water Treatment Plant" of approx. 1,705,928,000
liters/year;

Material Recovery;
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2.5
Construction Principles
Hafner Waste to Energy Plants (W2E), applied with modern incineration technology and
advanced equipment aimed to be an efficient and effective power station. The project design
follows the principles below:

According to the rules of "Reduction, Harmlessness, Recycling", we adopt grate furnace
in our treatment process. In addition, on the premise of cleaner production, we achieve
maximal heat recovery, steam production and electricity generation.

Protect the environment and prevent the pollution - The Hafner Waste to Energy plant
(W2E) is designed to function in accord with the most stringent European Union
industrial emissions standards and legislation, as defined by the European
Commission's Directorate General for the Environment (DG ENVI), in future known as
IPPC (Integrated Pollution Prevention and Control).

Improve User-Friendly Operation And Management - we achieve centralized operation
of the turbine, boiler and generator by improving the automation level of the equipment
and introducing advanced waste incineration control technology. The plant’s successful
compliance with full DRE standards (destruction and removal efficiency) is
accomplished through multiple technological synergy factors along with long standing,
field-tested design, construction, and incinerator management experience.

The plant will be designed with criteria to achieve an efficient structure, able to meet
the environmental protection parameters and such as to ensure the quality of working
conditions and consequently the safety of management personnel.

Save the use of land, water and resources.
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2.6
Environmental conditions
Geographic location:
- latitude
….° ….' …,…." N
- longitude
….° ….' …,…." E
- altitude
…… m s.l.m
Location:
Ambient temperature:
annual average
+ …. °C
minimum
- ….. °C
maxim
+ …. °C
Maximum wet bulb temperature:
…. °C
Design temperature:
+ …. °C
(electrical equipment)
…..-… %
Humidity:
annual average
Rainfall:
maxim
….. mm/m2
Wind speed:
average
….. m/sec
Wind force:
…. kN/m2
Snow load:
…. kN/m2
* the proposal is based on the environmental conditions estimated by Hafner Energy from Waste and is to be approved by the
customer.
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2.7
Plant locating
The installation location of Hafner Waste to Energy Plants (W2E), must still be communicated
by the customer.
The W2E plant covers an area of 75,000 m² (7.5 hectares). Inside the plant area, 20-30% of
available space will be covered with greenery and 10-15% for road,10%-15% for administration
building.
The preliminary lay-out of Qatar plants is shown below:
The Municipal Waste Treatment facility at Qatar will consist of the following units:

A W2E - incineration plant consisting of three household waste lines with a total
disposal capacity of 750,000 tons per year with “Energy Recovery”;

A slag treatment plant, to extract a variety of materials such as raw materials from these
residues – named “Material Recovery Plant”.

A “Drinking water treatment plant”;
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MSW – Waste to Energy 750,000 ton/year
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3. CIVILWORKS & INFRASTRUCTURE
According to the site conditions and production processes of W2E Plant project, considering
the environment around the plant and environmental protection, fire protection, afforestation,
labor and health requirements, the following arrangements are made for the project: the entire
plant is divided into two zones:
- production area,
- plant front area;
3.1
Production/Working area
Working areas including: main workshop (including waste unloading platform, waste pit
(bunker), burning room, turbine room, etc.), flue gas treatment system, slag silo, ash, chimneys,
approach viaducts, garage, booster stations, integrated pump room (not including wastewater
treatment, circulating water pump house, etc.), wastewater regulation pool, fire protection water
pool, chemical water treatment workshop, maintenance and materials room, hydraulic oil
system, guard and weighbridge room and emergency mention yard and so on. The working
area is located in the middle of the plant, original waste is weighing at weighbridge and then
into the unloading platform.
3.2
Plant front area
Front area includes: office buildings, complex building, parking place, guard room and gates,
squares. Taking into consideration of more and more staff and will concentrated in the building.
Office buildings are arranged, near the entrance flow layout in order to create a better working
environment and internal and external contact convenience.
The parking place lies near the office building to facilitate workers' access. In short, the general
layout of the partition is reasonable, smooth process, convenient transportation, working and
management for the creation of favorable conditions.
3.2.1 Plant road
To meet the needs of working, transport and fire administrative, set the ring road leading to
the plant area of the workshop, in order to meet the needs of fire and a variety of production
and auxiliary production materials transportation.
The form of the plant roads are city-roads, with double lane road tot. 7.0 meters wide.
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3.2.2 Transportation
The transportation of factory production and auxiliary production is given priority to car transport.
The waste truck plant logistics plant entrances along the loop by weighing afterwards discharge
into the main unloading hall, empty truck returns on the same route; ash carrying truck should
come and pick up the ash from ash storage room through plant road. Other auxiliary production
materials transportation needs to passed through the logistic entrance to each workshop;
administrative vehicles, consumption materials transportation and personnel should enter from
the personnel entrance.
Fire engines via the plant flow, logistics entrance into the factory by factory district met each of
the annular channels through workshops, facilities and venues.
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4. TECHNICAL PLANT DESCRIPTION
The component description refers to one plant line. The main collector, the condensate
system, the deaerator with feedwater tank and the water treatment station are parts of
the system which are designed for all 3 facility Lines.
4.1
Feeding system
4.1.1 Acceptance and feeding of solid waste - Bunker
4.1.1.1 Storage with waste pit and feeding using overhead crane
An overhead crane is installed in the top part of the waste pit (built part), which is used to feed
the solid waste made up from:

Gantry with wheels

Gantry carriage with rope-winder and cable-winder

Electro-hydraulic bucket/grab
The overhead crane girders are made with a welded box construction with the advantages of
reduced weight and high degree of vertical and horizontal stiffness, as well as the transmission
of small loads onto the wheels and the runway.
The carriage-winch runs on the wear-resistant material rails, which are welded to the upper
wing of the open box girders.
A grid walkway is envisioned for maintenance of the carriage festoon power supply and of the
mechanical sliding units.
The gantry is equipped with 4 wheels mounted on anti-friction bearings, 2 of the wheels are
driven directly by the hollow-shaft motors unit.
The carriage has 4 wheels mounted on anti-friction bearings, which are smaller but have the
same features as those of the gantry.
The carriage sliding unit is formed from an open winch made up from:

rope-winder drum with carved grooves, flanges on the two sides mounted on selfaligning roller bearings.

lifting gear reducer with helical gears, with frame;

motor with cage rotor for lifting (adjusted by frequency converter);

flexible joint installed between the motor and gear reducer drive shaft;
The bucket is suitable for handling special solid waste.
The bucket is essentially made up from several steel framework valves with closing blades in
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special steel.
The solenoid valve electro-hydraulic control unit is equipped with two fixed displacement pumps
to increase operational speed.
The electro-hydraulic unit, which is made up from a motor, pump solenoid valves, over-pressure
valve and hydraulic oil tank, is situated in the upper part and is protected by a steel shield.
The bucket has an adequate capacity, to load the feeding hopper.
4.1.1.2 Feeding hopper
The feeding hopper (and underlying pipe) acts as waste storage for the feeding pusher and, at
the same time, acts as a cap against the input of external air into the combustion chamber. The
presence of waste that must be introduced into the grate furnace regularly and continuously, is
controlled via the microwave level detector.
In the event of an emergency, the loading conduct can be isolated from the combustion area
through two shutters;
In the case of over-temperature, a temperature probe mounted in the feeding hopper,
automatically activates the injection of fire-prevention water through the opening in the AV
valve. The two shutters are always open during routine operation.

The upper part is made of sheet steel and Hardox plates in the required thickness with
stiffening ribs and possess access and inspection openings. The shaft part is formed as
a hopper up to the shut-off flap.

One or multipart preferably tightly shut-off flap, operated by hydraulic cylinders with final
position switches.

Lower part of the chute made complete from sheet steel in the required wall thickness
with stiffeners, linedon the inside with Hardox plates, with stoking openings arranged on
both sides. The chute opens up slightly towards the bottom.

Level control for the automatic control and or shutdown of the fuel feeding and the
simultaneous alerting, designed as microwave measurement type.

Temperature monitoring and automatic activation of the extinguishing process using
water.

All necessary final position switches and contacts.

Complete shop assembly in sub-segments.

Access and inspection openings.

The chute is equipped with a pressureless and upwards open cooling jacket till the
compensator.
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
In the design of the cooling jacket the heat-related expansions were considered.

Compensator.
4.1.1.3 Feeding pusher
The pusher moves via a proportional solenoid valve with integrated electronics. Following
energizing of the safety solenoid valve (with two positions), it is therefore possible to adjust
advancement of the piston, i.e. that amount of waste introduced inside the grate furnace
In the event of a power failure, by de-energizing the pusher safety solenoid valve, pressurized
oil is introduced through the accumulators onto the "rod" branch of the cylinder, making it return
to a minimum pressure.
Pusher advancement speed is adjusted by DCS. A totalizer, positioned on the grate DCS page,
provides the indication of the number of runs or cycles. One cycle consists in the reverse
movement and then forward movement.
Design with a stable sheet steel and Hardox construction in the required thickness.

All-side cooling jacket in pressureless design. The cooling medium is industrial water.

In addition to the cooling jacket, the side walls are provided with Hardox and casting
plates.

Heat resistant castings will be installed at the pusher and at the transition into the
combustion grate.

Maintenance side door on the side.

2 feeding pushers in a solid sectional steel construction with heat-resistant casting
plates including hydraulic cylinders with parallel feeding monitoring with rod eyes and
associated limit switches. The clearing stroke length corresponds to the maximum
stroke length of the operation that is flush to the edge of the feeding table. The maximum
roadway of the pushers are 2’050 mm. The feeding pushers are smooth-running
mounted on rollers in a relatively dust-free area. The side facing the combustion
chamber (front wall) of the input of fuel is equipped with castings.

It’s possible to operate all pushers parallel or individually.

Temperature monitoring and automatic initiation of the extinguishing process using
water or steam.

At the critical points, as for example on the surface of the feeding table wear-resistant
sheet plates (Hardox) or castings are installed.
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4.1.1.4 Hydraulic station:
The hydraulic plant moves three sections: feeding conduct shutters, pusher cylinders, and
cylinders for moving combustion grate zones. Two motor pump units; one as a reserve for the
other.
The oil pumps, oil tank and valve blocks are assembled together a single unit. The oil tank is
equipped with a cleaning opening, oil level indicator, reverse-flow filter and oil temperature
monitoring (there is no oil in the oil tank due to the transportation regulations). The required oil
cooling is done with either water- or air cooling, according to the site situation.
Hydraulic drive unit including the following components:

Hydraulic unit with:

Pumps (3x)

Cooling aggregate

Valve blocks for each cylinder package.

All necessary control and instrumentation.

Control cabinet / junction box for the hydraulic control (connection to PROFI-BUS).

Hydraulic cylinders for the emergency flap at the fuel feeding chute.

Hydraulic cylinders for the pushers of the input of fuel.

Hydraulic cylinders for the Combustion grate modules.

Hydraulic cylinders for the bottom ash discharger.

Piping between the hydraulic unit and the hydraulic cylinders
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4.2
Grate furnace
Grate design:
Forward feed grate
Type of cooling:
Air-cooled
Inclination:
angle Grate module 1:18 degree
Grate module:
2-4:0
degree
Design with a solid metal construction.

The combustion grate consists of 4 grate modules.

The grate rows are alternately bolted to fixed- and movable grate plate supports.

In a grate module, the movable grate plate supports are connected to a movable grate
plate carriage (stroke length 300 mm).

The wheel blocks of the grate carriages are outside of the grate modules in a dust-free
area.

The hydraulic drive of the movable grate plate is outside the grate modules in a dustfree area.

To absorb the linear expansion, the grate carriages have fixed- and movable wheel
blocks on the left- and right sides.

The grate modules are provided with dividing walls for the air zoning.

Transitions between the bottom of the grate modules and the ash hoppers are
mounted.
The air-cooled combustion grate is characterised by the following special features:

Suitable for fuels like:

Waste with low calorific value

The combustion grate can be built horizontally or inclined.

Individual adjustment of stroke length and stroke speed of the grate drive cylinders at
each grate module, therefore optimal adjustment of the grate modules according to the
fuel composition (such as Humidity, Piece size, etc.).

Controlled fire management with an equal gas burnout.

Optimal possibility to position the fire in the longitudinal direction.

To prevent that the individual grate bars can lift, they are bolted onto the grate together
in bundles.
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The weight of these bundles prevents them from lifting.

The material expansion of the grate bars is absorbed through the lateral expansion
box.

By bolting the grate bars to bundles, in combination with the expansion box, it prevents
the formation of gaps between the grate bars. This results in a minimal material falltrough and a minimal ash and non- ferrous metal deposit below the grate.

Self-cleaning air outlet openings on the grate bars.
4.2.1 Grate Drive
The grate drives are arranged sideways, outside of the combustion grate. It is a steel structure
to support the hydraulic drive cylinders and wheel blocks. The steel structure is welded to the
grate framework to form a single unit with it. Wheel blocks of the grate carriage, hydraulic drive
cylinders with joint bearings are installed on the grate drive steel structure.
4.2.1.1 Sealing- and purge air:
The casing of the grate drive station will be supplied with sealing- and purge air to prevent flue
gas exits as well as heat accumulations. The supplied sealing- and purge air will flow toward
through the expansion boxes into the ash hopper.
4.2.2 Combustion air
The combustion grate is divided into 6 primary air zones. Each air zone has for the regulation
an air volume measurement with a pressure and temperature compensationand motor driven
dampers.
The secondary air consisting of four nozzle groups. There are two levels of secondary air
nozzles in the front- and in the rear-wall of the combustion chamber. The volume flows of the
front and rear walls will be measured. The air distribution to the two levels is made by motor
driven dampers.
4.2.2.1 Primary combustion air system

Radial fan qualified for frequency converter operation including the necessary
equipment.
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
Flow-, pressure- and temperature measurement.

Motor driven dampers for the air zones 1 – 6.

Intake silencer

Special flap on suction side for emergency stop with an electromagnetic holding device.

Air ducts including the necessary equipment.
4.2.2.2 Secondary combustion air system

Radial fan qualified for frequency converter operation including the necessary
equipment.

Flow-, pressure- and temperature measurement.

Motor driven dampers for the air zones of the face and rear wall combustion chamber.

Intake silencer.

Special flap on suction side for emergency stop with an electromagnetic holding device.

Air ducts including the necessary equipment.

The air boxes for the secondary air, front and rear section

The secondary air nozzles for the installation into the boiler casing
4.3 Ash removal system
The lost unburned carbone and the slags (inert residue) created by burning on grate furnace
Is transported by ash discharger.
The ash discharger is provided with replaceable wear plates (Hardox 450) and cladding panels
- as well as anti- wear strips at the discharge piston. The drive system is obtained from the
hydraulic unit of the combustion grate. The ash discharger is filled with water with a constant
slag volume up to the front panel. This ensures an exclusion of air against the combustion
chamber. The burnt-out, hot combustion slag will be dropped from the end of the
burnout zone into the water quench of the ash discharger.
The complete extinguishing of the grate slag takes place in this water bath. The grate slag will
be pushed by the discharge piston under the end panel through to the slag dropping edge.
This way a dust free and odourless discharge of the complete quenched grate slag is
achieved.
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Ash removal below the combustion grate, combustion zones 1 – 5

Ash hoppers

Double pendulum flap

Compensator

Vibrating feed pipe
Vibrating conveyor with vibrating power drive between the ash discharger and rubber belt
conveyor. Vibrating conveyor with a drive console in a vibration resistant welded construction
with mechanical formed drive console for the vibration drive. The drive system is mounted
sideways below the vibrating conveyor. The vibrating conveyor and the drive console are
connected together. With highly elastic, certificated helical compression springs the connecting
parts are mounted on a substructure. The conveying trough will be provided with replaceable
wear plates and cladding panels. The rubber belt conveyor will have a cover and a safety
protection against accidents.
The transportation of the ash and slag between the drag chain conveyor and the ash bunker
will be provided by a belt conveyor. The design of the rubber belt conveyor is a stable metal
construction. Maximum length of the belt conveyor to the slag bunker is 15 m. From there, the
slags are loaded onto the trucks by crane.
4.4
Combustion chamber (part of boiler)
The fluegas produced in the grate furnace are sent to the Combustion chamber.
The Combustion chamber is dimensioned on the basis of the fumes flow rate coming from the
grate furnace (to which the secondary comburent air must be added), the increase of volume
of the fumes due to the increase in temperature in the combustion chamber and the residence
time.
In order to ensure complete combustion, a utility volume is envisioned such to guarantee the
last introduction of secondary air, a minimum residence time of the combustion fumes at a
temperature > 850°C of 2 seconds at the nominal heat load, therefore, longer than the 2
seconds envisioned by the regulation in force. The temperature is detected in the last quarter
of the chamber, in proximity of the wall and in a shielded position.
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4.4.1 Burner
The burner installed on the combustion chamber (boiler sidewalls) 2x 13,000,000.00 kcal/h are
the adjustable turbulence type, suitable for use with methane gas and liquid waste.
A fan blows the combustion air into the burner head and from here into the combustion
chamber; the gas reaches the burner at the pressure reduced to the desired value and
appropriately stabilised. An adjustment valve manoeuvred by a servo-command driven by a
temperature of pressure adjuster, appropriately partializes the passage of the gas and this
translates into lower or higher flow of combustible from the plate distributor nozzles; at the
same time, the same servo-command manoeuvres the system that doses the combustion air.
The following are mounted on the structure of the burner realised in painted steel sheet:

Fixing flange to the head of the rotary element or the plate of the after-burner, with door
hinged in a way to facilitate opening of the burner and maintenance of the fire outlet.

Shutter unit for adjustment of the combustion air.

Double toroidal distributor for methane gas.

Gas feeding ramp.
Flame sensor
The DURAG photocell with its programming panel is mounted. The job of the photocell is to
guarantee that the burner functions only when the flame is present. If for any accidental reason
there is no flame, after 3 seconds by means of its programming panel the photocell panel puts
the burner into flame shutdown.
The photocell’s ability to detect ultraviolet rays emitted by all the flames must not be altered by
extraneous objects. For this reason its sensor must be kept perfectly clean and nothing should
be put between it and the flame that can absorb ultraviolet rays (such as glass). The advantage
of this kind of photocell is that other sources of light different from the flame do not interfere
and cause false detections.
When a flame shutdown occurs, to resume normal functioning the programmer contained in
the unit must be reactivated manually by pressing the appropriate button.
Flame guard
This is mounted on a dedicated sliding pipe and prevents the flame from being stretched. The
aim of its special inclination is to create turbulence in the combustion air in order to facilitate
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its mixing with the gaseous combustible.
Regulation unit
This consists of a servo control, the gas regulation valve for the regulation of combustion air.
The gas regulation valve
This is located on the circuit supplying gas to the burner and is controlled from the PLC.
Air regulation chamber
On the cam contour there is a roller lever that when returned opens or closes the air shutters
depending on whether the quantity of combustible burnt is greater or smaller. The PLC controls
the air to supply the quantity necessary for good combustion by setting the values for the
process.
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4.4.2 NOx reduction system – SNCR + SCR
Due to the nitrogen content in the waste, the high combustion temperatures and the residence
times that are necessary to destroy organic compounds of the waste, as well as the oxygen
content in the flue gas lead to the formation of nitrogen oxides (NOx). To reduce NOx, the
selective non-catalytic reduction (SNCR) method is used.
A urea-water mixture (reactant) is sprayed by metering pump and compressed air into the
furnace at a temperature window of 850 to 1,100 ° C - atomized.
Furthermore, NOx reduction (SCR) also takes place in the catalyst installed downstream from
the bag filter.
The urea dosing system is supplied in a unique skid with storage tank made up from two
autonomous dosing lines. The first line will serve the urea nozzle positioned on the postcombustion chamber. The second line serves the urea nozzle upstream from the catalyst.
Skid NOx plant technical specifications for one Line:
Tank
n° 1
Dosing skid (urea injection device)
n° 1+1
Lance:
n° 2+2
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4.5 Steam generator – Boiler
The heat produced on the grate passes through the boiler-system and yields its heat to the
pipes filled with demineralised water, which is transformed into steam at 41 bar(a) and 420 °C.
This steam passes directly into the turbine and by means of special nozzles keeps a 40-bar
rotor and another 3.5-bara rotor turning. By means of a reducer, the driving force of the two
above-mentioned rotors is alternated to a three-phase synchronous 4-pole alternator, and a
frequency of 50 Hz, which produces current. The steam that comes out of the turbine at about
0.156 bara and about 56 degrees must pass from a gaseous state to a liquid state through
cooling. This is done by an air condenser which is in a vacuum. The steam passes over bundles
of finned pipes, cooled outside by axial fans. At this point the water goes into the hot-water
tank and is sent with a dedicated regulation system into the deaerator, where it is deaerated
and heated to 105 degrees and then introduced back into the boiler-feed circuit. A turbine bypass system is installed which automatically intervenes whenever the turbine is not working,
sending the steam, after reducing its pressure, straight to the air condenser.
4.5.1 Boiler overview
The enthalpic content of the exhaust gases can be advantageously recovered through steam
production.
The steam can be usefully employed to produce electricity, hot water or superheated water or
all three energy vectors at the same time.
To what extent and in what forms the steam is exploited depends on techno-economic
evaluations and contextual evaluations regarding the area in which the incinerator is situated.
In the present project a positive evaluation was given to the production of green energy to
satisfy the plant’s consumption needs, and to transferral to the grid.
Briefly described, the system consists of a recovery boiler using water pipes along the exhaust
gas line, by a power station for the production of electricity and an air-condensation system.
4.5.2 Constructional features of the generator
The retrieval boiler is a natural circulation boiler with a boiling pressure of 41 bar at 420 C°,
with the production of super-heated steam. The surface of exchange by radiation and
convection is made of vertical water pipes.
4.5.3 Components making up the boiler
The boiler is made up of 3 fundamental components:
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a)
Evaporator, made up of a radiant chamber and tube bundle
b)
Superheaters
c)
Economizers
Evaporator – The water-steam phase takes place in the evaporator. It consists of a radiant
chamber and shell and pipe.
In the radiant chamber heat is transmitted mainly by radiation. In the shell and pipe
transmission takes place both by radiation and by convection at the expense of the heat
contained in the gases produced by combustion.
Superheaters- The steam produced in the evaporator is introduced into a series of pipe coils
installed between the the radiant chamber and tube bundle, and becomes superheated at the
expense of the heat produced by combustion. Also in this case, heat transmission takes place
mainly by non-luminous radiation and partly by convection.
The passing of water and steam through the generator takes place:
- in the evaporator by natural circulation
in the superheater at the expense of the pression generated in the evaporator.
4.5.4 Natural circulation
As the water heats up, its specific gravity goes down and the hot water tends to settle over the
cold water.
It is on this principle that the natural circulation of steam generators is based.
The water continues to heat up until it vaporizes and then circulation increases because the
steam, being lighter than water, tends to separate and rise.
With the increase in pressure, the specific gravity of the water and that of the steam become
closer and closer until they are equal, at a pressure of 225 atmospheres.
At this pressure natural circulation is no longer possible.
4.5.5 Radiant chambers
The radiant chambers are made of walls of tangent vaporizer pipes.
The generatrices of the contiguous pipes are welded to each other with continuous welding in
order to create a completely gas-tight casing.
As all the parts consist of vaporizer tubes, refractory lining is limited to single points and the
flue hatches.
Compared to the convection surfaces, the walls of the radiant chambers play a preponderant
part in the production of steam and so the pipes of these walls are those subject to the greatest
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stress.
Consequently, these pipes are subject to greater danger in the case of incorrectly treated water
and of dirt on their external part.
4.5.6 Drum – level in the drum
In the drum the water phase and the steam phase which, mixed together, arrive from the
evaporator pipes, are separated.
The steam occupies the upper part of the drum and the water occupies the lower one.
The feed water is supplied to the boiler through a pipe mounted in parallel with the drum axis
and sufficiently perforated to enable the water to mix with the water in the drum.
The separation of the steam phase from the water phase is favoured by two successive
separation systems:
The first system is situated on the lower part of the upper drum and consists of two levels of
staggered fins through which water is separated from steam by beating.
The second system is situated on the head of the upper drum. This consists of a Vico-Tex
pack. This Vico-Tex pack consists of a special very compact multi-layer mesh of stainless steel
150mm thick and functions as a filter, allowing only steam to pass through and retaining any
droplets of water contained in it.
The steam leaves the upper drum and, passing over the superheating surfaces, reaches the
desired temperature.
In the drum there is also:
•
piping for the injection of chemical reagents used to condition the boiler water;
•
piping for the taking of samples and for continuous discharge used to take the samples
and for the discharge necessary to keep the level of salts in the water within pre-established
levels.
The height of the water in the drum is called “level”.
The water level in the drum must be kept within two values called “minimum level” and
“maximum level”.
Minimum level:
The water must always be above the minimum level because below it the boiler pipes begin to
be incompletely filled.
In this case, the pipes are no longer properly cooled and begin to overheat until they reach the
temperature at which they break.
In cases in which the level goes a long way below the minimum level, the pipes can burst.
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Maximum level:
The level must be below the maximum to prevent water getting into the superheater.
The water level in the drum is not a perfectly smooth sheet of water, as can be perfectly
understood when one thinks of water when it rapidly boils, with bubbles and sprays of water
thrown above the level.
4.5.7 Superheater
The superheater is composed of three banks of pipe coils, with the ends, through which the
steam passes and becomes superheated, welded to the collectors.
A “desuperheater” is fitted between the two banks of the superheater for the regulation of
steam temperature.
4.5.8 Desurrerheater
The desuperheater of the superheater has the purpose of keeping the temperature of the
steam at the planned value in the production scale set.
Below the production scale set the temperature of the superheated steam does not reach the
planned maximum value.
The injection-type desuperheater needs the water injected to be salt-free to avoid deposits in
the superheater and turbines.
The water used for the desurrrheater is taken from the boiler feed water collector upstream
from the valve for regulation of the feed water flow.
Automatic steam temperature regulation acts on the water flow regulation valve to keep the
temperature of the surrheated steam constant.
4.5.9 Economizer
When starting up, the ideal situation is to feed with water at a temperature as close as possible
to that of normal functioning. In this phase, this prevents exhaust gases escaping from the
economizer at too low temperatures, which, together with the low temperature of the feed
water, could cause corrosion.
During normal functioning, the temperature of the exhaust gases at the bottom of the chimney
and load losses on the exhaust gas side between the entry and exit of the economizer must
be constantly controlled.
Too high exhaust gas temperatures and abnormal load losses indicate poor thermal
transmission resulting from excessive soot deposits on the external pipe surfaces, which are
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to be resolved by a cleaning system.
4.5.10 Superheater function
The saturated steam produced by the boilers and released into the upper drum is superheated
using the heat contained in the exhaust gases when these are still at very high temperatures.
To do this, the saturated steam is made to flow through the superheater, which is a complex
of coils against which exhaust gases at high temperatures flow.
While the vaporizer pipes of a correctly designed and operated boiler are always adequately
cooled by water or by the water-steam mixture contained in them, the superheater contains
only steam.
4.5.11 Boiler cleaning system
To get maximum production with a good output from a boiler, it is necessary to keep the heat
exchange surfaces as clean as possible.
The solid residue created by combustion and suspended in the exhaust gases separates itself
from them along the whole boiler circuit, adheres to the thermal exchange surfaces, hindering
thermal exchange, obstructs the passage of the gases and consequently makes necessary an
increase of draught.
The convective section is introduced into a horizontal channel and is made up from 3
Superheater – 3 economizer sloping banks (tube bundle) positioned in series on the fumes
side.
Every bank sector can be easily removed from above. The side walls of the channel are formed
from membranes, which are also fluxed with water.
Ash collection hoppers are mounted under the convective banks, they are cut-off by a manual
guillotine valve and a double clapet sealing element. A reedler evacuates the boiler ashes.The
first hopper is refractory internally, while the others are made with high-resistance metal
components.
4.5.12 Boiler feed water treatment system
A complete system has been planned for administering the doses of additives to the boiler
feed water. In particular, there are two dosing pumps installed for injection of the additives, at
high pressure into the drum and at low pressure after the deaerator.
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4.6
Energy Recovery (thermal cycle) - functional description
The Thermal Cycle is composed of the following systems with are the thermal cycle consists
of the following systems, which are designed for all four system lines:

4.7
Recovery

Air condenser with collector and piping,

Hot well and relaunching condensate pumps,

Turbine By-pass System;

Boiler feed water system, deaerator, feedwater tank, boiler feed water pumps;

Tanks for boiler drainage;
Steam Turbine & electrical Generator – Turbo unit
The steam produced by the boiler is expanded into a steam turbine of the condensing and
tapping type – “multistage turbine”; the energy produced is used for self-consumption and the
excess sold to the national electricity grid.
Spills are foreseen for internal use of the cycle and for a possible supply of steam to the district
heating/cooling network (if required).
4.7.1 General requirements for steam for turbine functioning
The conditions for sending steam into the turbine, dependant on the thermodynamics of the
cycle, will generally be as follows:

P = from 38 bar a to 42 bar a

T = from 380 °C to 420 °C
The ideal steam must be saturated and dry and guarantee perfect functioning without
anomalies.
With steam of high humidity (boiler water entrainment) the conductivity of the steam must not
exceed 2µS/cm. In extremely rare cases deposits can form and, in the presence of chlorine or
sodium chloride, corrosion can occur on account of cracks due to oscillations or stress.
The values are in conformity with the recommendations provided by the directives of the VGB
(Vereinigung der Großkraftwerksbetreiber – Large Boiler Users’ Association) and by the
parameters of the VIK (Vereinigte Industrielle Kraftwirtschaft – Machine Motor Manufacturer’s
Association).
The turbine allows counter-pressure plug bleed-off of steam at about 3.5 bar(a) for sending to
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the deaerator for preheating, (to teleheating of homes if necessary for other users of the cycle.)
The data for sonic power refer to the method of sonic intensity measurement on
macrogeometrical surfaces.
The levels of sonic pressure on measurement surfaces were derived from power levels with a
correction of +2 dB.
The correction margin was inserted in view of the fact that the measurement surfaces are not
only crossed perpendicularly by the sound waves.
The steam sent into the turbine must meet the following requirements:
Conductivity at 20°C in the condensate ≤ 0,3 µS/cm
sample based on the exchanger of cations
with high acidity and CO² release.
continuous functioning
For the flow functioning mode, in addition this boiler must possess
the requisites for steam < 0.2 µS/cm in continuous functioning,
also in consideration of the characteristics of the feed water
Silica
< 0.02 mg SiO² /kg
continuous functioning
Whole iron
< 0.02 mg Fe/kg
continuous functioning
Sodium and potassium
< 0.01 mg/kg
continuous functioning
Copper
< 0.003 mg/kg
continuous functioning
Oxygen
< 0.02 mg O²/kg
continuous functioning
Chlorine
< 0.01 mg CI-/kg
continuous functioning
Ph value
9.2 - 9,6
continuous functioning
4.7.2 Construction details of the turbine
The steam passes through the turbine in the axial direction. After passing through the quick
closing valve (shut down valve) the live steam enters the valve chamber which is melted with
the upper external half-casing. The valve chamber has the shape of a transverse tube with
opening at both ends for assembly.
The turbine case consists of an inlet and a discharge section.
Depending on the conditions of live steam, the inlet sections will be melted with different wall
thickness.
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The entrance section is completed by a discharge section of suitable size. The two sections
are joined by bolts.
The turbine casing is divided horizontally. The upper and lower half-casings are provided with
flanges and assembled by means of bolts.
From the valve chamber the live steam, through the passages of the regulation valves, goes
into a nozzle chamber.
turbine view interior
The nozzle chamber normally has the structure of a half-shell and is supported by the external
case. Half of the turbine casing, in correspondence with the nozzle chamber, has the structure
of a simple protection half-ring to avoid excessive ventilation losses.
The nozzle chamber can be structured as an internal casing, divided into two halves on the
horizontal plane and inserted, with a circumferential groove, into a corresponding annular
support inside the external casing.
In this case the nozzle chamber is positioned in a lateral direction by an eccentric guide pin
and in a vertical direction by thicknesses.
Since the inner and outer walls of the nozzle chamber are exposed to almost the same
temperature, there will be no substantial thermal stress.
The nozzle groups are inserted into the nozzle chamber and can extend for the upper halfcircle only, or for a complete circle.
The nozzle chamber can mount the steam sealing tapes and support the steam seal ring of
the balancing drum. Downstream of the nozzle chamber there are the paddle rings, inserted
with their grooves in corresponding annular supports of the outer casing.
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The blade carrier rings are positioned in a lateral direction by eccentric guide pins and in a
vertical direction by thicknesses.
4.7.2.1 Turbine rotor and blading
The turbine rotor has the wheel of the iron adjustment stage and is made, for forging, by a
large compact piece.
With the exception of the adjustment stage, the blading is of the reaction type.
The moving vanes of the regulation stage and the high-pressure stages have the root, the leaf
and the canopy obtained by milling from forged blocks.
The moving vanes of the low-pressure stages are untightened. Because of their large size and
thin thickness, it is impossible to design them in such a way as to be milled.
The moving vanes of the high-pressure stages have T-shaped feet - reverse or hammer-head.
Normally only the blades of the regulating stage have a fork-type foot, but sometimes the
blades of the last stages of low pressure can have the fork-like feet due to the centrifugal
stresses to which they are subjected.
The fixed vanes are obtained from materials rolled into bars and are provided with a riveted
roof.
4.7.2.2 Features of spills
The turbine is equipped with various controlled tapping; one feeds the low pressure steam
collector dedicated to heating the boiler water, a second tapping (more properly called
regulated extraction) transfers the steam to the vacuum group exchangers - ejectors. Further
steam is also tapped to flush the turbine seals.
The tapping for the low manifold is in any case regulated externally on the line by means of a
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"sliding bleed" two-point sampling which allows maintaining a constant pressure of steam
extracted even at minimum loads; in this sense, the system adopted is the classic one with
external adjustment to the machine.
More specific is the control of steam extraction for district heating, if required.
4.7.3 By-pass turbine
The turbine by-pass system automatically intervenes by discharging the high-pressure steam
directly to the condenser each time the turbine is out of service.
The system consists of a BTG (CCI Valve – special valve) pressure reduction station and a
steam desuperheating, normally intended for the turbine and to be sent to the condenser. The
pressure regulating valve is equipped with instruments that measure steam flow, pressure and
temperature. The aging water is regulated by an adjustment valve that is fed by condensation
pumps.
4.7.4 Oil system for lubrication and regulation
The oil system supplies the necessary oil for the adjustment of the turbine (hydraulic valves)
and for the lubrication of the bearings of the turbo-alternator. The two circuits are distinct.
The system consists of:

oil tank on top of which the pumps are mounted, main oil pumps for the screw type
lubrication circuit driven by an electric motor,

emergency oil pump for lubrication driven by an electric motor,

screw-type adjustment oil pump driven by an electric motor,

lubricating oil coolant, one of the reserve to the other switchable in operation,

double filter for lubrication oil, switchable in service,

double filter for regulation oil, switchable during operation

electrical level indicator,

electric heater,

temperature control valve,

oil fumes extractor,

centrifugal oil purifier.
4.7.5 Electro-hydraulic turbine adjustment system
The turbine regulation system is of the microprocessor, multi-channel digital type.
The output signals from the regulator supply electro-hydraulic converters to drive the valve
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actuators.
The controller software is made specifically for each installation starting from standard libraries,
can be updated and modified by a personal computer or by replacing the memory modules.
Control functions - The controller can perform the following control functions depending on the
operating modes:

rotation speed control, for an isolated running turbine, in the range from 0 to 105% of
the rated speed,

pressure control at the inlet, for a turbine working in parallel with the external network,

control of the minimum pressure at the entrance which acts by closing the admission
of steam if the pressure falls below the set point set,

extraction pressure checks, which act by keeping the pressures of the extractions at
the set point values,
This system is interfaced both in hard-wired mode and in fieldbus mode with the DCS general
control system.
4.7.6 Instrumentation and control devices

The turbine is supplied complete with:

pressure gauges and thermometers in the field,

pressure switches and thermostats,

thermometers for metal turbine bearings,

pressure transmitters,

thermoresistances for live steam temperature control

primary elements for the detection of the rotation speed, axial displacement and
vibrations of the turbine shaft,

local instrument rack.
4.7.7 Turbine accessories

drain valves with related connection pipes (the recovered condensate is sent to the
condenser - hot well),

thermal insulation of the machine and soundproofing cover,

non-return valves, where necessary, on the tapped steam pipes, complete with
pneumatic servomotor and interlocked to the locking devices,

N° 1 turner with automatic arming and disengagement, for the rotation of the turbine
rotor during stops and before starting, driven by an electric motor, with the possibility
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of manual operation,

regulation system for sealing steam.
4.7.8 Alternator
The synchronous generator is an alternating current machine, without rings or brushes. The
machine is cooled by the flow of water through it. The excitation system is mounted on the side
opposite the coupling. The system is composed of two parts:
The excitation armature that generates a triple-phase current coupled to the triple-phase
rectifier bridge supplies the excitation current to the generator’s rotary field.
The excitation armature and the triple-phase rectifier bridge are mounted on the rotor shaft of
the synchronous generator and are electrically interconnected to the rotary field of the
machine. The excitation inductor is powered by continuous current regulation.
4.8
Air condenser with vacuum unit and hot well
The steam at the outlet of the low-pressure side of the turbine is conducted in an aerothermal
condenser inside which the state changes from the gaseous to the liquid phase.
The air condenser consists of finned tubes (lamellar packs) in which condensate steam flows
internally, lapped on the external surface by air at ambient temperature conveyed by
appropriate fans.
The condensate is collected in a closed tank placed under the air condenser and from here it
is pumped into the deaerator positioned on the top of the boiler feed water tank.
The condenser is also designed to condense the steam produced at the nominal load when
the turbine is in by-pass status with an ambient temperature of about 38°C.
Main components of the air condenser:
4.8.1 Air condenser
In the air condenser the steam is condensed with the use of tubular bundles of finned pipe
using ambient air as a cooling element.
This condenser is in the configuration K/D, a combination of tubular bundles using direct
contact, type K (with the steam flowing in the tubular bundles from above downwards in the
same direction as the condensation), and tubular bundles using dephlegmation, type D (with
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the steam flowing in the tubular bundles from the bottom upwards and therefore in the opposite
direction to that of the condensation that forms in them).
Each tubular bundle has two rows of finned pipes, with one placed over the other, with a
different spacing of finning between the pipes in the upper row (in contact with cold air) and
the pipes in the lower row (in contact with the hot air heated in passing through the lower row).
The cooling air is moved by means of manual-type axial fans under frequency converter (with
regulation of the blade angles with the fan off) designed to produce forced air.
The tubular bundles, supported on a roof-type hot-dip galzanized steel-frame structure have
hot-dip galvanized carbon-steel finned pipes. The heads are welded to guarantee perfect
sealing in the presence of a vacuum
4.8.2 Steam distribution pipelines
The air condenser is connected to the steam turbine discharge flange; the latter finishes at the
steam distribution pipe located on top of the air condenser and directly welded to the type-K
tubular bundles.
The tubular bundles (types K and D) are connected by an adequate number of shafts to the
condensate collection pipes (dephlegmator pipes) situated under the bundles.
The dephlegmator pipes have the following functions:

To carry the surplus uncondensed steam in the primary direct-condensation section (K)
to the secondary dephlegmation section (D).

To collect condensate from all the tubular bundles and send it to the collection tank (hot
well).
The condensate collected in the dephlegmator pipes flows into the collection tank (hot well) by
gravity and is then recycled into the system by means of two single-phase centrifugal pumps.
Welding is used in the construction of the whole system to guarantee perfect sealing in the
presence of a vacuum.
In addition, the various safety valves are applied, such as the discharge valve and the rupture
disk.
The exhaust steam line is built (designed) for the particular operating conditions that occur in
the case of low pressure steam at high flow rates and is also designed to condense all the
steam produced at the nominal load when the turbine is in by-pass status.
The supply includes the entire pipeline from the turbine exhaust to the connection to the steam
distribution pipeline and the complete evacuation system immediately downstream of the
turbine exhaust connection to limit the exhaust steam temperature in the event of turbine
operation vacuum or partial load, with accessories, regulating valve, pipes, fixings, etc.
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between the exhaust pipe and the passage opening, sealed and rainproof hermetic joint.
4.8.3 Axial fan units
The design features two axial fans with extruded aluminium blades installed on a suitable
supporting structure and designed to produce forced air (the angle of the blades can be
manually adjusted when the fan is off).
The electric motors are coupled to the axial fans using reducers with trapezoidal belt reducers.
The axial cooling air fans include for each:
•
fan transmission;
•
the fan impellers consist of the hub and the profiled blades attached to the latter. The
adjustable inclination blades are joined to the hub by means of fixing brackets or pins;
•
the motor, with predisposition for frequency converter;
•
aerodynamic air inlate;
•
the protection grid;
4.8.4 Sound-absorbing protection wall
The sound-absorbing wall with sandwich structure with galvanized perforated metal sheets on
the inside, mineral fiber felts as anti-acoustic material and trapezoidal profiled sheet coated on
the outer side, placed on all sides between the condenser platform and the upper edge of the
distribution pipe vapor. (The sound-absorbing wall is supplied only in the event requested by
the end customer - otherwise it remains an optional supply).
4.8.5 Steam Ejector system
There will be a suitable steam ejector vacuum unit of a capacity great enough to guarantee the
extraction of the air and uncondensable substances inside the part of the system in a vacuum
(air condenser, steam adduction pipe, etc.) both during start-up and during normal running.
For starting up of the system there will be a single-phase ejector complete with silencer able
to pre-evacuate a total volume from atmospheric pressure to the absolute pressure of 150mbar
(a) in about 30-40 minutes, with the turbine seals closed by steam.
For normal running there will be two two-phase steam ejectors, complete with interphase and
final surface condenser (sustainment ejectors). One of the two units is kept working while the
other is kept in reserve (stand-by condition).
The ejectors for normal running (2 x 100%) will work with both phases active in the suction
pressure field between 70 and 500 mbar (a).
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The group for production and maintaining the vacuum consists of:
•
a vacuum forming ejector, complete with all the accessories necessary for operation
(mainly the AP steam power circuit, condenser and condensate drain).
•
two pairs of retention ejectors powered by low pressure steam, complete with
condenser and all the accessories necessary to maintain the vacuum.
Main components "vacuum group":
•
starter ejector with connecting flanges;
•
exhaust steam muffler for the connection ejector;
•
operating ejector with connection flanges;
•
intermediate and post-condenser capacitors for operating ejectors, designed as twin
units, complete with connection sleeves, steam and condensate collectors, etc.;
•
all necessary supply and discharge pipes, including valves;
•
support brackets for piping ejector and fixing system;
4.8.6 Hot well – condensate collection tank
The hot well or condensate collection tank provides a high level of storage for the safe and
regular operation of the condensate extraction pumps, located under the air condenser. The
hot well has an adequate capacity to give the extraction pumps a necessary beater as they
pump the condensate to the deaerator.
The hot well is composed of the various components:
•
Main steel condensate tank (tank volume for an accumulated stock of at least 10
minutes under design conditions), flue with flanged cover, tank support, control and
level indicator (DCS), temperature indicator and pressure.
•
Main condensation pumps: main condensate pumps (including 1 redundant), complete
with foundation plate, motor, coupling coupling protection and fixing screws, design for
operating conditions with the greatest stresses that may occur, as well as for local
installation conditions.
•
Low pressure preheater: for heating the condensate from the air-condenser with
tapping steam (low pressure) coming from the turbine, complete with connection
sleeves, steam and condensate collector, etc.
•
Other components installed on the hot shaft:
Pneumatic regulating valve for condensate level regulation, filter, valve bypass
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duct;
Pneumatic regulating valve for sending the condensates to the deaerator, filter,
bypass pipe of the valve;
All the pipes required on the steam side and on the condensate side with the relative
valves for the connection of the above-mentioned system components;
Complete control air distribution starting from the main power supply of the
aforementioned plant components, complete with supply and distribution lines, line,
accessories and pressure maintenance valve with pressure indicator.
Main condensation pumps (condensate pumps):
Three single-phase centrifugal pumps are installed to send the condensate from the hot well
to the deaerator. Only one of the pumps is kept working while the second pump is kept 100%
in reserve (stand-by condition).
The control system that selects, operates and stops the above-mentioned pumps, as well as
the control of the minimum condensate flow is part of the system’s PLC. In particular, whatever
the operating conditions, a minimum condensate flow must be guaranteed.
This is always guaranteed, even when the volume of condensate is very low (low steam
charging), by the opening of the minimum recycle valve.
The minimum recycle valve works in “split range” with the valve for drainage to the deaerator.
4.8.7 Air condenser control
The air condenser control system is managed by the following signals (sent by the plant
instrumentation):
Exhaust steam pressure after the turbine discharge output, measured on the steam
adduction pipe (PT-pressure transmitter).
Exhaust steam pressure after the by-pass input, measured on the steam adduction
pipe (PT-pressure transmitter).
Condensate temperature taken in each single dephlegmator pipe (TE-temperature and
TE-temperature).
Ambient air temperature (cooling air, TE-temperature).
The condenser control system acts on the electric motors that power the axial fans by selecting
their rotation speed. All the other plant components such as pumps, ejectors, tank, etc. are
fitted with local instrumentation (thermometers/manometers/level gauges) and the transmitters
necessary for their monitoring and remote control.
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4.8.8 Semi-automatic condenser cleaning system
The semi-automatic condenser cleaning system is installed on each side of the air-condenser;
(The condenser washing system is supplied exclusively upon request by the end customer and
offered in part as an option, otherwise not included in the supply).
Possible supply consists of:
Lightweight frame construction chassis with walkable ladder, bilateral railing and guide rails for
nozzle support carriage, guide rail system for the system chassis along each side of the
condenser:
•
trolley with nozzle support, nozzles and trolley drive;
•
high pressure pump on trolley with manual movement;
•
control panel for high pressure trolley and pump;
water pipes and high pressure hoses, including fasteners and valves;
4.9
Deaerator & Feedwater Tank
The deaerator is a mechanical devices that remove dissolved gases from boiler feedwater.
During the deaeration process, concentration of the dissolved carbon dioxide and oxygen is
reduced to a level where corrosion is minimized; hence the steam generation system is
protected from the harmful effects of corrosive gases. To prevent corrosion, steam generation
systems work with adequate pressure and a dissolved oxygen level of at least 5 parts per
million (ppb) is required. However the dissolved carbon dioxide is essentially completely
removed during the deaeration.
The deaerator uses steam to heat the water to the full saturation temperature corresponding
to the steam pressure in the deaerator and to carry away dissolved gases. The deaeration
system consists of deaeration tank, a storage tank and a vent.
In the deaeration tank, water is heated and agitated by steam bubbling through the water.
Steam is cooled by the incoming water and condensed at the vent condenser. Noncondensable gases and some steam are released through the vent. Steam provided to the
deaerator provides physical stripping and action and heats the mixture of returned condensate
and boiler feedwater make-up to saturation temperature.
While most of the steam condenses, a small percentage of steam must be vented to
accommodate the stripping requirements.
The deaerator is a vertical cylinder. Entry is through an manhole in the side of the vessel. A
metal frame is welded inside the deaerator to hold trays and rings
The storage tank is a horizontal cylinder. Entry is through a manhole in the north head.
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This part of equipment is composed of two main parts:
a) Vertical cylinder - deaerator completes with:

air valve;

vacuum-break valve;

condensate feed line with interceptor valves and a backflow shut-off valve;

reintegrative demineralized water line fitted with interceptor valves and a backflow
check valve fitted with interceptor valves and a backflow check valve;

bled-off steam feed line fitted with a backflow check and interceptor valves;

spray nozzles in stainless steel (AISI 304);

perforated stainless steel contact plates.
b) Horizontal cylinder - storage tank fitted with:

safety valve for excess pressure;

dregs drainage valve;

too-full, low and very low level gauge

sight glass;

manhole;

pipe connecting to the boiler feed pumps, complete with interceptor valves downstream
from the tank and upstream from the pumps;

too-full level gauge with relative discharge valve.
4.9.1 Boiler feed pumps
Two pumps for each facility line keep the boiler feed. The pumps, one of which operates while
the other is on stand-by are made of stainless steel and are fitted with:

suction filter

differential manometer

control valves

lubricated bearings

gland stuffing box with water cooling
The pumps are equipped with an automatic recycling valve calibrated to the pump curve.
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4.10 Demineralize water production system
The demineralized water production system provides water with adequate chemical and
physical characteristics for the restoration of the thermal cycle and for other users, starting
from industrial raw water available on site.
The technology used is that of reverse osmosis and mixed bed resins in series, not
regenerable, of guard and / or emergency.
Reverse osmosis exploits the tangential filtration principle, in which the fluid to be treated,
pushed under high pressure, is separated by a semipermeable membrane in two flows, the
permeate and the concentrate.
The demineralized water production plant feeds a storage system.
4.10.1 Process description
The demineralized water produced has characteristics that comply with the requirements for
the reintegration of the thermal cycle. The parameters of the incoming water and the requisites
required for the outgoing water are reported in paragraph 3.
The plant consists of two reverse osmosis lines, with mixed beds working alternately. In case
of malfunctioning of an osmosis line, the water will flow to the mixed bed, treated by a single
osmosis stage.
The second line of osmosis allows, however, to be able to use, through recirculation, the
proportion of waste water (concentrated). Sampling points are prepared at the exit of each
treatment phase, at the entrance of the mixed beds and at the exit of the system.
The system works in a totally automatic way without surveillance being required.
All the functions are controlled by a local control and supervision system, equipped with the
instrumentation necessary to perform the intended functions and to inform the DCS control
system on the operating status and to signal any faults in a profibus way.
It is also possible to carry out the main operations also from the DCS control system.
The start-up and shut-down of the plant are subordinate to the levels of the storage tanks.
The type of system avoids contamination of the environment in the event of malfunctions.
4.10.2 Pre-treatment
At the entrance of the system, the water to be treated is filtered through a cartridge filter with
the purpose of eliminating any particles or foreign bodies that might end up in the circuit.
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with “Drinking Water Treatment Station”
Demineralization - first phase
The first phase, with membrane technology, consists of a reverse osmosis unit, followed by a
second in series.
Demineralization - guard / emergency group
To achieve the quality of the specified water follows an aging group, consisting of two units,
with mixed bed technology. The low and constant conductivity value at the output of the 2nd
osmosis stage allows the use of non-regenerable mixed bed resin columns. At the exit from
the mixed bed, a resin trap is installed, with a degree of retention suitable for the granulometry
of the resins adopted.
A general list of the main components of the system is shown below:

The first treatment stage of the system consists of a cartridge filtration,

First stage desalination - water softener

First stage desalination - reverse osmosis

Electrodeionization Unit (EDI)

Exchangers mixed bed

Reintegrating water tanks

Option: If necessary, considering the quality of water on site, a deferrization and /
or a demanganisation plant is also provided.
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MSW – Waste to Energy 750,000 ton/year
with “Drinking Water Treatment Station”
4.11 Flue gas cleaning system
The flue gas that is produced during the incineration of residual waste is enriched with a wide
variety of particulate and gaseous pollutants. Each pollutant emission means an interference
with the natural composition of the atmosphere. In order to remove these substances as far as
possible, the flue gas passes through various purification stages. Constant measurements are
used to check the constant effectiveness of the individual cleaning stages. The system adopted
is of the “Dry type” and has the following main components of the flue-cleaning:

Cyclone

Reactor N. 1

Bag filter N. 1

Reactor N. 2

Bag filter N. 2

Catalyst

ID-fan

Chimney
4.12 Cyclone
Cyclones are abatement systems that, without using moving parts and using appropriately
shaped inlets, allow to separate the contaminating particles. In particular, the gas and dust
stream are passed into a system consisting of two concentric cylinders. At the incoming gas a
spiral motion is imposed in the gap between the two cylinders, from top to bottom. The gases
can then exit through the inner cylinder, lower than the external one. The particles, having
greater inertia with respect to the gas, will tend to bump against the walls of the outermost
cylinder, and to fall on the bottom of the system, where a hopper for the recovery of the
powders is located (principle of operation is the centrifugal force)
The powders can then be recovered for a subsequent treatment step. Ideally a cyclone can be
represented by a cylindrical structure with a funnel outlet, consisting of an inlet of the gas to
be treated and an outlet. The ability to treat particles with a more or less fine particle size
depends on the diameter of the cyclone.
The particles are subjected to a centrifugal force, which allows the separation of dust from the
air
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Generally, the cyclone is used as a pre-slaughtering system, above all with important quantities
of material to be filtered:
-
safeguards the next filtration stage (bag filter or cartridges) from high dust loads, with yields
ranging from 50% to 97%,
-
pre-felling and total elimination as applied to the combustion process;
4.13 Reactor 1+2
The flue gases leaving the cyclone enter at approx. 220°C the vertical cylindrical housing of
the reactor.
In the reactor, the adsorbents sodium bicarbonate and activated carbon are injected to reduce
the pollutants. The sodium bicarbonate is used to adsorb HCl, HF and SO2. The addition of
activated carbon adsorbs dioxins, furans and volatile heavy metals.
The geometry of the reactor and the suitable residence time of the flue gases ensure good
mixing of the flue gases with the additives.
The mixture of sodium bicarbonate (ground to 20 microns) and activated carbon is blown
through a special tube.
Furthermore, the first reactor also fulfills the task of a "high-temperature" alarm, which is
activated at the filter inlet opening. A flue gas damper mounted on the reactor prevents the
damaging of the filter hoses by the inflow of tertiary air.
4.14 Bag filter 1+2
The bag filter has a very high reducing efficiency and has the type of cells that can be excluded
for the cleaning and maintenance operations; the Teflon bags (high specific weight filtering
membrane) assure very high filtering capacity and allow the following:

to dimension the bag filter with lowest filtering speed,

to limit dimensions of the filter and, consequently, facilitate the maintenance operations,

to decrease the head loss,

to handle fumes at high temperature up to 250°C,
The Teflon filter sleeves (high specific weight filtering membrane) assure very high filtering
capacity.
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The resulting filter cake on the filter bags causes a secondary reaction between the unreacted
or partially reacted sodium bicarbonate/activated carbon and still free gaseous pollutants
(HCL, HF and SO2, dioxins, furans and volatile heavy metals).
The filter elements are mechanically cleaned in adjustable intervals by means of compressed
air.
The resulting filter dust (salt, dust and excess reagent deposit) deposit in the hopper under the
bag filter and are unloaded by an extractor auger with rotary feeder, which unloads the residues
directly into a transport line, which conveys the dust pneumatically or mechanically into a
storage silo.
Filtration
cycle
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4.15 DeNOX catalyst (catalytic system for the reduction of dioxins and furans)
The fumes exiting bag filter with a temperature of approx. 178°C pass through the low
temperature vertical DeNOX type catalyst with two sections.
In the first section CO and HC are eliminated and NO is transformed into NO2.In the second
section, the NO2 allows oxidation of the particulate at normal fumes temperature. The NOx
are not significantly reduced, but the elimination of the other pollutants is allowed, such as
dioxins and furans. The small cells of the honeycomb structure are alternately closed and
opened; the walls, impregnated with catalyst, allow the passage of gases but not of the
particulate.
The catalyst is metal oxides based (WO3, V2O5) on a support of TiO2 in the form of anatase
and is envisioned as honeycomb. During crossing, the oxidative action takes place on CO and
HC. Also, in this case, there is not a significant reduction of NOx. The main task of the DeNOX
installed is to remove the presence of any dioxins and furans (PCDD and PCDF) and
secondarily, also part of the NOX present in the fumes already activated by the previous SNCR
system.
The great advantage of this geometry with approx. 70% of free transversal section, constitutes
the best combination of the minimum loss of pressure with the maximum geometric reaction
surface. Furthermore, this geometry minimises the clogging hazard, which can be caused by
fly ashes. The catalytic reaction takes place with the injection of urea mixed with water. The
work range is between 160 and 220°C.
Honey comb catalyst
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4.16 ID fan
The variable speed fan with steel impeller, ensures the negative pressure necessary for the
entire MSW plant. The negative pressure in the furnace grate is adjusted by the PLC via Delta
P instruments and with the fan under inverter control.
4.17 Chimney
For the evacuation of the combustion products there is an industrial double-walled flue system,
for modular assembly, for dry and wet operation.
The chimney is partly made of special steel, resistant to corrosion due to atmospheric agents,
and in high-alloy steel, as acid condensation conditions can occur.
The inner tube is made of stainless steel and the outer one is made of carbon steel with a static
function.
The cylinder is height of approx. 25 m and with diameter of approx. 1,600 mm an insulated
externally by an insulating mat of ~ 100 mm.
Flanges are also set-up on the chimney for the withdrawal operations by the control authorities,
and for the withdrawal of samples for determination of the parameters not measured
continuously, such as dioxins, furans and metals, there is an inspection door and condensate
drain flange. Under the cylinder there is a hopper for collecting rain and / or any condensation
which, by means of a pipeline, discharges directly into a collection tank for dirty water.
In order to reach the Analysis part on the chimney, a platform will be installed at a suitable
height with a rope ladder for access. On the top of chimney are attached with aviation safety
light in reference to the ICAO (International Civil Aviation Organization) standards.
4.17.1 Protection against atmospheric discharges
Being a plant element so called in "exposed situation", the chimney is equipped with an
adequate lightning protection system with earth leakage devices that are independent of the
system grounding
4.17.2 Analysis at the chimney
The analysis of several typical parameters are performed continuously and in particular:
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CO, CO2, NOX, O2, HCL, SO2, TOC, dusts, dioxins and furans (sampling only) temperature,
pressure and volumetric capacity. The signals are transmitted to the control and command
room PLC where they are processed, taken to 11% of the content of dry oxygen, displayed on
the monitor and printed daily.
The system is made up from - at the withdrawal point:

SICK sampling probe or similar,

SICK dust measuring device or similar,

SPAN/Air/ sample transfer line;
at the position RACK in air-conditioned place:

SICK analyser or similar

SICK model analyser or similar x TOC

SICK model air humidification panel or similar,

T.I.G. calibration panel or similar;

Software for processing, calculation and production report model ADAS, Loccioni or
similar, complete with PC, SVGA, Windows XP and printer.
The software implements the data validation procedures and assessment of the emissions
described in Italian Ministerial Decree dated 21 December 1995 Decree regulating the
methods for controlling emissions into the atmosphere by industrial plants and in Italian
Legislative Decree n. 133 dated 11 May 2005, Implementation of Directive 2000/76/EC,
regarding incineration of waste.
Container: cabin with pre-fabricated metal structure complete with insulation, air conditioning
and electric plant.
Dimensions: in metres Length 2.5 x width 2.4 x height 2.4
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with “Drinking Water Treatment Station”
4.18 Additives- and Residues storage & feeding systems
The following storage systems are provided for the residual waste collection and the necessary
resources for the flue gas cleaning system:
- Storage silo sodium bicarbonates and mill,
- Storage silo activated carbon storage,
- Storage tank urea,
- Storage silo boiler ash,
- Storage silo of residual sodium products,
4.19 Storage silo sodium bicarbonate and dosing with Mill
The sodium bicarbonate is stored by silos, from where the product falls into its relevant hopper
with conical bottom that vibrates intermittently (during the extraction period only, if the material
does not escape) and with and outlet on the bottom with shear gates. The bicarbonate is
loaded into the micronization mill via the rotary feeder and transfer auger.
The mill grinds the bicarbonate to 20 micron. In this way, the absorption surface is greatly
increased thus promoting the chemical reaction with the acid particles. Furthermore, the
consumption of sodium bicarbonate is greatly reduced.
In the intermediate hopper where a level detector adjusts the flow rate, the bicarbonate is
transported via a dosing auger into a selector that develops two successive functions:
-
grind the material in order to produce a determined particle size,
-
select the ground material, in a way to obtain the desired particle size curve.
After having passed the rotary feeder, the micronized product is sucked by the fan and blown
into the reactor downstream from the boiler.
The entire system is adjusted via the PLC from the control and command room.
The mill is insulated with sound-absorbing panels to prevent the infiltration of moisture and to
reduce the noise made by the same.
The bicarbonate is injected in the reactor 1 and reactor 2 in according to the emission levels
of SO2 and HCL.
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4.20 Storage silo and dosage of activated carbon
Like the bicarbonate, the activated carbon is stored in a silo on a steel load-bearing structure,
from where the product falls into the relevant hopper with conical bottom that vibrates
intermittently (during the extraction period only, if the material does not escape) and with and
outlet on the bottom with shear gates.
The rotary feeder and auger unload the carbon onto the dosing unit, made up from another
hopper and weighing auger. Consequently, the charcoal passes beyond the successive rotary
feeder and from there is blown via blower device and tubes with suitable diameter into the
reactor downstream from the boiler.
The activated carbon is injected in the reactor 1 and reactor 2 according to a fixed control
variable and adjusted to the emission values.
4.21 Storage tank and dosage of urea
Please refer to chapter 4.4.2 NOx reduction system – SNCR + SCR.
4.22 Storage of ash
The ash is stored in a cylindrical silo with the lower part. The silo, has a cylindrical shape with
the truncated-cone bottom, is equipped with the following components:
-
Sleeve filter for venting the transport system;
-
Depression and overpressure valve;
-
Manhole on the roof;
-
Analogue level indicator with indication from 0 to 100%;
-
vane level indicators (minimum, maximum, very high);
-
Air shock (4) for cleaning the lower cone.
Two horizontal shut-off shutters in series are installed under the discharge of the movable floor.
Dry ash discharge, for direct loading in tankers, consists of:
-
double guillotine damper and a terminal regulation rotary designed to stop a sudden flow
of dust due, for example, to the collapse of a bridge in the silo;
-
bulk loading systems dust-free loading of bulk goods into silo vehicles,
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4.23 Storage residual sodium products
Storage of residual sodium products coming from bag filter it takes place in a cylindrical silo
with the truncated-cone bottom, equipped with the following components:
-
Sleeve filter for venting the transport system;
-
Depression and overpressure valve;
-
Manhole on the roof;
-
Analogue level indicator with indication from 0 to 100%;
-
vane level indicators (minimum, maximum, very high);
-
Air shock (4) for cleaning the lower cone.
Under the bottom there is the extractor formed by an elliptical mobile frame with
trapezoidal section traversing and control by means of hydraulic cylinders.
The cylinders are operated by a special control unit.
Two horizontal shut-off shutters in series are installed under the discharge of the
movable floor.
Dry ash discharge, for direct loading in tankers, consists of:
-
a terminal rotary valve able to stop a sudden flow of dust due, for example, to the collapse
of a bridge in the silo
-
exhaust duct formed by a flexible tube with lifting winch - bulk loading systems dust-free
loading of bulk goods into silo vehicles,
-
bag filter for dust collection with suction fan.
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with “Drinking Water Treatment Station”
4.24 Steel structures, platforms, ramps, stairs
All necessary steel structures for the plant components as well as stage stairs are
manufactured in uniform steel quality with an extensive surface coating. The railings in
industrial construction are manufactured according to local standards. The gratings are hotdip galvanized and fastened with their own quick-mounting brackets.
4.25 Piping and Valve
Plant piping includes pipes of various types of materials pressure in black and galvanized steel
and not under pressure. Pipes for boiler water, superheated & saturated steam, demi water,
compressed air, methane gas, condensation, process water, and various drains and vents,
main collector superheated steam, hydraulic oil.
In general all brackets, supports, fixed points, expansion joints, linear and angular
compensators, fittings, curves, tees, reducers and accessories are to be considered
compensated as part of the piping supply.
All shut-off valves are suitable for temperatures and pressures maximum levels of the circuit
going to serve, as well as the nature of the fluid conveyed. The valves will be positioned in
such a way that they are easily reachable from the service staff; any metal structures or
necessary pipe changes to make the valves accessible, they are considered an integral part
of the supply. The valves installed must have a nominal pressure of at least 1.5 times the
operating pressure of the network considered. In general all the valves will be welded on
circuits with operating pressure greater than 25 bar, while connection flanges must be used
for minor pressures.
All two or three-way control valves will be installed in place easily accessible. All motorized
valves will be installed in a manner such as to be able to replace or control the motor without
putting the entire system out of service. The control valves serving the process will be equipped
with a by-pass system, so that valve maintenance is possible without requiring the out of
service of the plant or line on which it is placed.
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5. MATERIAL RECOVERY SISTEM
Slag/Ash present in domestic waste incinerator plant where wet discharge takes place
presents a particular challenge for subsequent processing. High moisture levels and a metal
content to which, predominantly, other material adheres demands a separation technology
specially designed for the purpose. As an alternative, dry procedures are used for the ash
removal in which metal separation in the fine grain range can generally be achieved more
efficiently.
The slag/ash coming out from the incinerator will result in, fine-grain content with grain
diameters d<10 mm may be obtained of up to 50% and d<4 mm up to 30%. These fine fractions
contain a particularly high proportion of recoverable heavy metals such as copper. Because
electronic components with ever-smaller parts are being burnt along with municipal solid
waste, however, a significant proportion of noble metals are present in the <2 mm grain range.
The slags/ashes thrown out by the conveyer are taken to a material processing station where
the raw materials still contained in the slag are recovered. The slag processing plant operates
in several stages.
Materials recovered from reprocessing can be the follow:

Glass

Ferrous Metals

No ferrous Metals

Stainless Steel

Copper

Precious Metals

Minerals
Typical slag without recovery materials system
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5.1
Location and logistics of the recovery material plant
The materials recovery plant was immediately installed behind the waste incineration plant,
to avoid long transport routes for the wheel loader within the two facilities.
Materials recovery plant
Specially trucks and wheel loader are used to transport the slag from the plant to the recovery
material plant. Both transport the slag directly into an intermediate storage box consisting of
open concrete boxes. From there, the processing plant is fed directly.
The wheel loader gives the slag on the various conveyor belts and vibration conveyers.
The wheel loader and the truck are not included in the offer.
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Loading the slags/ashes:
typical bottom ash wheel loader
5.2
typical slag/ash transport truck
Slag/Ash Treatment
Example for a treatment process
5.2.1 Ferrous metals
For the separation of ferromagnetic materials, we use the special permanent magnetic guide
pulley, the self-cleaning ceiling suspension magnet unit and the robust magnetic drums with
maximum selectivity.
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5.2.2 No ferrous Metals
The equipment we used to expel the non-ferrous metals have been tried and tested with
innovation in the separation. We used and continue to use the established eccentrically
mounted magnetic pole system with powerful neodymium-iron-boron magnets and robust
construction of all machine elements in its eddy current separators.
The core features of the extraction facility are a self-supporting frame construction allowing
faster belt replacement, variable adjustment of the pole system's application point, optimised
accessibility to and overview of the separation area and a fundamentally revised external
design.
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6. DRINKING WATER TREATMENT PLANT
Multi-Stage-Flash (MSF) Distillation is a large scale sea water desalination plants that are
widely used in Gulf area. Most installations of MSF plants are operated in cogeneration with a
power plant. Also, MSF plants can be combined with other desalination technologies such as
Nano filtration and Reverse osmosis (RO) in new installation. However, the new MSF plants
are recommended, where large amounts of cheap or waste energy are available (e.g.
conventional power plants). Also, the plant location is playing an important role for economic
operation due to cold or hot weather conditions.
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7. Electrical parts & process control system
7.1
PCS - Process control system (DCS)
7.1.1 Philosophy of automation
The control system is dimensioned to specific plant requirements and combines simplicity of
use with an appropriate degree of complexity.
In particular for the command, control and supervision of the plant systems two PLC systems
are installed with each separate supervision that corresponds to the following requirements:

compatibility with other systems and with popular programs;

easy management

fast response;

flexibility;

modularity;

suitability to future upgrades;

suitability to remote access;
The automation system tasks include the following:

collecting system operating parameters

processing these parameters and displaying them to the operator

carrying out a sequence of automatic operations that maintain the system in optimal
operating conditions during the various functioning conditions,

precisely timed execution of a variety of automatic tasks in the event of anomalous
process conditions in order to limit the extent and duration of failure and avoid system
damages.

easy execution of various operations by the operator.
The system collects all the analog and digital values necessary for the above. The system
works continuously automatically; normal system operation and normal or abnormal status
changes are controlled by making the status of the components, the status and the operating
parameters and the evolution of the command sequences available to the operator.
In particular, an automatic and timely intervention is envisaged every time the system or the
components are brought into conditions of potential damage to themselves or to other subjects
and in any case for any evolution of the rapidity system incompatible with the response time
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of the operator. (protection function).
The control system includes operator stations, keypads and monitors, on which the synoptic
of the system will be displayed with the instant operating conditions, faults, alarms and status
signals and how much useful for the optimal management of the system.
All main switching and control components are installed in the control room building
The control panels are positioned in such a way as to allow easy intervention by the operators.
The panels are sized considering the possible need to insert additional input and output
signals.
The hardware is so specified:

n ° 1 supervision centre - SCADA

n ° 1 supervision client - SCADA

n ° 2 PLC with the relative remote units composed of necessary racks connected with
coaxial cable and/or optical fiber complete with:
digital input acquisition cards
analog input acquisition cards
digital output control boards
output control boards and / or analogue output settings
SCADA
PLC
Field instruments
I/O signals
Fig. 4 Field level: Example of an automation pyramid
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7.1.2 SCADA - Supervisory Control and Data Acquisition
To meet the needs of the system it is essential that the solution is based on a Client-Server
software architecture that guarantees the easy expandability and adaptability of the system to
respond to changing needs.
In detail, plant control, monitoring and supervision is ensured by a SCADA system featuring
FIX INTELLUTION supervision, meeting the following requirements:

maximum data reliability

optimal software maintainability

accessibility of data from each workstation independently

number of operative positions of the Supervisory System in fact bound solely by the
type of network

possibility of installing local Clients (connected in LAN) or remote Clients, for example
connected via a dial-up telephone network, from which all the functionalities available
at central stations are available
7.1.2.1 Supervision center configuration:
Supervision Server Post of plant:
-
N° 1 PC Server

Ethernet network switch

Communication card with redundant PLC

Two Industrial Ethernet network switches

Italian mouse and keyboard

Operating System Windows

Monitor 27" LED, 1280 x 1024 pixels

A4 color inkjet printer

Alarm printer

N° 1 - PowerTag Run-Time License
Supervision Client Station of plant:
-
N ° 1 PC Client:

Italian mouse and keyboard

Operating System Windows

Monitor 27“ LED, 1280 x 1024 pixels

A4 color inkjet printer

UPS 500VA

SCADA Run-Time license
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TECHNICAL PROPOSAL
MSW – Waste to Energy 750,000 ton/year
with “Drinking Water Treatment Station”
7.1.2.2 Supervision system - main features:
The Central Unit must be accompanied by a WINDOWS Operating System complete with user
licenses and related manuals.
Main features by the supervision system are as follows:
-
Data acquisition
The measurements collected by the peripheral units are divided between normal status
(digital and analogue) and emergency/non-standard information. All the information will
be transferred in the normal cyclic interrogation process of the Supervisor, for the
anomaly and/or alarm conditions will automatically activate a visual signal on the
monitor, thus alerting the shift operator.
-
Data storage
Measurements: consumption, levels, flow rates, valve positions, temperatures and
pressures etc.;
Utilities: reports, anomalies, out of range, on/off status, local/remote
Alarms: alarm signals of anomalous conditions coming from the Control Units
-
Data processing
collection of information;
automatic management of process functions;
collecting and sending alarms;
synoptic representation of the plant sections;
processing and viewing and printing of data.
-
Videographic synoptics
An important feature of the proposed system will be in any case the operational
presentation of the data and the states of the system under control, because in addition
to maintaining the intrinsic validity of the numerical values of the physical quantities
detected, ample space was given to the immediacy of the situation taking advantage
of tools of video representation present in the current technology.
7.1.2.3 Process video pages
The process video pages contain the schematization of the units that make up the system with
the visualization of the status of the various components (motors, valves, level switches, at
states, etc.), and of the operating parameters acquired by the measuring instruments
(transmitters) pressure, temperature, level, pH, oxygen, etc.).
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MSW – Waste to Energy 750,000 ton/year
with “Drinking Water Treatment Station”
7.1.3 PLC- Programmable Logic Controller (SPS)
The systems envisaged are modular automation systems for highly complex applications, with
a very wide range of modular units and many convenient auxiliary functions allow the user to
better configure the equipment using only the blocks required for the specific application. For
future extensions, additional blocks can be added at any time without major problems.
It is therefore possible to summarize the main advantages of PLC envisaged:

high processing capacity

expansion flexibility for new signals

system security (redundancy)

security of data transmission
The configuration foreseen in the present project guarantees the solution for the needs of the
plant and for a reliability of the products thanks to the solution adopted. In fact, the PLCs have
redundant configurations for power, CPU and network cards.
Each PLC is equipped with two power supplies, two CPUs and two network cards for
communication with the supervision center, each of these components, in the event of
malfunctioning of the other, is able to take over without compromising the operation of the PLC
and consequence of the implant.
7.1.3.1 The main functions performed by the PLC are as follows:

automatic storage and processing of data transmitted by primary elements;

automatic control of the process according to the operating logic;

sequence controls;

concentration of data to be sent to the supervisory system;

generation of limit values for alarm and control needs;

diagnose any malfunctions of the various devices;

safety sequences in the presence of particular conditions.
The operation of the system is supervised by the command and control room.
All the organs and components involved in the management of plant conditions are controlled
by centralized or local control stations.
The PLC also includes the necessary interconnections with the other systems (solid handling
cranes, storage control, transformer cabin, compressed air, etc.).
Local operating devices are essential for starting pumps, compressors, conveyors, etc.
(example - key selector)
Information and manoeuvring commands selected are forwarded by the PLC to the
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MSW – Waste to Energy 750,000 ton/year
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subordinate management level. The tools and equipment used are reliable and already in use
in the industry like Endres Hauser, Siemens, ABB etc.
They meet the requirements of the process. The execution complies with the prescriptions and
standards of reference.
If a supervision station fails it does not affect the operation of the system, as the operator can
use the second independent station.
7.1.4 Instrumentation in the field
The instrumentation to be installed in the field is guaranteed and has the following
requirements:

presence of redundant instrumentation where necessary to allow;

the punctual control of the process even in the event of an out of service of part of the
instrumentation;

cross-checks for the verification of the good operation of the process and the eventual
staring of some meters;

compatibility of the overall instrumentation installed on the system;

use of tools aimed at a limited number of activities to avoid that the malfunction of a
single instrument leads to the unreliability of several measures;

use of instruments with a spare part easily available and possibly common to several
meters;

Personnel able to carry out periodic and extraordinary maintenance of instruments with
rapid intervention times; as required by the legislation, continuous measuring systems
must in fact be checked and calibrated at regular intervals of time and calibrated at
least annually
The instrumentation is suitable for the place of installation and is equipped with the degrees of
protection required by the design standards and the relevant standards.
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7.2
Electrical part
The electrical systems are divided into two main categories:
PRODUCTION SIDE:
It includes the main electrical distribution systems, from power generators to the interface with
the National Electrical System Manager distribution network and will be composed of the
following production plant:

1° facility line with a maximum total production of 12 MWe;
SELF-CONSUMPTION side It includes the main electrical distribution systems, electrical and
electronic equipment and the supervision system necessary to power and manage the energy
production plant and related general services.
The production side and the self-consumption side are completely separate.
7.2.1 Main distribution and general wiring diagram
It envisages the construction of a centralized electric substation, the main center of the entire
energy production and supply system, divided into 2 main blocks:

the delivery compartment for the exclusive use of the distributor body in which it will
insert its protection and maneuvering equipment

and the user compartment.
In the user compartment will be inserted:

the medium voltage switchboard called + QMTPROD (medium voltage electrical
cabinet – production side) including the protection and switching units of the individual
generators and the relative transformers and the interfacing devices for the supply to
the national distribution network.

the medium voltage panel called + QMTG (medium voltage electrical cabinet –
generator side) including the protection and switching units of the transformers for
powering all the users of the production plant.

The general low voltage panel called + QGBT (low voltage electrical cabinet) from
which all the power lines of the motor control panels and utilities of the individual
production plants and general services, including adjacent to the electric cabin will also
be installed the generator set for emergency service.
In summary, the planned systems are composed as follows:
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
Draw/feed in of electricity from/to the main grid at “…. kV” (to be defined kV) coming
directly from the substation of the local electricity supplier, with the possibility of
absorbing up to “…. MW” (to be defined MW).

Draw/feed in of electricity from/to the “… kV” (to be defined kV) reserve network from
the local electricity supplier network, with the possibility of absorbing up to “… MW” (to
be defined MW) and submit up to “… MW” (to be defined MW).

Armored electric cabinet of medium voltage M.V., for the distribution, sorting and
protection of electricity, both absorbed and produced.

Service transformers, each with a power of “… MVA” (to be defined mega volt ampere
MVA), one of which is a reserve for powering the electric loads.

Generator power unit set in emergency service with a nominal power of “… MVA” (to
be defined) around cosfi 0.8, to feed the privileged loads, both in the first phase for the
safety of the plant and for the possible operation at reduced plant performance.

The aforementioned transformers, both the generator power unit supply the low voltage
switchboard, the Power Center from which all the machines/motors in the plant are
connected.

An MCC panel, for the protection and control of the motors and electrical loads of the
Rotary kiln - Boiler section.

An MCC panel, for the protection and control of the motors and electrical loads of the
Flue gas treatment section.

An MCC panel, for the protection and control of the motors and electrical loads of the
thermal cycle section.

An MCC panel, for the protection and control of the motors and electrical loads of the
plant services section.

If necessary: a “… MVA” (to be defined MVA) power transformer and a 690 V
secondary transformer, for supplying the frequency inverter group to serve the ID-fan.

A UPS suitable to power the control system, the instrumentation, the emissions
analysis systems, etc.

110 Vdc power supplies, with battery charger and batteries of “… A/h” (to be defined
A/h) batteries, one of which is back-up, for the power supply of the reserve oil turbine
pump, electric protections and safety devices of the entire facility.

Voltage reducers from 110 to 24 Vdc, derived from the above-mentioned batteries, one
of which is in stand-by, for the supply of the process instrumentation.

Electrical connections with bus ducts only for the main power supplies.

Electrical connections with insulated rubber cables with low emission of fumes and
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toxic gases, both for power and control.
The cables are laid inside metal channels of hot-dip galvanized steel after processing.

Local controls for each machine, with emergency push-button and start and stop
buttons, accessible through a key.

A transformer with a nominal power of 630 kVA (always to be defined kVA), for the
supply of all service loads, such as lights, circuit boards, air conditioning of the rooms,
etc.

Data network with structured hardware cabling, with equipment and cables in category
6, with the latest generation Switch, some of which are suitable for IP telephony; said
network is able to support the simultaneous, separate functioning of the data flows of
the following services:

Process control system

Process storage system

Data flow of the daily work of the offices

Telephone system with IP devices

Centralized control system for "Building Automation
Abbreviations:
MV = Mega Volt
MW = Mega Watt
kVA = kilo Volt ampere
MVA = Mega Volt ampere
MCC = Motor control center
The complete description of the scope of supply and services in chapter 6.2 on the topic
of medium and low voltage is defined in more detail in the “Detail Engineering” or
adapted to local conditions and is therefore not a binding part of the technical proposal.
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MSW – Waste to Energy 750,000 ton/year
with “Drinking Water Treatment Station”
8. PROCESS CHARACTERISTICS
Grate Furnace
single facility data,
summary data
31,250 Kg/h
Waste flow-rate
Solid,
Waste type
215,937.5 MJ/h
Design heat flow in furnace
4%
Miscellaneous thermal dispersions
Furnace operating temperature
850 – 1,200 °C
Design temperature in furnace
Fume volume
113,541 Nm³/h
Fume density
0.705 Kg/m3
Dimension Grate furnace (air cooled)
8.1 x 12 m x m
Combustion air (Primer airflow)
54,272 Nm³/h
Combustion air (Secondary airflow)
38,912 Nm³/h
25 °C
Combustion air temperature
Combustion chamber integrated in the boiler
single facility data,
summary data
Combustion operating temperature
850 – 960 °C
Operating condition
2.4 sec
Actual time of fumes in combustion chamber
% of free CO² in combustion chamber
9.71 % vol
116,394 Nm³/h
Combustion gas flow
1,058 °C
Combustion gas temperature
Flow gas retention time (at 850 °C)
3.9 sec
Oxygen value (dry)
6,7 %
Boiler
single facility data,
summary data
200 °C
Outgoing fume temperature
114,722 Nm³/h
Incoming fume flow-rate
Fume speed
3.5 - 5 m/sec
Water required
57,000 Kg/h
Total heat output water/steam
49.2 MWt
T water feed
105 °C
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MSW – Waste to Energy 750,000 ton/year
with “Drinking Water Treatment Station”
water feed enthalpy
448
boiler water blowdown (at T evap.)
T evaporation
KJ/Kg
1,8
%
278
°C
water enthalpy at T evaporation Drum
2,782
KJ/Kg
Spraycooler water
6,000
Kg/h
T steam produced
420
P steam produced
41
62,700
Surrheated steam produced
3,260
steam enthalpy
Turbine Generator Unit
single facility data,
41
High pressure steam
Temperature
Quantity normal
Heat flux
Steam entalpy
Generator output power
Condensate system
°C
Bar(a)
Kg/h
KJ/Kg
summary data
Bar(a)
420
°C
188.1
t/h
56.7
MWt
3,260
kJ/kg
36.0
MWe
single facility data,
summary data
Steam quantity
170. 0 t/h
Steam Pressure
0,165 Bar(a)
56 °C
Steam temperature in
Steam entalpy
2,423 Kj/kg
m³/h
air quantity
air temperature Design
35 °C
Condensate temperature
54 °C
243 Kj/kg
Condensate entalpy
Cyclone
single facility data,
197 °C
Outcome fume temperature
114,722 Nm³/h
Incoming fume flow-rate
Dust
OsalHafner Energy from Waste
summary data
162 Kg/h
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Reactor 1
single facility data,
summary data
196 °C
Incoming fume temperature
114,722 Nm³/h
Incoming fume flow-rate
50 Kg/h
Reagent activate carbon
715 Kg/h
Reagent bicarbonate (NaHCO3)
Bag house filter 1
single facility data,
summary data
188 °C
Incoming fume temperature
117,222 Nm³/h
Incoming fume flow-rate
Fume filtration speed
0.84 m³/m²,min
Sleeve diameter
130 mm
6 qt
Compartments
Sleeves per compartment
230 pieces
Filtering surface for 1 sleeve
2.86 m²
Total filtration area
9,945 m²
Actual number of sleeves
1,380 pieces
Filterdust
750 Kg/h
Reactor 2
single facility data,
summary data
187 °C
Incoming fume temperature
118,022 Nm³/h
Incoming fume flow-rate
Reagent activate carbon
50 Kg/h
Reagent bicarbonate (NaHCO3)
48 Kg/h
Bag house filter 2
single facility data,
summary data
188 °C
Incoming fume temperature
118,022 Nm³/h
Incoming fume flow-rate
Fume filtration speed
0.9 m³/m²,min
Sleeve diameter
150 mm
Filtering surface for 1 sleeve
2.35 m²
Total filtration area
330 m²
Actual number of sleeves
140 N°
Filterdus
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80 Kg/h
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with “Drinking Water Treatment Station”
Catalyst (DIoxine & Furance reduction)
single facility data,
summary data
Incoming fume temperature
186 °C
Outgoing fume temperature
178 °C
118,022 Nm³/h
Incoming fume flow-rate
2.5 sec
Fume speed
Stack
single facility data,
summary data
158 °C
Fume temperature
118,022 Nm³/h
Fume flow-rate
7,193 KW
Heat yield
Emissions concentration
summary data
single facility data,
Analyzed parameter
Limit value (daily
average
Dust concentration
10 mg/Nm³
HCl concentration
10 mg/Nm³
SO2 concentration
50 mg/Nm³
NOx concentration
200 mg/Nm³
TOC concentration
10 mg/Nm³
CO concentration
50 mg/Nm³
1 mg/Nm³
HF + HB concentration
0.5 mg/Nm³
Heavy metal concentration total:
Hg
0.05 mg/Nm³
Cd + Tl
0.05 mg/Nm³
0.1 ng/Nm³
Dioxins + furans (ng/Nm3 GS)
3%/ by weight
Slug TOC
Values express in terms of dry gas 11% O2
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with “Drinking Water Treatment Station”
Estimated consumptions
single facility data,
Electrical power installed
summary data
approx. 4.95 MW
350 mbar
Gas burner fire room (comb. chamber sx)
For Single Line
1,625 Nm3/h
350 mbar
Gas burner fire room (comb. chamber dx)
For Single Line
1,625 Nm3/h
8-10 bar
Compressed air (dry & wet)
10,000 Nm3/h
Reagents:
2,289 Kg/h
Sodium bicarbonate (NaHCO3)
Activated carbon
300 Kg/h
Urea 30% - liquid
50 kg/h
Glycol for Mill sodium bicarbonato
15 l/h
Residues:
20,780
Kg/h
Boiler ash
1,275
Kg/h
Filter dust
1,645
Kg/h
Slag
Values express in terms of dry gas 11% O2
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9. PROPERTY / CONFIDENTIALTY
All documents delivered HAFNER ENERGY FROM WASTE l remain the intellectual property
of HAFNER ENERGY FROM WASTE SRL and may not be copied or reproduced, either
completely or in parts, or be brought to the knowledge of or made available to third parties
and/or competitors without the authorisation of HAFNER ENERGY FROM WASTE SRL
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