Industrial Incinerator

PCE is already a name to reckon with in an Incinerator business. PCE has proven
expertise in Design & Construction of Industrial Soild / Aqueous / Gaseous hazardour
waste incinerators.

Solid Waste Incinerator :

The Solid waste incinerator is typically a static dual dual chambered furnace. The
primary chamber is operated under 'Starved Air' condition with the secondary chamber
operated under ' Excess Air' & high residence time conditon to achieve complete
combustion. The incinerators incorporate tailored waste feeding arrangements and ash
disposal systems for continuous operation.

1] Large volume waste can be handled.

2] Controlled combustion due to "Starved Air" condition.
3] Significant reduction of volume.
4] Handles any type of soild waste.

Capacity : 10 to 500 kgs/hr.

Diagram :
Application :

1] Municipal solid waste.

2] Infectious / bio-medical waste.
3] Garbage, trash, paper, cloth etc.
4] Semi-solid, viscous organic & incorganic waste.
5] Contaminated debris etc.

Waste Incineration Plant

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From waste to energy by intelligent analysis

Waste management today is increasingly supported by incineration processes. Here the

organic compounds of waste are used to produce energy in waste incineration plants or as
alternative fuel in cement kilns or even coal fired power plants. For the emission of these
plants special regulations are applicable where as the emission limits are more stringent
than for conventional power plants.
SICK analyzing systems are highly qualified for waste incineration applications. With its
wide range of products SICK is able to provide the optimal solution for all relevant
parameters, even for the most stringent European Waste Incineration Directive. SICK is
the only manufacturer with own solutions for dust, gas flow, pollutants, reference gases,
and data evaluation systems.

Scheme of a waste incineration plant

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Combustion optimization and control

Combustion processes require O2 to react chemically with the fuel. Incineration of waste
materials converts the waste into ash, flue gas, particulate, and heat, the latter can be used
to generate electric power (waste to energy). O2 is supplied to the combustion process via
combustion air. Monitoring the O2 concentration at the boiler outlet is the most important
measure for control and optimization of the incineration process. Our solution:

• Oxygen analyzer ZIRKOR302

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SNCR flue gas denitrification

Due to environmental protection NOx emissions have to be reduced prior to the release
into the atmosphere. In the NOx control process with selective non-catalytic reduction
(SNCR) either gaseous ammonia or a mixture of urea and water is sprayed directly into
the combustion chamber at temperatures between 900 °C and 1.100 °C. Here NOx
molecules react with the ammonia compounds and form nitrogen and water. The NOx
emissions are reduced accordingly. In addition to O2 (boiler efficiency), NO is monitored
at the boiler outlet for control and optimization of the DeNOx process. With the same
system HCl, SO2 and H2O concentrations can be monitored as important control
parameters for a subsequent scrubber. Our solution:

• O2 measurement: Oxygen analyzer ZIRKOR302

• NOx/HCl/SO2/H2O measurement: Analyzing system MCS100E HW

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SCR flue gas denitrification

For the process with selective catalytic reduction (SCR ) gaseous ammonia is fed into the
catalyst inlet. The conversion of NOx into water and nitrogen takes place at temperatures
between 200 °C and 400 °C. At the inlet of the catalyst NO concentration is monitored to
control the ammonia injection. At the outlet of the catalyst NO and NH3 are measured:
The NH3 concentration (ammonia slip) indicates the efficiency of the denitrification
process while the NO concentration is monitored to ensure compliance with the
environmental regulations. Our solution:

• NO measurement: Gas analyzer GM32

• NH3 measurement: Laser gas analyzer GM700

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Flue gas scrubber

After the dedusting typically scrubbers are used to remove acidic gases like HCl and
SO2. Two scrubbing processes are used, wet scrubbers and (quasi-)dry scrubbers. In wet
scrubbers the flue gas is sprayed with an aqueous mixture of water and lime. The gaseous
acidic pollutants react with the liquid to form gypsum which can be removed from the
waste water to produce drywalls. Using the dry scrubbing process the aqueous solution is
replaced by lime powder or a pasty mixture of water and lime. For proper operation
control of the dry process continuous monitoring of HCl, SO2 and H2O concentrations is
essential. Our solution:

• Analyzing system MCS100E HW

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Heavy metal and dioxine removal

For controlling the emissions of heavy metals and dioxines / furanes activated charcoal
filters are a commonly used method. Activated charcoal has a high porosity combined
with a large active surface and is therefore ideal for adsorption of pollutants.
Disadvantage of use of activated charcoal is the self combustibility. Early detection of hot
spots in the charcoal filter is possible by using differential CO measurement between in-
and outlet of the filter. Our solution:

• Analyzing system MKAS Compact

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Continuous emission monitoring

According to environmental regulations, waste incineration plants have to monitor
continuously a large number of gaseous components (HCl, HF, CO, NOx (NO+NO2),
SO2 and TOC), particulate matter, as well as the reference values gas flow, gas
temperature, pressure, O2 and H2O. In some countries additional continuous monitoring
of total mercury is obligatory (e.g. Germany). The monitored data is transferred to an
emission data acquisition system for further processing and reporting to the
authorities. Monitoring equipment used for CEM applications must be approved by the
government (for example Waste Incineration Directive 2000/76/EC). Precondition is
an approval test according to EN15267-3, and fulfilling the quality standard EN14181.
Our solutions:

• HCl/SO2/CO/NOx/O2/H2O measurement: Analyzing system MCS100E HW

• HCl/HF/SO2/CO/NOx(NO+NO2)/O2/H2O measurement: FTIR-Analyzing
system MCS100FT
• Hg measurement: Mercury measuring system MERCEM
• In-situ HF measurement: Laser gas analyzer GM700
• Integrated extractive TOC measurement: FID-Analyzer EuroFID
• Integrated extractive HF measurement: Laser gas analyzer GME700
• Gas flow measurement: FLOWSIC100
• Dust concentration measurement: DUSTHUNTER SP100
• Extractive dust measurement after wet scrubber (gas conditions below dew point):
Bypass measuring system FWE200
• Data acquisition: MEAC2000
What is Thermal Treatment?
Thermal Treatment is a process by which heat is applied to waste in order to sanitise it
and reduce its bulk, prior to final disposal. While thermal treatment plants can operate
without generating energy, Irish waste management policy requires thermal treatment
facilities to incorporate energy recovery capacity; the energy generated can, in turn, be
used for example to power the plant and for district heating systems.

Thermal treatment can involve a number of processes most of which are commonly
referred to as incineration. According to the most recent EU Directive on Incineration of
Waste 2000:��Incineration plant "means any stationary or mobile technical unit and
equipment dedicated to the thermal treatment of wastes with or without energy recovery.
This includes the incineration by oxidation of waste as well as the other thermal
processes such as pyrolysis, gasification or plasma processes in so far as the substances
resulting from the treatment are subsequently incinerated"

EU Directive on Incineration of Waste (Approved by EU Parliament and Council

November 2000).

Purpose of Thermal Treatment

The primary function of thermal treatment is to convert the waste to a stable and usable
end product and reduce the amount that requires final disposal in landfills. Thermal
treatment processes recover the energy in municipal solid waste (MSW) and convert it to
electricity and/or useful heat, gas etc. Because a high proportion of MSW can produce
methane on landfilling, recovering energy from the waste will help reduce the
'greenhouse effect'.

Thermal Treatment in Europe

When Ireland was failing to address the waste issue our European neighbours were
developing and implementing sustainable integrated waste management practices.
Thermal treatment is used as an integral part of integrated waste management throughout
Europe because it is a safe, clean technology superior to landfill and is compatible with
high levels of recycling. Countries with high recycling levels also have high levels of
thermal treatment. The graph bellows shows domestic waste management in EU
countries from 1999-2000 indicating the percentages recycled, incinerated and landfilled.
Types of Thermal Treatment
While the terms thermal treatment and incineration are often considered synonymous, it
is important to understand that in the context of the Dublin Waste Management Plan the
phrase thermal treatment refers to a number of processes, of which incineration in one
such process. Other thermal treatment processes include Gasification and Pyrolysis.

Incineration

Incineration is the most common technology used for converting municipal solid waste
into energy. Pre-sorted (segregated) waste or unsorted waste is the fuel in a combustion
process that uses excess air to ensure complete combustion. Waste is delivered to the
plant, where it is stored in a large enclosed bunker that serves as waste buffer capacity.
The bunker area is kept under negative pressure thus preventing odours from escaping the
building. Overhead cranes feed the waste to the incineration unit, where it is converted
into energy. This usually takes place on a moving grate in the bottom of the combustion
chamber.

Pyrolysis

Pyrolysis is a thermal pre-treatment method, which transforms pre-shredded waste into a

gas and a residue consisting partly of inert materials, and partly of a char. The process
takes place in an externally heated reactor in which the pyrolysis gas is formed. The gas
may be used partly to heat the reactor and partly for generating stream in a boiler. The
char may be used as a low-grade fuel in a large power plant, if available or it may be
disposed of in a landfill.

Gasification

This process is similar to pyrolysis in some ways. With gasification, the pre-treated waste
is fed into an externally heated reactor where the carbonaceous material in the waste
stream reacts with a gasifying agent (e.g. air, oxygen or steam) at temperatures of 800-
1100°C or higher. Chemical reactions form a combustible gas (with traces of tar) which
is stored or burned to generate heat. The process is very inefficient in terms of energy
recovery and therefore has a higher cost of processing.

The likely technology for the project will be conventional incineration, with the energy
from the waste being converted into electricity for the national grid.

How Do Incinerators Work?

Click on image to enlarge.

Incineration - The Facts

• Old badly managed incinerators are being closed down in Europe where they do
not comply with the new standards for monitoring and operating. However, new
facilities are being provided in their place. Incineration capacity across Europe is
increasing.
• Modern incinerators reduce waste to between 6-13% of the original volume. Of
this, approximately 5-10% is bottom ash and is inert and only 1-3% of the original
volume is fly ash requiring disposal in a special facility.
 • Uncontrolled burning of waste is one of the biggest threats to the Irish
environment today because it involves burning waste at temperature levels which
create dioxins. Modern well-managed incinerators burn waste at much higher
temperatures at which dioxins are destroyed. For example, a modern municipal
incinerator treating 1 million tonnes of waste in controlled conditions, releases
just 0.54 grams of dioxins to the atmosphere. A 2001 EPA report estimates that
60,000 tonnes of waste burned in the back yard produced 18 grams of dioxins.
• There is a broad spectrum of chemicals emitted from incinerators but even in rural
situations the overall contribution is usually less than 1% of existing background
levels - including dioxins and furans.
• Even if 1 million tonnes of municipal waste was to be incinerated in Ireland this
would contribute less than 2% of the dioxins emitted to the air (EPA 2001).
• The EPA, FSAI and WHO have all indicated that properly managed well run
incinerators do not impact on the environment or on human health.
• There are 11 incinerators operating in Ireland. Studies carried out by the Food
Safety Authority of Ireland (FSAI) show no increase in dioxins in dairy products
produced in the vicinity of the plants.
• Levels of dioxins in mothers breast milk and in dairy products (key indicators)
have decreased over the past 20 years despite the increased use of incineration in
Europe.
• Legislation controlling emissions from incinerators is among the strictest
environmental legislation in the world.
• Incineration will not compete with recycling as infrastructure like thermal
treatment plants and landfill will be sized to take the appropriate non-recyclable
percentage of the waste stream.

Some Frequently Asked Questions about Incineration

What residues do incinerators produce?

Incinerators produce two different residues: Bottom Ash and Fly Ash. Bottom ash is
between 5-10% of the original volume of waste but up to 20-25% of the original weight.
It consists of part of the waste stream that cannot be burnt, i.e. glassy elements, grit,
metals, inert matter, etc. The metal fraction of the bottom ash can be separated out using
magnets and the remaining fraction is a stable aggregate which can be used in the
construction of roads, etc. Fly ash, however, is hazardous and is usually 1-3% of the
original volume of waste. This material requires special handling in an appropriate
facility in Ireland or abroad. It is the by-product of the gas cleaning processes.

Do Incinerators Produce Electricity?

One tonne of Municipal Solid Waste in a modern incinerator produces 650Kwh of

electricity. In a plant handling 400,000 tonnes of waste enough electricity is generated to
service 20,000 homes. If heat is recovered from the plant and provided to local
communities through a district heating system, the energy efficiency of the plant is
between 75-80%. An average conventional power plant has an efficiency of 35%.
Do emissions from modern incinerators harm health and the
environment?

Properly managed and monitored Municipal Waste Incinerators do not impact on the
environment, health or food quality. This is because incineration of waste is strictly
controlled and the gases emitted are cleaned and scrubbed to ensure that any emissions
are extremely low.

However, incinerators do emit a broad spectrum of chemicals to the environment - albeit

in extremely small quantities. Many opponents of incineration argue that because
incinerators emit these chemicals they should not be built. However, the reality is that
chemicals like dioxins already exist in our environment and come from very familiar
sources like smoking, traffic, illegal burning of waste - even home heating systems. What
determines whether they do us harm is the amount or DOSE we are exposed to; for
example, common chemicals like salt can be toxic to the human body if taken in large
enough quantities. Even if we incinerated 1 million tonnes of municipal waste in Ireland,
this would contribute less than 2% of the dioxins emitted to air (EPA, 2001). Most
dioxins will continue to come from uncontrolled burning of waste in back gardens,
bonfires and accidental fires.

What are dioxins?

Dioxins are the unwanted by-product of low temperature uncontrolled burning.

At a certain dosage, 17 dioxins have been identified as posing a risk to human health.
Most of our exposure (over 90%) to dioxins comes through the food chain. They persist
in body fat and remain in the body for a very long period of time. There are many sources
of dioxins to the Irish environment including smoking, transport, home heating and some
types of industrial processes, but back-yard burning of waste is the single greatest source
of dioxins to the Irish environment.

"If dioxins are so toxic, and incinerators produce them, surely building
incinerators will increase the levels of dioxins in the Irish
environment?"

Properly managing our waste will reduce the impact waste has on our environment -
including dioxin emissions. Currently most dioxins come from uncontrolled backyard
burning of waste. Most of this waste should be composted or recycled with the remainder
going to disposal in properly managed incinerators or landfill sites. If all of the waste that
is currently being burned was handled in this way, the levels of dioxins in Ireland would
decrease dramatically. This is because backyard burning usually occurs at a temperature
of about 200-400°C which is the temperature at which dioxins are formed; incinerators
burn waste at over 850°C, the temperature at which dioxins are destroyed. Ensuring that
waste management has the least possible impact on the environment will involve
providing all of the infrastructure necessary to maximise recycling, recover energy from
the waste that cannot be recycled and keep landfill to a minimum.
How do Incinerators work
The diagram below gives a simplified overview of what happens to municipal solid
waste in an incinerator. While the exact design of each incinerator may be slightly
different, they will generally follow the diagram above and will consist of the
following areas:

Reception Area/Tipping Hall

On entering the incineration facility, waste trucks make their way to the tipping hall. Here
the waste is offloaded into large bunkers for storage. The airin the reception area and in
the bunkers is maintained at a lower pressurethan outside (negative pressure) and this
prevents odours escaping.

Grab System

Waste will be received from both household and commercial sources. Some of the waste
will be bulky in nature, so it may need to be broken down into smaller pieces. Overhead
traverse cranes fitted with grapples mix the waste before feeding it into the furnace
hoppers. The mixing of the waste is useful in producing a more uniform fuel that will
help maintaining a steady combustion process within the desired operating conditions
Combustion Chamber
The cranes and grabs transfer the mixed waste from the bunker to the furnace 'hopper'.
This process can be fully automatic in modern incineration plants. At the bottom of the
hopper a metering ram pushes the waste onto the combustion grate, which agitates and
transports the waste through the combustion chamber. Combustion takes place at
temperatures of 850 - 1100oC, the temperature at which odourous gases and all dioxins
will be destroyed.

Fly Ash
Fly ash is the particulate removed during the gas cleaning phase. It is generally about 1-
3% by weight of the original waste. Fly ash is considered hazardous and so it must be
disposed of in a specially designed facility. At present there are no hazardous waste
facilities in Ireland, so hazardous material will be exported for safe disposal.

Flue Gases
The combustion process produces flue gas containing water vapour, nitrogen, carbon
dioxide, nitrogen oxides, oxygen and particulate matter. Some of these compounds are
harmful to health and therefore the flue gas is thoroughly cleaned before it is discharged
to the air. The flue gas cleaning equipment of a modern incineration plant is complex and
can take up about half of the space within the plant. There are various flue gas cleaning
designs, but modern plants generally include the following stages:

• Electrostatic Precipitators (ESP)

The ESP will initially remove 99% or more of particulates. These are primarily
dust and ash particles, but may also include minute quantities of heavy metals,
dioxins and furans.
• Acid Gas Scrubbing
This consists of a lime mixture being injected into the gas stream. This reacts to
neutralise acid gases such as sulphur dioxide, hydrogen fluoride and hydrogen
chloride. Activated Carbon Activated carbon injection is used to remove organic
compounds such as dioxins and also volatile metals such as mercury or cadmium.
The activated carbon provides a surface onto which the heavy metals can adhere
and these will then be filtered out at a later stage.
• Filtration
The final filtration of particulate matter typically uses a bag house filter (fabric
filter). At this stage of the cleaning process, particulate matter is primarily made
up of spent activated carbon and spent hydrated lime (from the earlier part of the
cleaning process). This material is usually recycled back into the combustion
chamber to ensure that dioxins are properly destroyed in the high temperatures.

Electricity Generation
A boiler converts the energy from the combustion into high pressure steam. The
combustion chamber is surrounded by water tube walls, which are heated by radiation
from the combustion. The hot flue gases release additional heat in additional tube panels
in the boiler. The steam goes into a turbine, which drives an electric generator. Generally,
about 10% of the electricity is used on site and the remainder is fed into the national grid.
The incineration of 400,000 tonnes of waste can supply the annual electricity
consumption of more than 30,000 homes. The heat remaining after the electricity
production can be used to heat water, which can be directly piped to people's homes in a
district heating system. This can supply the annual requirements for heating and domestic
hot water for approximately 25,000 homes.

Bottom Ash
At the end of the grate the solid waste has been completely burned out. The remaining
residue is called bottom ash, which is ejected at the bottom of the combustion chamber.
The bottom ash corresponds to about 15 - 20% by weight or 4-6% by volume of the
original waste. After storage the bottom ash may be screened into fine and coarse
fractions and the ferrous metals (iron or steel) in the ash will be extracted using large
magnets. The metals represent 5 - 10% of the bottom ash and are sent to the steel works
for recycling. The remaining bottom ash is non-hazardous and is typically used in other
applications such as an aggregate in concrete or for road building.