1
SOLID WASTE DISPOSAL PLANT
(ECHUTO-150.03)
ТU 4859–050–39183755 – 00
OPERATING INSTRUCTION
Moscow
Content
1. General part…………………………………………
2.Design of the plant and its operating principle…..
3.Stages of the technological process …
4.Maintenance …………………………
5.Accident prevention and labor safety
……………...
Supplements:
1.* Principle circuitry and front panel of the control desk …..…………….
2. Mode card………………………… ……………
3. Average composition of waste processed by the plant ECHUTO-150.03
.
*) Manufacturer may introduce changes in the circuits and design of the control desk panel, which do not affect operation of the plant.
1. General part.
1.1. General information
1.1. ECHUTO plant is intended for ecologically clean disposal of solid organic-containing wastes, which accumulate at industrial enterprises, in medical institutions, municipal services, etc.
1.2. Technical name - Plant ECHUTO 150 TU 4859-050-39183755 - 00
Trade name: ECHUTO 150.03, figures in the second group of the name mean the size of the chamber of thermal decomposition in cubic meters.
1.3. The technology envisions thermal disposal of waste, which ensures that the content of harmful substances in the free air and in the coke-ash residue is within the limits of maximum allowable concentration.
1.4. The technology envisions a sequentially implemented oxidizing pyrolysis (gasification) of random waste in the chamber of thermal decomposition (CTD) with an external heating and reburning of the coke residue.
When accumulated the coke-ash residue (CAR) should be taken out.
CHARACTEISITICS OF ECHUTO 150.03
Volume of the chamber of thermal decomposition – 300 l.
Volume of the processed waste (in case of its average caloricity up to 4500 kilocalories/kg)
– up to 3.7 m3/day
Mode of operation – cyclical
Duration of a cycle (depending on the initial humidity and caloricity of waste)
- 40-90 min.
Duration of a preliminary heat-up of the thermoreactor up to the working temperature
- not more than 60 min.
Primary source of the thermal energy – burning of external fuel.
Diesel fuel consumption - 2-5 kg/hour.
Power consumption - 10 kWh.
Weight of the plant - 4500 kg.
Dimensions of the plant - 4.75х 2,06 х 2.06 m
Serving personnel - operator - 1 person per shift.
2. Design of the plant and its operating principle.
2.1. Units of the plant.
№ / Main units / Quantity / Specifications1 / Thermoreactor / 1
2 / Cartridge of the catalyzer / 1 / Volume V= 20 l
3 / Heat exchanger / 1 / -
4 / Scrubber / 1 / 0.55х0.55х0.8 m
5 / Smoke exhauster -ventilator / 1 / ВР100-35-4.01
6 / Chimney / 1 / Height Н=10m
7 / Burner for diesel fuel / 1 / RIELLO 40 F5
8 / Gas distributor / 1 / -
9 / Cyclone collector / 1 / TsN-40
10 / LRF* pump / 1 / GNOM 10-10
11 /
Circulating pump
/ 1 / TsVTs-6.3-3.512 / Control desk (CD) / 1 / -
*LRF – general-purpose lubricating-refrigerating fluid.
1
2.2.Description of the operating principle of the plant.
Fig.1 presents the technological scheme of the plant
Fig.1
1
The thermoreactor accommodates chamber of thermal decomposition (CTD), furnished with a loader, ventral hatch and agitator.
CTD is located in the heating chamber, at the bottom of which there is a fire-grate for incineration of solid fuels and reburning of the coke residue. In the edge part of the heating chamber there are two vertical cyclone furnaces, the internal volumes of which are connected between themselves at the bottom by a channel and furnace.
In the top part of one of the cyclone furnaces there is a pilot flame.
The heating chamber has an outside stratum of thermal insulator.
The plant is furnished also with a gas distributor for the stream of flue gasses, a catalytic cartridge for reburning of organic compounds, a heat exchanger, a cyclone collector, a scrubber for an additional cleaning of the flue gasses from hard inclusions, and a smoke exhauster-ventilator providing air indispensable for the process in the plant and extracting the flue gasses in the chimney, a control desk, a service site and a circulating pump of the heat exchanger.
The plant is supplied with a service site.
The processing technology is the following: pyrolysis (gasification) of random wastes in the chamber of thermal decomposition (CTD) with an external heating. Emitted as a result of the pyrolysis steam-gaseous mixture (SGM) goes from CTD to the cyclone furnaces, its combustible components are burned and the resulting flue gasses, having donated their heat to CTD, pass through a catalytic cartridge, heat exchanger and scrubber, and then they are ejected in the atmosphere. Half-coke is periodically reburned on the grate bars of the heating chamber, and the resulting flue gasses follow the same way - cyclone furnace and gas cleaning system. When accumulated the ballast should be removed.
A given temperature is maintained by veering of the direction of the flue gasses on their way from the burner to the catalytic cartridge.
3. Stages of the technological process.
ATTENTION!
Technical characteristics of the plant allow to process wastes with an average caloricity not more than 4500 kcal/kg. If higher energy materials (polyethylene, plastics, rubber, etc.) are to be processed, it is necessary to limit their share in the total mass of the waste within 25 % of the weight by burdening of them with less-calorie waste (solid household waste, sawdust, etc.).
Processing of liquid and paste-like combustible materials is possible but also in the amount no more than 25 % of the weight of the total mass of the load.
Fig. 2 presents the operating principle of the plant
1 - Thermoreactor, 2 – Chamber of thermal decomposition, 3 –Loader,
4 – Ventral hatch, 5 – Agitator, 6 – Heating chamber, 7, 8 – Cyclone furnaces,
9 –Burner, 10 – Gas distributor, 11 – Cartridge of the catalyzer, 12 – Heat exchanger, 13 – Cyclone, 14 – Scrubber, 15 –Smoke exhauster-ventilator, 16 – Chimney, 17 – Control desk, 18 – Service site, 19 – Circulating pump, 20 – Furnace hatch, 21 – LRF tank, 22 – LRF pump, 23 – Gate of rarefaction control, 24 – Water tank, 25 – Water supply tap, 26- Safety valve, 27 – Air gate, 28 – Fuel tank, 29 – Fuel supply tap.
Fig. 2 Operating principle of the plant
3.1. Preparation for operation of the plant
- Prepare the fuel system, check serviceability of the fuel lines, armature, availability of fuel in the tank - 28.
- Make sure there is no accumulated combustion gasses and combustible vapors in the furnace and CTD and ventilate them by opening for 2 or 3 minutes the hatch of the loader - 3 and furnace hatch - 20.
- Check the ground connection.
- Check electric power by turning power supply switch -2 on the control desk (CD see. Supplement 1), and the smoke exhauster-15 by turning it on (button on/off - 15 CD) for 2 or 3 minutes.
- Remove ash residue remaining from the previous cycles from the furnace.
- Check the agitator- 5 for ease of rotation and longitudinal travel.
- Close all hatches and check them for tightness.
- Check the glasses of the viewers and if necessary, clean them.
- Check serviceability and correctness of layout of the thermocouples.
- Check the control instruments and mechanisms.
- Make sure the site of service is clean.
3.2. Starting and operating procedure.
Turn on the control desk of the plant (tumbler - 5 CD), smoke exhauster -15 (button - 15 CD), circulating pump - 17 (button - 16 CD) and LRF pump (button - 17 CD), close the air gate - 27.
Open the shut-off valve on the fuel supply line -29 and start operation of the burner -9 (tumbler - 12 CD) in accordance with its operating instruction.
After the flue gasses reach the temperature of 650-7000С in the heating chamber - 6 (temperature meter control - 7 CD) open the hatch of the loader – 3, place in the loader a portion of a combustible material (for example - paper) but do not compact or ramming it, set fire and by turning on a pusher from the local control desk sequentially by buttons " forward - back ", put it in CTD - 2 (this operation is indispensable for liquidation of oxygen in CTD).
- Put a portion of waste in the loader and by turning on the pusher load the portion into CTD. The pusher should be turned on by stages: press the button "forward" for 1 or 2 seconds. After a pause of 5-10 seconds again press the button to do the loading. If additional loading is necessary, repeat the operation after the pusher return in its home position and stops.
The aggregate cycle volume of loading depends on the humidity and caloricity of waste.
ATTENTION! When you have to process high-calorie waste (for example plastics, oil-containing waste, etc.) do it by small portions only. Weight of a portion of loading should be no more than 5 or 6 kg. An interval between loadings - approximately 15 min.
If you have to process waste containing small amount of inorganic inclusions, it is possible to do several loadings without intermediate unloading of the coke-ash residue on the grate bars.
When heated, the waste begins to emit steam-gaseous mixture (SGM), which comes to the furnace - 7, where the combustible components of SGM are burned.
The process of operation of the plant can be controlled either manually or automatically, simultaneously by two parameters – the temperature of the flue gasses in the heating chamber and rarefaction in CTD.
The temperature is controlled by the position of the gate of the gas distributor-10 directing the stream of the flue gasses either to be heated in CTD, or through a by-pass to the outlet of the thermoreactor.
In an automatic mode of operation the control is carried out in the following sequence: a temperature sensor (TS) – temperature meter control (TMC - 7 on CD - ТРМ12 or 2ТРМ1) - ESTM1 (electrical single-turn mechanism) – gas distribution gate -10 regulating either heat or cooling of CTD.
For an automatic maintaining of a given rarefaction in CTD the following chain is similarly used: sensor DТ-2-50 - rarefaction meter control (RMC - 6 on CD - ТРМ12) - ESTM2 and gas distribution gate -23.
The automode of temperature control for the process is set up by inputing in TMC of the value of a given temperature for the process and allowed range of its change. The tumbler "Т" (9 on CD -17) is set in the position "Авт"(“Auto”).
The automode of maintaining of rarefaction is set by inputing in RMC of a specified value of rarefying and allowed range of its change. The tumbler "Р" (8 - on CD - 17) is set in the position "Авт" (“Auto”).
In case of manual control the tumblers "Т" and "Р" are set in the position "Руч" (“Manual”) and the operator controls:
- The temperature – with the mechanism ESTM1 by the data of the display of the instrument ТРМ, by buttons - 13 "by-pass" on CD, "open /closed";
- Rarefaction – with the mechanism ESTM2 by the data of the display of the instrument ТNМP-52 by buttons - 11 " rarefaction" on CD, "more / less".
In case of processing solid household waste, at temperatures of 750- 8000С of the flue gasses in the heating chamber there is an active gas emission, which continues depending on the composition of waste and its amount during approximately 30-40 minutes, after that the basic process of gas emission is over. On average the duration of the pyrolysis process is 60 – 90 minutes (depending on the composition and caloricity of the waste). When high energy materials are processed the cycle time is shorter.
- For deceleration of the undesirable growth of temperature (or for its lowering), it is necessary to let refrigerating fluid (water) to CTD from the tank - 24, by opening tap - 25 for 10 - 20 seconds, with an interval 1 - 2 minutes.
When there is a steady tendency of lowering the temperature of the flue gasses at the outlet of the thermoreactor (after several stirrings of the material inside CTD) and simultaneous lowering of the intensity of the flame to the stand-by mode, the cycle is considered finished.
-Depending on the mode of operation of the plant and composition of waste a new portion of waste can be loaded and the cycle repeated.
-The unloading of the coke-ash residue on the grate bars of the furnace should be done depending on the composition of waste.
In the automatic mode of operation the termination of the basic process of pyrolysis is signaled by the extreme (closed) position of the by-pass gate and steady lowering of the temperature in the heating chamber below 7000С (the recommended working temperature - 750-8000С).
3.3.Recommendations on the technological process
During ALL the period of operation of the plant the flame of the burner in the cyclone furnace should be PERMANENTLY maintained.
This is necessary to ensure complete burning and thermal neutralization of all the products of thermal decomposition coming out of the chamber.
The hatch of unloading should be opened only at the end of the cycle of thermal decomposition, when the temperature goes down steadily, even if material is stirred.
The loading of a new portion of material should be done quickly to ensure that the hatch is open for a minimum duration of time.
It is necessary to have in mind, that at the moment of unloading of CTD an increased amount of sooty fragments can go to the chimney and this will result in more smoking.
3.4. Shutdown.
A scheduled shutdown of the plant is done after the cycle is completed in the following sequence:
- Unload the last portion of the coke-ash residue on the grate bars.
- In 15 minutes after reburning of the coke-ash residue open the heaved and switch off the burner as requested in its operating instructions.
- After the temperature in the heating chamber of the thermoreactor goes down to 500 - 5500С sequentially stop the LRF pump, the circulating pump and the smoke exhauster. At below zero temperatures drain the water and LRF from the tank - 24, scrubber and LRF tank.
- Take the burner from the burner throat. Close the burner throat with a shutter.
3.5. Emergency shutdown.
- Switch off the burner RIELLO 40 F 5 as requested in its operating instructions.
- Open the tap - 25 and let the refrigerating fluid go to the internal volume of CTD.
- After termination of an intensive smoking from the chimney switch off the smoke exhauster, the circulating pump and LRF pump.
3.6. Control of the technological process
During operation of the plant the work of the burner, temperature level of the process and exhaust smoke emission are controlled.
The process is regulated by feed control of the air in the burner and the firing space, and water in CTD.
The control of the temperature is carried out by observations of the instrument measuring temperature in the heating chamber of the thermoreactor.
The optimal range of this temperature - 750-8000C. A short-lived rise of this temperature up to 8500C is admissible. If there is a trend for exceeding this temperature with a full opening line of the by-pass (when high-calory waste is processed) water should be sent to the internal volume of CTD in the amount necessary to stabilizing the temperature at a given level.
As the process of pyrolysis fades out, which is obvious by the reduction of the flame, stir up the material inside CTD, which will be accompanied by visually observable short-lived increase of the flame.
When the next stirring up cease to produce visible effect, open the ventral hatch and the unload the coke-ash residue on the fire-grate bars. The ventral hatch should then be closed, the cover of the loader - opened and a new portion of material - loaded.
All operations of the process control should be done with observance of accident prevention requirements (section 5).
3.7. Emergency situations, ways to avoid and to eliminate them
Emergency situations can arise in the following cases:
- When the flame goes out before the process of pyrolysis is finished,
- Smoke exhauster stops because of a mechanical breaking or owing to disconnection of electric power,
- Violation of tightness of compactions.
If the flame goes out when the process of gas emission continues, it is necessary to rerun the block burner.
If it is impossible to start the burner, begin operation for lowering the temperature in
CTD (par 3.5)
If the smoke exhausterstops, when the process of gas emission is not completed, it is necessary to take measures for cooling the process as soon as possible. For this purpose it is necessary:
- To turn off the burner and take it out from the burner mouth,
- To send water inside CTD,
- To send water to the firing space in case solid combustible is still burning there at the moment.
In case of failure of tightness of the container accompanied with emission of pyrolysis gases, it is necessary to take the above measures, aimed to stop the process. After cool-off of the plant undertake repair works.
3. 8. Possible malfunctions in the technological process and ways to eliminate them
Malfunction Cause Remedies
- Malfunctionsof the burner should be eliminated in accordance with the operating instructions of the burner RIELLO 40 F 5
In heating mode gas is emitted from any point of the working smoke exhauster / There is no sufficient rarefaction / By gate –23 reduce the air inflow at the input to smoke exhauster.
Eliminate air inflows
The flame of the burner is red-orange, not stable and emits smoke / There is no sufficient air for burning / By gate –23 at the input to smoke exhauster increase rarefaction in the burner volume
4. Maintenance
The smoke exhaustershould be inspected periodically and maintained in accordance with its passport data.
The burner RIELLO 40 F 5, pump "GNOM" and pump TsVTs-6.5-3.5 should be serviced in accordance with their passports and operating instructions.
The fuel-distributing and shut-off armature should be inspected daily and the faults found should be eliminated immediately. Periodically (approximately once a week) it is necessary to unload dust from the bin of the cyclone collector and slime from the scrubber and LRF tank.
It is necessary to systematically check the state and if necessary to add water to the hydraulic gate of the hatch of loading.
Maintenance of the electric equipment should be done in accordance with the existing standards.
5. Accident prevention and labor safety
5.1. By a fire hazard category the plant belongs to the gas-using plants operated in premises.
5.2. The main hazards are the following: risk of an uncontrolled gas escape, its accumulation in the volume of the device and, as a result, risk of poisoning or detonation, if there is fire, and also a risk of infection by parasitogenic and intestinal taints.
5.3. In order to ensure a safe operation of the plant it is necessary:
- Before operating it, make sure there is no odor of combustible and make maximum possible ventilation of the plant by opening the upper cover and hatches. Turn on the smoke exhauster-ventilator for several minutes;
- If long time not in use, disconnect the device from the fueling main;
- Before igniting the burner check once again tightness of connections and if a leakage is found – eliminate it;
- See to it that the gas-lock armature is in good condition;
5.4. At the plant there should be the following fire fighting equipment:
- Box with sand with capacity of 1.0 m3;