SKID 1000

SKID MOUNTED INCINERATOR UNIT
SKID 1000
Incinerator and flue gas cleaning/filter plant,
constructed on a frame.
made
in
Germany
Hazardous waste Incinerators
for a clean environment !

SKID MOUNTED INCINERATOR UNIT
SKID 1000 - 5G
In the field of combustion technology, we have an extensive know-how, experience and references.
We guarantee our customers high availability of made-to-order equipment.
BASIC
A SKID mounted Incinerator Unit is an Incinerator and flue gas cleaning/filter plant, constructed on a frame and has
an excellent combustion capacity (standard capacity 100 kg/hour, 200 kg/hour, 300 kg/hour, 500 kg/hour and 1000
kg/hour), depending on the type of SKID. SKID's are designed for local assembly.
The main design demand for the construction of the incinerators are easy operability, rigid construction and long life
time together with made in Germany quality and according to EU regulations.
Our SKID's are available in two versions.
Designed as manual fixed bed with manual feeding and slag extraction (100 and 200 kg/hour) or automated moving
bed combustion plant with automated feeding and slag extraction (300 – 1000 kg/hour). Both units are to be operated
uncomplicated, safe and shall require only low maintenance efforts.
Automatic systems are subject to engineering work. Design of automated moving bed plants are supported only
project-related!
Design: Fixed bed plant
Design: Automated moving bed plant with heat recovery and flue gas filter
MAIN DATA
Capacity:
up to 1000 kg/h
Feeding :
Automated feeding and slag extraction
Kind of waste : Domestic waste and Hazardous waste like Industrial waste, Medical waste, Chemical
residues that are solid and paste-like up to 30% moisture content.
Calorific value waste: ~ 1 - 45 MJ/kg
Density of waste: ~ 50 - 1.250 kg/m³
Thermal capacity: ~ 3600 kW
Flue gas volume: ~ 9100 Nm³/h
Oil consumption: ~ 0 – 100 kg/h
Electrical connection: ~ 90 kW
Ash amount: ~ 10%
Each incineration system will be adapted to the local requirements. The data indicated on the table are reference
values. The data are calculated with a calorific value of waste of 12.500 kJ/kg and a moisture content less than
10%. If the composition of the waste changes the data given will also change.
STANDARD SKID CONSISTING OF
1 pce. skid mounted furnace unit to be fixed on a RF concrete slab
1 pce. skid mounted cooling and filtering unit to be fixed on a RF concrete slab
1 pce. stack, with its supporting structure
1 pce. control cabinet
1 set of connection piping between units
1 set of cabling materials between units and cabinet
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SKID MOUNTED INCINERATOR UNIT
SKID 1000 - 5G
OPTIONALLY
- 1 pce. fuel tank and its supporting structure
- 1 pce. water tank and its supporting structure
- Consumables
- Spare and wear parts
FEATURES
- Since it is delivered on skids, installation of the unit is very easy and do not need big scale construction work, i.e.
if you can prepare the RF concrete slabs beforehand, the parts of the unit can be unloaded from truck directly into
place and can be fixed immediately,
- Automatic ash discharging: safe technology
- Continuous incineration: the waste is moved over steps with a ram system
- Incineration without grate: absolutely sterile ashes by a complete burnout in the combustion chamber, the waste is
mechanically mixed
- Postcombustion chamber: elimination of odour and organic matters
- Rigid construction: use of standard components
- Refractory lining: resistant against wear, high heat storage, low heat emission of the furnace
- Easy operability: automatic function control
- Low maintenance: all important components are clearly arranged and easy to access
- Made in Germany quality: long-life cycle
PROCESS DESCRIPTION
CHARGING
Moving Bed System
Automated feeding and automated slag extraction.
The feeding will be done automatically with a feeding belt through a top opening for the solid wastes.
INCINERATOR
MAIN COMBUSTION CHAMBER
The waste is incinerated in a two stage combustion chamber. The dimensioning of the combustion chamber and the
controlled incineration ensure a minimum consumption of Diesel oil. Continuous incineration because the waste is
moved over steps with a ram system. Incineration will be done without grate. Absolutely sterile ashes by a complete
burnout in the combustion chamber. The waste is mechanically mixed and is burned directly on the refractory lining.
The continuous incineration process is ensured by an automated system. Combustion air is blown into the incinerated
waste by a nozzle system controlled by the incineration parameters. A mixing takes place between the waste and the
air. Depending on the calorific value of the waste the temperature in the combustion chamber is approx. 850 °C. The
temperature will be controlled by combustion air injection and burner operation. Auxiliary fuel is only necessary at low
calorific value and/or high moisture content of the waste. The combustion chamber is lined entirely with high quality
refractory material. The refractory material of the step floor has high alumina oxide content and has high resistance
against wear.
Temperature : 850 °C
Residence time of waste : 30 – 60 minutes
LANCE SPRAY SYSTEM FOR LIQUID WASTE
Option
A lance system is consisting of one or more sprayers in the combustion chamber and a pumping unit for it. It will
spray the waste in liquid form into the combustion chamber, but not more than 10% in weight per feeding sequence.
Because, liquid spraying into combustion chamber can cause a rapid cooling down of the temperature in the
chamber and endanger the incineration process in one hand, the liquid waste needs additional evaporation energy
and this reduce the incineration capacity of the unit on the other hand. Burning of high-calorific-value-materials is
itself a problem of overheating, not the substance. Therefore, the total amount of waste must be compensated in
case of high calorific value.
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SKID MOUNTED INCINERATOR UNIT
SKID 1000 - 5G
INCINERATION OF POLYMERIC SUBSTANCES
The incineration of high amounts of polymeric substances such as plastic, PVC, rubber etc. could lead into an
overheating of the system and also be harmful for the environment.
STANDARD AMOUNT OF POLYMERIC SUBSTANCES
Not more than 3% of total waste amount per feeding batch.
During combustion PVC can be broken down into water, carbon dioxide and HCl. Furthermore, combustion of HCl
can cause formation of dioxins. Therefore, the polymeric substances and PVC products should not be incinerated
intensively, e.g. not more than 3% per feeding sequence in standard execution.
INCREASING THE AMOUNT OF POLYMERIC SUBSTANCES
Option
Up to 30% of total waste amount per feeding batch is possible by means of special technical arrangements of the
System. To do this, the combustion chamber, the cooling system, the additive dosing system, the filter system and
the plant control must be adjusted.
The values can vary according to the requirements from project to project.
POST COMBUSTION CHAMBER
The flue gas from the combustion chamber can contain not burnt components. In a post combustion chamber
(secondary combustion chamber) an additional burner ensures the complete combustion of all smell and organic
components. The selected residence time of the flue gas in the combustion chamber will be 2 seconds at 1.100 °C.
A burner and a temperature measurement after the post combustion chamber ensure the destruction of organic
pollutants and CO.
Temperature : 1.100 °C
Residence time of flue gas : > 2 seconds
Visualisation
Option
All relevant process parameters and data are monitored
and stored on a PC visualisation system.
Picture: Visualisation on touch screen
FLUE GAS CLEANING SYSTEM
A gas treatment system in accordance with EU regulation will be installed in our incineration plants.
Each filter system will be adapted to the local requirements. Such systems are
composed of an additive dosing system, a ceramic filter system and a draft fan.
The additive can be varied according to waste characteristics. Mostly sodium
bicarbonate is indicated, with addition of activated carbon. This additive is stored
in big bags and fed by an air conveyor system. The sodium bicarbonate is an
efficient reagent to remove SO2, HCl and HF. The activated carbon removes
heavy metals and dioxin.The products from the neutralization reaction are
removed by a filter with ceramic filter elements.The filter will be cleaned
periodically through pressurized air impulses.
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SKID MOUNTED INCINERATOR UNIT
SKID 1000 - 5G
COOLING OF EXHAUST GASES
WATER SPRAY COOLING SYSTEM
As standard cooler we use a Water Spray Cooling System to reduce the temperature of the exhaust gases and also
to protect the flue gas filter system.
Thermal shocks generated due to the high temperature are prevented by spraying the water particles uniformly
inside the exhaust gas cooler. The water droplet evaporated into a flow of exhaust gases. The spray cooler length
Is optimized for an optimum mass flow rate. Water injection velocity and pressure are varied as using number of
nozzles depending on the type of SKID.
ENVIRONMENTAL FRIENDLY AIR COOLING SYSTEM
Option
The hot flue gas is cooled down from a temperature
of approx. 1100 °C to 600 °C in a U–shaped pipe
cooler system through natural convection and
radiation by ductwork.
To ensure a good cooling effect, at its downstream
installed air cooled heat exchanger will cool the
flue gas down to a temperature between 200 °C
up to 250 °C (averagely 230 °C).
The cooler system is mounted between the
incinerator and the filter plant.
The air cooler requires approx. 5 - 30 kW power
depending on the type of plant.
Pictures: Air cooling system
The advantage is that this facility do not require water consumption. In contrast to a spray cooling system this facility
saves approx. 8000 kg water per hour for a SKID1000.
Advantages on a view:
- Low energy consumption
- No water consumption
- No steam is emitted to the atmosphere
STEAM BOILER
Option
The hot flue gas from the combustion plant is cooled down in a steam boiler to
about 230 °C. The steam boiler is a flue gas pipe type boiler with flue gas routed
through the pipes. Saturated steam with a pressure of 10 bar will be produced.
The steam boiler is mounted between the incinerator and the filter. Untreated flue
gas passes through the boiler to the filter plant.
Due to the dust emission from the incinerator a certain fouling of the steam boiler
will occur. On experience a cleaning cycle of every 4 – 8 weeks is necessary.
It depends on the mass and on the pollution of the flue gas. The duration of a cleaning cycle will be about 6 hours.
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SKID MOUNTED INCINERATOR UNIT
SKID 1000 - 5G
CONTINUOUS EXHAUST GAS MONITORING SYSTEM (CEGM)
Option
Envisaged analyses could be e.g. HCL, CL2, NOX, SOX, CO and TOC.
More on request.
The operation frequency can be either continuous operation
or activation at a predefined frequency or upon demand.
ELECTRICAL EQUIPMENT
Picture: CEGM of a moving bed system
- EMSR Equipment
- Automatic start and shutdown
- Control of all necessary process conditions
- Control of all safety measurements
- Control Box
Control box for indoor erection incl. main switch, redundant emergency stop as well as all necessary fuses,
contacts, relays and clamps, key switch for start-up, completely cabled.
- Instruments: The measuring device keeps the demands for an automatic and safe system. The electrical equipment
conforms to the current standard (VDE and DIN) and is produced according to the state-of-the-art.
- Cabling
Cabling material within battery limit of the unit will be delivered by us.
STANDARDS
- Construction according to DIN/EN
- Electrical parts according to VDE
- Documentation according to DIN
- DIN EN 746
- Burner section according to DIN 4788
RESOURCES (requirements)
- Electric Power: Voltage 230 / 400 V
Frequency 50 Hz
- Fuel
- Compressed air
- Water
CONSUMABLES
Additive (Sodiumbicarbonate): approx. 24 kg/h *
Activated carbon (if necessary): approx. 1,0 kg/h
Filterash: approx. 22 kg/h *
Ash from incinerator: approx. 100 kg/h *
Compressed air: 60 Nm3/h
Electrical power: 90 kWh/h
Diesel oil: < 0,10 l/kg waste *
* Data may change, depending on the composition of the waste (please see also the “main data” on page two).
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SKID MOUNTED INCINERATOR UNIT
SKID 1000 - 5G
FORBIDDEN MATERIALS
- Amunitions and other explosives
- Lightning amunition
- Akkus und Batteries
- Mercury containing thermometer
- PVC, only smaller amounts per feeding sequence
SUPERVISING
We can send two supervisors, one for mechanical and one for electrical erection, during the local erection period.
The cost of supervisors shall be paid separately, in accordance to the current rates of services.
DOCUMENTATION
- Description and list of components
- Layout drawing and process flow diagram
- Instruction manual in English
- Spare/Wear part list
LIMIT OF SUPPLY
- Additional access, stairs, etc. if necessary
- Big bags for residuals
- Buildings
- Civil works (also civil works drawings must be prepared locally acc. to local legal regulations)
- Connection to the Control Cabinet
- Consumables supply, including compressed air
- Emission measurements if necessary
- Electric Power
- Erection
- Fuel
- Insulation
- Lighting
- Lightning protection if necessary
- Local approvals and permissions
- Main electrical cabling to the control system
- Official permits to install and operate the system
- Oil and lubricants, except the first filling
- Scaffolding, lifting devices, cranes, if necessary
- Transportation and customs clearance
- Unloading of equipment
- Water
WARRANTEES
Material:
In respect of the components supplied by us, we undertake a warranty of 12 months following commissioning, but
not exceeding 18 months following notice of the readiness for dispatch of the main equipment. The warranty
includes the quality of the materials, the structural design and the workmanship of the plant components supplied
ex works, as well as the mechanical and thermal functioning of the correctly installed equipment. Wearing parts are
not included in our warranty. In the event of defects in respect of our supplies and services notified to us in writing
within the above-mentioned warranty period, we will undertake improvement work within a reasonable period. Our
warranties are subject to the uninterrupted, total prove of the operating conditions of the plant, available to us.
Claims for reparation of consequential damages, lost profit and production failure - irrespective of the legal basis on
which the claims are asserted - are precluded.
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SKID MOUNTED INCINERATOR UNIT
SKID 1000 - 5G
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SKID MOUNTED INCINERATOR UNIT
SKID 1000 - 5G
Pictures:
Automated Moving Bed Plant with Heat Recovery
Funded by the Government and the EU
MORE INFORMATION ONLINE
ZANNI.DE
ZANNI-TECH.DE
- ZANNI-TECH INCINERATOR SKIDS
EU DIRECTIVES
- Protection of Groundwater
- Hazardous Waste
- Criteria and procedures for the acceptance of waste at landfills
- Landfill of waste
- Incineration of waste
- Hazardous Waste
- National emission ceilings for certain atmospheric pollutants
- 10 years program on reducing emissions
- Criteria and procedures for the acceptance of waste at landfills
- Waste
- Machinery
- Waste and repealing certain Directives
- Limitation of emissions of volatile organic compounds due to the use of organic solvents in certain paints and ...
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CONTACT
ZANNI + PARTNER Ltd.
Prinzenallee 7
40549 Düsseldorf
Germany
Phone: +49 211 52391406
Fax: +49 211 52391200
email: mail@zanni.de
web: http://www.zanni.de
LOCAL OFFICE
(C) Zanni + Partner Ltd. - SKID1000 - 5G - 20140825