Impact System

Impact cylinders used for cleaning of heating surfaces

at industrial and waste incineration plants

Alexander Haug

2Alexander Haug, 21.03.2009

Waste-to-Energy Plant / Impact SystemDelivery Incineration Flue Gas Cleaning

» Pneumatic impact cylinder is used for the efficient cleaning of contaminated heating areas in waste-to-energy plants

» Adjustable impact energy allows precise and effective cleaning

» Clean heating elements are the basic to keep the overall efficiency of the evaporator, super-heater and economizer at a constant level

» Extending the OPERATING TIME of the plant and maximizing waste throughput

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Cleaning Heating Surfaces of Incinerators

Existing Techniques

Electro-pneumatic impact wagon Pneumatic Single Rapping

Alternative

Mechanical drophammer system

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Waste-to-Energy-plant – Flowchart of burning process

» Delivered waste is collected in the storage pit.

» Cranes then transport the waste to the funnel tube.

» The waste is then evenly distributed on the grate where it is dried, vented and incinerated at temperatures between 850ºC and 1100ºC

» Resultant smoke gases collect in the reburner zone where the waste is complete burned

» The heat produced during this process produces stream which, in turn, is used to generate electricity through a turbine

storage pit

funnel tube

grate

reburning zonesteam boiler

Burning Process

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Cleaning the Tube Bundle Heat Exchanger

hopper

convectiveheating surfacehot flue gas

» High concentration of sticky particles in the flue gas

» These particles will blockage the flue gas path

Cleaning the heating surface is necessary to run the plant and guarantees a high degree of efficiency

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Rapping Process

» High impact force provide an efficient cleaning

» Rapping the polluted heating tube bundles caused an oscillation, which shake off the build up material

» Cleaning with air or water is no longer required

»Extension of travel time before shut down the plant

»Increase the overall efficiency and waste throughput of the plant

boiler casing

tubebundle

stickyparticles

plunger

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Demand of the customers

Optimization of the cleaning system

» Optimal cleaning of the heat exchange surfaces to optimize the absolute efficiency

» Subsequent and Individual adjustment of the impact force

» Reducing maintenance costs

» Reducing the construction volume

» Feedback to control room of the cleaning activity

» Check the wear and inform about failures

» Process stability

» Guarantee maximum travel time

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Pneumatic Single Position Rapping

» Individual adaptation of impact force for each point

» Wear indicators

» Check the wear and inform about failures

» Low noise level

» High process reliability

» Low maintenance cost and just a few spare and wear parts

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» Elements of the Norgren Impact System - Project

» Product Impact Cylinder

» Control Cabinet SPS (S7) Profibus DP S7 Touch Panel

Coupler for Profibus or Fibre Optic Cable Valve Islands (3/2 way function)

» Software

» Engineering/Documentation

» Installation

» Commissioning

» Optional

» Mounting flanges with plungers and springs

Norgren Impact System

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Impact Cylinder SPCH/080003

Application: cleaning of heating surfaces at industrial and incineration plants

» Technical data - SPCH/080003

» Temperature range: -20ºC to + 80ºC» Pressure range: 3 – 7.5 bar» Impact energy: 125 Joule at 7.5 bar control pressure» Triggering via valve islands with 3/2-way double

solenoid valve (single-acting)» Compressed air: filtered 40 um » Junction: hose fitting PA-pipe (Ø10mm)» Air consumption: approx 5 litres per impact

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Adjustment of the Impact Energy

Adjusting screw

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Force Compensation

» Force reduction in the end position leads to better vibrations on the pipes

Without compensation

With compensation

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Wear measurement of the striking pins inside the boiler

DipstickMin- Max display

Status at the flangeAutomatic

wear-indicator – can be replaced with electrical pressure switch

Dipstick (go, no-go status) of pin wear

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Optical Wear Indicator for SPCH/080003

Wear of the impact pin inside the boiler can be assessed with the dipstick:• Remove visual indicator• Insert dipstick • Assess whether it is within acceptable region• Reassemble the indicator

When the wear is > 16 mm, the indicator is red and the cylinder will not impact.

Remove indicator to reset.

This protects both the cylinder and the boiler parts.

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Drawing Impact Cylinder SPCH/080003

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» High efficiency constantly during heat exchange due to effective rapping of the pipes

» Savings in support and operation

Picture description:

Left side: pipes due to bad rappingRight side: pipes after good rapping (Norgren)

Benefits of the Norgren Impact System

17Alexander Haug, 21.03.2009

Reference List - Impact Systems

Germany Built» MVA Leuna Boiler I + II 2006» MVA Sonne (Großräschen) 2008» MVA Premnitz 2008» MVA Hameln 2009» MVA Herten 1982» MVA Mannheim 2009

International» WTE Dürnrohr Boiler I + II (Austria) 2005» WTE Dürnrohr Boiler III (Austria) 2009» WTE Pfaffenau (Austria) 2009» WTE Delfzijl Boiler I + II (NL) 2009» KEBAG Emmenspitz (Switzerland) 2006» KVA Chevenez, Geneve (Switzerland) 2002/2009» KVA Turgi Aarau (Switzerland) 1996» WTE Allington* (UK) 2005» WTE Moskau* (Russia) 2007

*Impact wagon system

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Project Dürnrohr Boiler I + II + III

Impact system with 94 impact cylinders per boiler

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Control Cabinet Impact System

Dürnrohr (Austria)

» SPS (S7 300) Profibus DP

» Signal via Profibus- or LWL coupling

» User input with S7 OP touch panel

» Solenoid valve island 48 x 3/2-way double valves

» Push- In slot via 10 mm PA- pipe

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Impact System

» Each impact point is controlled with one cylinder

» Access via angle screw coupling and a 10 mm PA- pipe

» Assembly of the impact cylinder on the boiler with a flange or welding bell

» Each side of the boiler is controlled via control cabinet with valve island and control panel

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Cleaning of heating surfaces with single impact spots

Dürnrohr (Austria)

» Single-acting impact cylinders(94 per boiler)

» Triggered via valve island with double 3/2-way solenoid valves

» 5 liters / impact at 6.5 bar

» One 10mm PA tube per cylinder

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Key Advantages of Norgren Impact System

» Optimal cleaning

» Extend the maximum travel timeof the plant

» Guarantee high overall efficient

» Maximize the waste throughput

» Keep an “Eye” into the boiler

» Check the wear and inform about failures

» Subsequent adjustment of the cleaning system to your plant

» In- / decrease the impact force

» Change the iteration of the cylinder groups

» Nearly no maintenance and no spare and wear parts

» Comfortable operation and feedback to the control room

23Alexander Haug, 21.03.2009

Contact

www.norgren.com