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Impact System

Impact System. Impact cylinders used for cleaning of heating surfaces at industrial and waste incineration plants Alexander Haug. Waste-to-Energy Plant / Impact System. Delivery. Incineration. Flue Gas Cleaning.

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Impact System

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  1. Impact System Impact cylinders used for cleaning of heating surfaces at industrial and waste incineration plants Alexander Haug

  2. Waste-to-Energy Plant / Impact System Delivery 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

  3. Cleaning Heating Surfaces of Incinerators Alternative Existing Techniques Mechanical drop hammer system Electro-pneumatic impact wagon Pneumatic Single Rapping

  4. reburning zone steam boiler funnel tube grate storage pit 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 Burning Process

  5. Cleaning the Tube Bundle Heat Exchanger convectiveheating surface hot flue gas hopper • 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

  6. 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 tubebundle boiler casing plunger stickyparticles

  7. 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

  8. 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

  9. Norgren Impact System • 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

  10. 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

  11. Adjustment of the Impact Energy Adjusting screw

  12. Force Compensation • Force reduction in the end position leads to better vibrations on the pipes Without compensation With compensation

  13. Wear measurement of the striking pins inside the boiler Dipstick (go, no-go status) of pin wear Automatic wear-indicator – can be replaced with electrical pressure switch Dipstick Min- Max display Status at the flange

  14. 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.

  15. Drawing Impact Cylinder SPCH/080003

  16. Benefits of the Norgren Impact System • 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 rapping Right side: pipes after good rapping (Norgren)

  17. 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

  18. Project Dürnrohr Boiler I + II + III Impact system with 94 impact cylinders per boiler

  19. 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

  20. 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

  21. 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

  22. Key Advantages of Norgren Impact System • Optimal cleaning • Extend themaximum travel timeof the plant • Guaranteehigh overall efficient • Maximizethewaste throughput • Keep an “Eye” into the boiler • Check the wear andinform about failures • Subsequent adjustment of the cleaning system to your plant • In- / decrease theimpact force • Change the iterationof the cylinder groups • Nearlyno maintenanceandno spare and wear parts • Comfortable operationand feedback to the control room

  23. Contact www.norgren.com

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