CWE/HILLS/PGH/36 OF 2023-2024 SPECIAL REPAIR/ REPLACEMENT OF OIL FIRED INCINERATOR PLANT AT MH PITHORAGARH UNDER GE PITHORAGARH

Amount

Supply, install, testing and commissioning of Electric fired incinerator fulfilling the criterion of new CPCB norms having 50 Kg/Hr burning capacity horizontal/ vertical type comprising of primary chamber, secondary chamber, designed on "controlled air" incineration principle and provided with minimum of 115mm thick refractory and insulation bricks conforming to IS 8-1994 and IS 2042-2006. This is equipped with loading door, ash removal door and automatic burner operated by temperature indicating controller to sustain minimum temperature of 800±50 Degree centigrade in the primary chamber and 1050±50 °C in secondary chamber, one fully automatic pressure jet type burner for each chamber, chamber made of mild steel plate of adequate thickness (minimum 5mm thick), 30 metre high chimney, exhaust system, high pressure ventury Scrubber, PLC based control panel, droplet separator etc., including all other accessories and piping, equipments and civil works required for installation of incinerator, control panels and chimney and Erection and commissioning charges includes hiring of hydra/ crane for installation of chimney and other equipments and other connected job for making of necessary arrangements for fixing of new Incinerator and fixing of new technology to record the datas as per new CPCB norms complete all as specified and as directed.

Construction feature of Incinerator includes:- (a) Incinerator Electric heated with primary & secondary chamber return. (b) An emergency stack to vent out the gases in case of power failure. (c) Quencher, Air pollution device, venturi scrubber, Automatic work feeding system, droplet separator & circulation pump, recirculation tank, inter connection piping, ID fan, FD fan, Electric burners - 02 for each chamber (Primary & Secondary), Plug gas analysis, instruments, valves, dampers & fittings and all necessary pollution control devices (as per CPCB Norms). (d) Electrical control panel with all electrical power, earth & control cabling. (e) Minimum 3mm Rubber lined Chimney with 30 mtr heights with all fittings & fixtures like ladders & other accessories as directed. Note: Before execution of work, contractor has submitted the technical details & drawing to GE for his approval.

INCINERATOR 1. Type of Waste - Biomedical Waste 2. Burning Capacity 50 kgs/hr 3. Electrical heated Burners of 48 KW for each chamber (Primary & Secondary) 4. Type of Blower Operation Mono block fully automatic electric blowers 5. Temperature Primary Chamber 800±50°C Secondary Chamber 1050±50°C 6. Operation of burner Fully Automatic 7. Connected electrical load 100 KW 8. Expected hours of operation (a) For Pre-heat 45 minutes (b) For cooling of furnace 45 minutes

Main Combustion Chamber/Primary Chamber This is fabricated out of mild steel conforming to IS-2062 and is refractory lined from inside with refractory bricks 115mm thick backed by insulation bricks 115mm thick conforming to IS-8. This is equipped with loading door, ash removal door and automatic burner operated by temperature indicating controller which is set at 800±500 °C. High pressure air from a blower is provided through a number of nozzles fitted in the walls of the primary chamber. Since refractory is very thick and air is circulated within the chamber, it ensures a very low skin temperature of the Incinerator. The primary chamber is provided with an automatic waste feeding system. The waste is introduced on the hearth in a way so as to prevent the heap formation. Suitable raking arrangement is provided for uniform spreading of waste on the hearth.

PRIMARY CHAMBER 1. Type Static Solid Hearth Cylindrical & vertical 2. Material of Construction Mild Steel, 5mm thick 3. Volume 1.16 cubic meter 4. Refractory thickness 115mm thick 5. Material Refractory bricks confirming to IS-8 6. Temperature resistance 1400°C 7. Temperature inside primary chamber 800+50 deg. C. 8. Insulation thickness 115mm thick , ceramic blanket 25mm cold face 9. Material Insulation bricks confirming to IS2042 10. Automotic waste feeding through Hydraulic Ramp Pushe, Hydraulic power pack (05 HP), Two-way operated solenoid valves, automatic and manual operated. 11. Ash Removal Manual 12. Charging door size 750 mm x 750 mm 13. Outer diameter 1620 mm and Height of chamber 2185 mm

Post Combustion Chamber/Secondary Chamber This is also fabricated out of Mild Steel and is refractory lined similar to primary chamber. This is equipped with automatic burner. A temperature indicating controller is provided, which is connected to the control panel. The operating temperature is 1050+500C. The secondary chamber is so designed so as to ensure a minimum 1 second residence time to gas flow. SECONDARY CHAMBER 1. Type Static Solid Hearth Cylindrical & vertical 2. Material of Construction Mild Steel, 5mm thick 3. Volume 0.65 cubic meter 4. Refractory thickness 115mm thick 5. Material Refractory bricks confirming to IS-8 6. Temperature resistance 1400°C 7. Temp. inside secondary chamber 1050±50 deg. C. 8. Insulation thickness 115mm thick ceramic blanket 25mm cold face 9. Material Insulation bricks confirming to IS2042 10. Outer diameter 1235 mm to achieve 1 second residence time as per CPCB Guidelines 11. Height of chamber 2185 mm

Electrical Control Panel The control panel supplied with the Incinerator is placed separately. It consists of PLC along with display unit. A printer is provided which is connected to the display unit to take recording of critical parameters on a regular basis. The display unit automatically and continuously monitors and record dates, time of day, batch sequential number and operating parameters such as temperatures in both the chambers. The panel has provision to run on the manual mode in case of malfunctioning of the PLC system. The panel is duly powder coated. It houses the primary and secondary burner controls, all the temperature controllers, motors starters, isolator switches, overload relays for burners and fans and audio-visual alarms for abnormal workings. All electrical power, earth and control cabling from the control panel to the individual drives and components are provided by contractor. The control panel is pre-wired. and GI strip earthing 32x6mm- qty-02 Nos included in quoted rate. CONTROL PANEL 1 Type PLC based with printer & recording device having both Manual and Auto Operation 2. MOC CRCA Sheet 3. Type of temperature controller Digital 4. Finish & Painting type Powder coated 5. Audio-visual alarm system Provided

Quencher Hot gases are cooled to near the saturation level in the quenching system. If not cooled, the hot gas stream can evaporate a large portion of the scrubbing liquor, adversely affecting collection efficiency and damaging scrubber internal parts. If the gases entering the scrubber are too hot, some liquid droplets may evaporate before they have a chance to contact pollutants in the exhaust stream, and others may evaporate after contact, causing captured particles to become re-entrained. Cooling the gases reduces the temperature and therefore, the volume of gases, increases the overall efficiency of the Air Pollution Control Devices in the incinerator. QUENCHER 1. MOC of outer body Mild Steel refractory lined from inside 2. Water Circulation system Provided with centrifugal pump 3. Purpose to reduce flue gas temperature before venturi scrubber

Venturi Scrubber (Air Pollution Control Device) The flue gases from the Secondary chamber are then sent to venturi scrubber. Venturi Scrubber is a high-energy device (minimum pressure drop of 350mmWC) fabricated out of Stainless Steel –316L Grade where particulate matter as well as acidic pollutants is scrubbed. Here the acidic gases are removed by absorption with caustic soda and the particulates by the inertial impaction energy. A high-pressure drop across the venturi scrubber, imparts sufficiently high energy, which helps in atomizing the scrubbing liquid and thus trapping the particulates. 5% caustic solution is used as scrubbing liquid to neutralize the SO2 present in flue gases. The temperature of the flue gas at the outlet of the venturi scrubber is approx. 80°C to ensure the saturation of the flue gas. The scrubbing medium is circulated @ 2-2.5 Ltrs/m3 of saturated flue gas at venturi outlet. This is done using a pump & piping made of Stainless Steel –316 grades RE-CIRCULATION PUMP FOR VENTURI SCRUBBER 1. Type centrifugal 2. MOC PP/SS 3. Piping SS 4. Height 2200 mm 5. Dia 350 mm at the top

Droplet Separator cum Re-circulation Tank The flue gases then enter tangentially into the droplet separator, which is of cyclonic type. By the action of centrifugal force, the larger droplets present in flue gases settle down. The droplet separator is manufactured out of Mild Steel Rubber lined. A Mild Steel Rubber lined water re-circulation tank of suitable capacity is provided. Ducting All inter connecting ducting between scrubber and droplet separator/demister is provided. Water Circulating Pump for Quencher & Venturi Scrubber Water re-circulating pump for quencher and venturi scrubber is provided. DROPLET SEPARATOR & RE-CIRCULATION TANK (INTEGRAL) 1. Type cyclonic 2. Application to separate water droplets from flue gases 3. MOC Mild Steel Rubber lined 3mm thick

Interconnecting Piping All interconnecting water piping between quencher, venturi scrubber, droplet separator and re- circulation tank is provided. 1 Nozzle 3 nos 2. Fresh water inlet 1 inch 3. Pump inlet & outlet 40 mm 4. Drain size 50 mm 5. Overflow size 50 mm 6. Manhole size Recirculation tank cleaning door 300 mm dia

I. D. Fan The Induced Draft Fan maintains the balance draft and draws out the clean gases into the atmosphere through a 30 mtrs high stack. The I. D. Fan is dynamically balanced and has a pressure of 450mmWC. The I.D. Fan is belt driven and connected to an electric motor. I. D. FAN 1. Type High Pressure Centrifugal type 2. MOC Stainless Steel Impeller and Mild Steel Rubber lined casing 3. Drive Belt Driven 4. Capacity 2000m3/hr 5. Static pressure 450- 500 mm WC 6. Look Mild steel rubber lined from inside with SS impeller 7. Motor – 10HP 8. Pulley as per designed

Forced Draft Fan A forced draft fan is provided to supply air inside the primary and secondary chambers. The F.D. Fan is dynamically balanced and is connected to the electric motor of suitable rating as per OEM of Incinerator. Earthing 02 Nos include in quoted rate for the motor. COMBUSTION FAN (FD Fan) 1. Type centrifugal 2. Modulation Manual damper control 3. MOC Mild Steel 4. Drive Direct drive

Heating Elements Electrical heater of capacity 24+24(48 KW) each chamber primary and secondary chamber 48 KW(primary) + 48 KW(Secondary). BURNERS 1. No. of burners 1 Nos. in primary Chamber and 1 No. in Secondary Chamber. 2. Type Mono-block fully automatic 3. Electric type 48KW (24KW primary) + 48KW secondary.

Chimney Chimney of 30 mtrs height is provided with accessories stay and supporting guy wire and all the necessary foundation and civil work included. Earthing 02 Nos include in the quoted rates for Chimney & Lightening arrestor. CHIMNEY Stack OF 30 MTRS HEIGHT 1. MOC - Mild Steel 2. Type - Self supporting AS PER IS -2062 (2011) 3. Height - 30 mtrs from ground level (a) Internal dia of every 5 meter - Bottom 600 mm, top 300 mm, Top 20 mtrs – 300mm, bottom 10 mtr -600 mm reducing to 300mm

(b) Thickness of plate at every 05 meter Bottom 10 mtrs – 8mm Conical portion Top 20 mtrs – 6mm Cylindrical portion 4. Method of joining - Flanges 5. Reciprocating pump/ Monoblock pump - Same details as in Venturi scrubber pump Capacity 15m3/hr , Head 12 mtrs , Motor 2HP 5. Other Standard Accessories - Aviation lamp, lightening arrestor, stack, drain, inspection platform, sampling port 5 Paint - The chimney is painted externally with two coats of heat resistant aluminium paint over a coat of primer. 6 Ladder - Provided till the top (enclosed with cage type semisphere support.) 7 Inside Protection - 3mm thick rubber lining from inside 8. Chimney design and foundation details including stay assembly, ladder shall be as per OEM specification. Contractor will submit details structural/ architectural design and specification drawings of chimney including foundation, ladder, stay assembly and standing platform duly vetted by IIT/ NIT/ Govt Engineering college to GE before execution of the work.

Emergency Stack An emergency stack to vent out the gases in case of power failure is provided. The emergency stack is of Mild Steel. EMERGENCY STACK 1. MOC(Material of Construction) Mild Steel, 3mm thick 2. Refractory 75mm thick castable 3. Insulation 25mm thick castable

Tools One set of tools consisting of hoe, shovel, rake, poker etc. is supplied with each incinerator.

Dismantling of Old unserviceable Oil Fired Incinerator Cap 50 Kg/Hr complete with all connected unserviceable equipments and chimney stack and shifting to MES store yard without any damage to the existing building complete all as specified and directed.

Electromech Engineers