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

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
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3. Cleaning Heating Surfaces of Incinerators
Alternative
Existing Techniques
Mechanical drop
hammer system
Electro-pneumatic impact wagon
Pneumatic Single Rapping
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4. Waste-to-Energy-plant – Flowchart of burning process
storage pit
funnel tube
grate
reburning zone
steam boiler
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
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5. Cleaning the Tube Bundle Heat Exchanger
convective heating 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
tube bundle
boiler casing
plunger
sticky particles
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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 Technical data - 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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11. Adjustment of the Impact Energy
Adjusting screw
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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
Dipstick
Min- Max display
Automatic
wear-indicator – can be replaced
with electrical pressure switch
Status at the flange
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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.
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15. Drawing Impact Cylinder SPCH/080003
Norgren Confidential

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
MVA Hameln
MVA Herten
MVA Mannheim
International
WTE Dürnrohr Boiler I + II (Austria)
WTE Dürnrohr Boiler III (Austria)
WTE Pfaffenau (Austria)
WTE Delfzijl Boiler I + II (NL)
KEBAG Emmenspitz (Switzerland)
KVA Chevenez, Geneve (Switzerland) /2009
KVA Turgi Aarau (Switzerland) 1996
WTE Allington* (UK)
WTE Moskau* (Russia)
*Impact wagon system
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18. Project Dürnrohr Boiler I + II + III
Impact system with 94 impact cylinders per boiler
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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
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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
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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
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22. Key Advantages of Norgren Impact System
Optimal cleaning
Extend the maximum travel time of 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

23. www.norgren.com Contact
Norgren Confidential