E-book Incinerators

FOREWORD

This report is a part of the Ship Power Plant (SP2101). The purpose of this report is to
provide information about to shipboard incinerator which will provide various information
related to incinerator such as Related laws, Type, Usability, Checking, Maintenance etc. In
which the internal content comes from searching and collecting in order to be summarized
for easier study and understanding

I hope that our report will be useful to many people. If any internal content has any
errors, please apologize here too.

Pantavat
janin

TABLE OF CONTENTS

Page
INTRODUCTION……………………………………………………………………………. 1

What is an Incinerator?..................................................................................... 1
What can be incinerated?................................................................................. 2
What is prohibited to be incinerated?............................................................... 2
OPERATING CONTROLS………………………………………………………………… 3
OTHER REQUIREMENTS………………………………………………………………… 4
RELEVANT LAWS…………………………………………………………………………. 5
Types of incinerator………………………………………………………………………. 6
EVAC CYCLONE INCINERATOR………………………………………………………... 7
COMPONENTS OF AN INCINERATOR………………………………………………… 8
Things to remember………………………………………………………………………. 11
NOTE…………………………………………………………………………………………. 12
Common Problems of Ship’s Incinerator……………………………………………... 13
REFERENCE………………………………………………………………………………… 16

1

INTRODUCTION

The cargo ship that is at sea is like a big house floating on the water. Which can sail
of the ocean. However, then there are limitations in the area on the ship. Therefore, there
must be many systems on the ship that can be equivalent on the ground. Including waste
management systems that are on board every day. But in the disposal of garbage, we are
not able to have the municipality to bring the car to receive the garbage of the boat in the
middle of the sea Or if dumped into the sea, it will create more pollution to the environment,
so what is called a waste incinerator is born. To be used for incineration or change the

garbage condition to be smaller in size and able to store and add more space on the ship.

What is an Incinerator?

Incinerator is an enclosed system waste incinerator or “Enclosed Reactor” in cone
shape foe waste to react with the heat generated by the incinerator system. This reaction
occurs at temperatures between 1,200 – 1,500 degrees Celsius under low oxygen content
control. To prevent complete combustion This reaction is called the incinerator reaction,
which causes organic molecules to break down into gases with a simple gaseous structure,
consisting of CO CO2, CH4 and H2, which are combined. Together is a synthetic fuel gas
which has heat value for use the remaining inorganic substances will melt at the bottom of
the furnace. And is released outside and to cool down to a crystal-like solid called Slag,
which is non-toxic. The purpose of a shipboard incinerator is to get rid of solid and/or sludge
waste generated on board as an environmentally friendly approach

Photo 1 - Incinerator

2

What can be incinerated?

According to the IMO regulations the following solid and liquid waste can be burned in
an IMO certified shipboard incinerator:

▪ Plastic, cardboard, wood
▪ Rubber, cloth, oily rags, lube oil filters
▪ Diesel engine scavenge scraping
▪ Paint scraping
▪ Food waste, etc.
▪ Sludge oil, waste lubrication oil
▪ Hospital waste, female hygienic binds
▪ Destruction of contaminated water

What is prohibited to be incinerated?

▪ Material, which contains more than traces of heavy metal such as light bulbs, he
category of heavy metal:
▪ Mercury
▪ Lead
▪ Nickel
▪ Vanadium
▪ Zinc

▪ Refined petroleum products containing halogen compounds

3

OPERATING CONTROLS

1. The entire unit should be capable of being disconnected from all sources of electricity
by means of one disconnect switch located near the incinerator.

2. There should be an emergency stop switch located outside the compartment which
stops all power to the equipment. The emergency stop switch should also be able to
stop all power to the fuel pumps.

3. If the incinerator is equipped with a flue gas fan, the fan should be capable of being
restarted independently of the other equipment on the incinerator.

4. The control equipment should be so designed that any failure of the following
equipment will prevent continued operations and cause the fuel supply to be cut off.

5. Safety thermostat/draft failure A flue gas temperature and combustion controller, with
a sensor placed in the flue gas duct/combustion chamber should be provided that will
shut down the burner if the flue gas temperature exceeds the temperature set by the
manufacturer for the specific design.

6. A negative pressure switch should be provided to monitor the draft and the negative
pressure in the combustion chamber.

7. Flame failure/fuel oil pressure the incinerator should have a flame safeguard control
consisting of a flame sensing element and associated equipment for shut down of the
unit in the event of ignition failure and flame failure during the firing cycle. The flame
safeguard control should be capable of closing the fuel valves in not more than 4 s
after a flame failure.

8. Loss of power If there is a loss of power to the incinerator control/alarm panel (not
remote alarm panel), the system should shut down

9. Fuel supply Two fuel control solenoid valves should be provided in series in the fuel
supply line to each burner. On multiple burner units, a valve on the main fuel supply
line and a valve at each burner will satisfy this requirement. The valves should be
connected electrically in parallel so that both operate simultaneously.

10. Alarms An outlet for an audible alarm should be provided for connection to a local
alarm system or a central alarm system. When a failure occurs, a visible indicator
should show what caused the failure. The visible indicators should be designed so
that, where failure is a safety related shutdown, manual reset is required.

4

OTHER REQUIREMENTS

Documentation
A complete instruction and maintenance manual with drawings, electric diagrams,

spare parts list, etc. should be furnished with each incinerator.

Installation
All devices and components should, as fitted in the ship, be designed to operate when

the ship is upright and when inclined at any angle of list up to and including 15° either way
under static conditions and 22.5° under dynamic conditions (rolling) either way and
simultaneously inclined dynamically (pitching) 7.5° by bow or stern.

MARKING
Each incinerator should be permanently marked, indicating:

1. manufacturer's name or trademark
2. style, type, model or other manufacturer's designation for the incinerator.
3. capacity – to be indicated by net designed heat release of the incinerator in heat
units per timed period; for example, British Thermal Units per hour, megajoules per
hour, kilocalories per hour

Required emission standards to be verified by type approval test
▪ O2 in combustion chamber 6 – 12%
▪ CO in flue gas maximum average 200 mg/MJ
▪ Soot number maximum average BACHARACH scale or RINGELMAN scale (A higher
soot number is acceptable only during very short periods such as starting up.)
▪ Unburned components in ash residues Max 10% by Weight
▪ Combustion chamber flue gas outlet temp. range 850 – 1200 °C

5

RELEVANT LAWS

MARPOL

▪ Annex VI - Regulations for the Prevention of Air Pollution from Ships
▪ Chapter 3 - Requirements for control of emissions from ships
▪ Regulation 16 - Shipboard incineration

Regulation 16 - Shipboard incineration
▪ Shipboard incineration shall be allowed only in a shipboard incinerator.

▪ Each incinerator installed on board a ship on or after 1 January 2000 shall meet the
requirements contained in appendix IV to this Annex. (Appendix IV - Type approval
and operating limits for shipboard incinerators).

▪ Each incinerator shall be approved by the Administration taking into account the
standard specifications for shipboard incinerators developed by the Organization.

Shipboard incineration of the following substances shall be prohibited:
a) Annex I, II and III cargo residues of the present Convention and related contaminated
packing materials;
b) polychlorinated biphenyls (PCBs);
c) garbage, as defined in Annex V of the present Convention, containing more than
traces of heavy metals; and
d) refined petroleum products containing halogen compounds.

6

Shipboard incineration of sewage sludge and sludge oil generated during the normal
operation of a ship may also take place in the main or auxiliary power plant or boilers, but in
those cases, shall not take place inside ports, harbor’s and estuaries. Shipboard incineration
of polyvinyl chlorides (PVCs) shall be prohibited, except in shipboard incinerators for which
IMO Type Approval Certificates have been issued. Personnel responsible for operation of
any incinerator shall be trained and capable of implementing the guidance provided in the
manufacturer's operating manual.

Monitoring of combustion flue gas outlet temperature shall be required at all times and
waste shall not be fed into a continuous- feed shipboard incinerator when the temperature
is below the minimum allowed temperature of 850 degrees Centigrade.

For batch-loaded shipboard incinerators, the unit shall be designed so that the
temperature in the combustion chamber shall reach 600 degrees Centigrade within five
minutes after start-up.

Types of incinerator

Vertical cyclone type and horizontal burner type are two most commonly used
incinerator on the ship.

Horizontal burner type
The setup is similar to a horizontal fired boiler with burner arrangement horizontal to

the incinerator combustion chamber axis. The ash and noncombustible material remaining
at the end of the operation has to be cleared out manually.

Vertical Cyclone type
In this type, the burner is mounted on the top and the waste to be incinerated in

introduced into the combustion chamber from the top. A rotating arm device is provided to
improve combustion and remove ash and non-combustibles from the surface.

7

EVAC CYCLONE INCINERATOR

Photo 2 – Evac cyclone incinerator

Evac cyclone incinerator the incinerator fulfills the emissions requirements set out in
Annex VI of the IMO guidelines

Evac cyclone incinerator the incinerator fulfills the emissions requirements set out in
Annex VI of the IMO guidelines. The incinerator is modular, consisting of two separate
chambers:

▪ The moving grate chambers.
▪ The cyclone chambers.

The moving grates are in the primary chamber, forcing the waste to flow downwards
so that it doesn’t accumulate in any one location. This increases the surface area of the
waste, resulting in a higher burning rate. A secondary cyclone chamber ensures high flying
ash separation and the burning of flue gases. Gas can be cooled using the boiler (energy
recovery) or through air cooling. Airflow in the incinerator is actively controlled using
advanced measurements, resulting in a smaller flue gas pipeline and blower. Evac cyclone
incinerator

The important parts of the incinerator are:

▪ Combustion chamber with diesel oil burner, sludge burner, pilot fuel heater and
electric control panel

▪ Flue gas fan which may be fitted with flue gas damper or frequency inverter
▪ Sludge service tank with circulating pump and heater
▪ Sludge settling tank with filling pump and heater (Optional)
▪ Water injection (Optional)
▪ Rotating arm to remove ash and non-combustibles (for vertical cyclone type)

8

COMPONENTS OF AN INCINERATOR

Photo 3 – Incinerator Structure

9

PREPARATION FOR START-UP OF THE INCINERATOR
Before start-up of the incinerator, the following is to be carried out:

1) Open all inlet and outlet valves for diesel oil.
2) Open all inlet and outlet valves for waste oil and air.
3) Make sure that there are no hindrances for air admission to primary blower as well

as flue gas outlet.

START-UP OF THE INCINERATOR OP PROGRAM 'SOLID WASTE’

1) Activate the main switch on the control panel.
2) Reset the alarm lamps on the push button 'reset alarm’
3) Make sure that all the lamps are alight by pressing the button 'lamp test’
4) For starting of the incinerator, activate the switch for 'incinerator- start’
5) The incinerator will now start automatically by activating the secondary burner in the

secondary combustion chamber.
6) The secondary combustion chamber will have a temperature of 650℃, and the

primary burner in the primary combustion chamber will be activated. The incinerator
the operate within set temperatures.
7) If the flame in the incinerator goes out, the incinerator is to be reset by means of
"reset flame failure primary and secondary burner"
8) If add solid waste to the primary combustion chamber using the sluice by activating
the pushbutton on the incinerator wall.

10

START-UP OF THE INCINERATOR ON PROGRAM 'W.O.'
1) Make sure that switch is turned to 'W.O. on’
2) Before start-up of the incinerator, follow the instructions manuals.
3) When the temperature of the secondary combustion chamber is 650℃ the primary
D.O burner in the primary combustion chamber will be activated. After a preheating
period of 25 seconds the W.O burner starts automatically and operates within the
set points.
4) When the 'delay burner' is switched to automatic 'AUT', the primary D.O burner
operates for 25 seconds to ignite the W.O burner automatically.
5) When the 'delay burner' is switched to manual 'MAN' the primary D.O burner
operates all the time together with the W.O burner.

ADDING OF SOLID WASTE
Before adding a new charge of solid waste, control whether the incinerator is ready to

receive more waste or not, by looking through the sight glass.

STOPING OF INCINERATOR
1) Activate the switch 'incinerator stop’
2) When the temperature in the incinerator drops to below 100℃, the incinerator stops
automatically.
3) When the incinerator has stopped, switch off the main switch on control panel after
the blower has been off for 30 minutes.

11

Things to remember

▪ Keep the incinerator chamber inlet outlet and burner parts clean. A daily inspection
must be carried out before the start in the morning

▪ Do not throttle the air/steam needle valve more than 3⁄4 turn closed. If the pressure
increases above the defined limit, clean the sludge burner nozzle

▪ Do not turn off the main power before the chamber temperature is down below
170°C. Keep the fan running to cool down the chamber

▪ If experiencing any problem with high temperature in the combustion chamber, flue
gas or control of sludge dosing, replace the dosing pump stator

▪ Do not transfer sludge to the service tank during sludge burning in a single tank
system as it can damage the refractory

▪ It is always recommended to heat the sludge overnight, without starting the
circulating pump. Drain off the free water and start the sludge program before
performing the incinerator operation

▪ Never load glass, lithium batteries or large quantities of spray cans in the
incinerator. Avoid loading large amounts of oily rags or filter cartridges as all these
may damage the flue gas fan

▪ Inspect the cooling jacket every six months (open the cover plates) and clean as
required with steam or hot water

▪ Read the instruction manual, and never change any settings unless instructed by
the makers

12

NOTE

▪ Do not incinerate metals as soda and food can plate, flatware, serving spoons/tray,
hardware (nuts & bolts), structural pieces, wire rope, chains, etc., glass such as
bottles, jars, drinking glasses, etc.

▪ Flammable materials such as bottles or cans containing flammable liquids or
gasses and aerosol cans must not be incinerated. Loading of glass will result in a
rock-hard slag, which is hard to remove from the refractory lining.

▪ In the case of a blackout, when the combustion chamber temperature is above
220°C, it is important to start the flue gas fan as soon as possible in order not to
damage the incinerator by accumulated heat in the refractory lining

▪ Wrong operation or under maintenance of incinerator may reduce the overall
efficiency of the equipment and can also lead to serious accidents.

▪

13

Common Problems of Ship’s Incinerator

1. Flame Failure Alarm

One of the first things that needs to be done when receiving flame failure alarm is to
check the flame sensor. More than often flame sensors get dirty resulting in flame failure
alarm.

Some other reasons for flame failure alarm are:
▪ Dirty Burner
▪ Ignition failure
▪ Blocked diesel oil nozzle
▪ Defective flame sensor
▪ Defective solenoid valve
▪ Incorrect opening of air damper
▪ Clogged fuel line filter

2. High Flue Gas Temperature Alarm

There can be several reasons for high flue gas temperature alarms and the most
common one is faulty or defective temperature sensor.

Some of the other reasons for this alarm are:
▪ Blocked air-cooling inlet
▪ Faulty inverter and transmitter
▪ Leaking or defective solenoid valve
▪ Leaking dosing pump stator
▪ Defective pressure control
▪ Clogged cooling panel slot
▪ Throttling brick fallen out

3. High Combustion Chamber Temperature Alarm

Main reasons for high combustion chamber temperature alarm are:
▪ Faulty alarm sensor
▪ Solid waste inside the incinerator is more in quantity
▪ Poor refractory condition
▪ High combustion chamber temperature alarm can also occur if the outlet is
blocked with slag or the slot at the combustion chamber floor level is blocked.

14

4. Sludge Oil Leaking

Sludge oil leaking mainly takes place from the base plate corners of the combustion
chamber. Some of the main reasons for sludge oil leaking are:

▪ Improper opening of oil burner air damper
▪ Very low under-pressure • Closed Atomizing valve
▪ Incorrect valves in Programmable logic controller (PLC)
▪ Blocked sludge nozzle atomizing slot

5. Cracks in Refractory of Combustion Chamber

The main reason for cracks in combustion chamber refractory is rapid change in
temperature caused by filling of water in the sludge tank during sludge operation at high
temperature.

It should always be noted not to fill the sludge tank when the sludge is burning.

Vibrations of the machinery are also a prime reason for this problem. Adequate deck
support should be reinforced to prevent this.

Leaking door gaskets can also lead to this issue. Adjust and change the gaskets
whenever required.

6. Draft failure / Low Pressure Alarm

One of the main things to check for solving problems related to draft failure or
extremely low under pressure alarm is faulty pressure sensor. Some other reasons for the
problem are:

▪ Damaged door gasket
▪ Broken fan belt
▪ Wrong rotation of fan direction
▪ Failure in opening of flue gas damper
▪ Leakage in sensor tube

Always make sure that fan belt and door gasket are properly checked at regular
intervals of time. Faulty fan, flue gas damper and sensor tube must also be checked and
repaired as required.

15

7. Leaking Mechanical Seal Sludge Pump

In order to prevent leaking of mechanical seal, it should be noted that the sludge pump
is not running dry for a long time. If need arise, change the seal. Also, large amount of debris
in the sludge can also damage the mechanical seal. In such cases, restart the system by
flushing and cleaning the lines.

8. Leakage in D.O. Pump Shaft End

The main reason for this problem is blocked return. Open the return valve or remove
return blocking. Replace the shaft seal if required.

16

REFERENCE

Nejat Öztezcan, (2018, October 21), Marine Incinerator, Retrieved May 14, 2020,
from https://www.slideshare.net/Nejatztezcan/marine-incinerator

MIURA CO., LTD, (no date), Shipboard incinerator, Retrieved May 14, 2020, from
https://www.miuraz.co.jp/en/marine/bgw-n.html

Anish, (2019, December 9), Waste Oil Incinerator: Construction And Working,
Retrieved May 14, 2020, from https://www.marineinsight.com/guidelines/construction-and-
working-of-waste-oil-incinerator/

IMO, (no date), Shipboard incineration – Regulation 16, Retrieved May 14, 2020,
from
http://www.imo.org/en/OurWork/Environment/PollutionPrevention/AirPollution/Pages/Shipb
oard-incineration-%E2%80%93-Regulation-16.aspx

Harris Jeffery, (no date), MARPOL 73/78 Annex VI, Retrieved May 14, 2020, from
https://www.slideserve.com/harris/marpol-73-powerpoint-ppt-presentation