Infrastructure for Incinerator Manufacturing

 

For manufacturing incinerators, suitable infrastructure, consisting of ample space for production, testing and storage,  power and utilities, some key items of machinery, etc. are  required if the end product has to be made right.  Without these, it will not be possible to turn out quality, reliable and performing incinerators either in the short run or in the long run.

 

At Haat we have 3 fabrication bays of reasonably large size, equipped with overhead cranes and a forklift. There are cement concrete roads for vehicles to move within, in the event of despatches and shipments. There is also a sizable green belt with a variety of plants. There is a back-up diesel generator of 250 KVA capacity.

 

When it comes to key equipment, it has to be understood that manufacturing incinerators involves both semi-automatic and manual operations.  While semi-automatic operations give higher productivity, take lesser time and assured quality, manual operations are necessary in this business because certain activities can only be done manually.  It is not only unavoidable but necessary in our work, even though it is time-consuming. However, you will see from the following how we try to reduce time-consuming activities by certain simple automation and jigs and fixtures, not only to save time but also to avoid human error.

 

Some of the key areas of work along with equipment used are listed below:

 

1.      When the GA drawing, followed by fabrication drawings are made, the first step is to cut the metal sheets. These have to be further dressed, put together as fit-ups and welded.  This activity involves the following actions and machines.

 

a.      Shearing:

The steel sheets/plates come in standard sizes of 1.25 meter x 2.5 meter and these have to be cut as per the fabrication drawings.  This can be accomplished by oxy-acetylene gas cutting or by a semi-automatic profile cutting or plasma cutting.  However, none of these methods will give a good finish, requiring re-work and there will also be cutting losses. 

 

At Haat we use a Hydraulic Shearing Machine which requires only positioning of the sheet below the shear and operating the blade using a pedal and guides.  This gives excellent results with no further finishing required. This hydraulic shear can handle sheet steel and stainless steel of thicknesses of up to 8 mm with a cutting length of 2.5 meters.

 

The Air plasma cutting machine is essentially used for cutting stainless steel up to 15 mm thick (as SS cannot be cut by gas). This is also used for cutting steel of thickness up to 25 mm (which cannot be cut by the shearing machine).

 

b.     Rolling:

This is also a hydraulic system which can handle plate thickness up to 35 mm, rolling dia. of 3 m and length of 2 m.  There is also a flange rolling machine which can take up to 3 metre dia and 16 mm thick plates.

 

 

 

c.      Welding:

The sheared plates are put together by tack welding and dimensions are checked with the drawing. This is performed by the QC team to make sure there is no error.  It will be easy to rectify the error, if any, at this stage rather than later.

 

There are several systems available here.  Welding processes such as manual metal arc welding, MIG and TIG welding are all semi-automatic processes which require human intervention. The consumables used here are stick electrodes, solid wires, flux cored wires and TIG consumables.

 

We have progressed from the very conventional manual metal arc welding to flux cored wire welding as we find this gives excellent finish with no porosity or spatter.

 

We have a good number of MIG and TIG welding systems in place with qualified welders to do this very important task of fabricating the incinerator, which is similar to laying the foundation for building strong and reliable equipment.

 

We also have a column and boom welding system as well as welding positioner. The column and boom system can handle diameters of up to 2.5 mtr and length of 1.25 meters. The positioner can take up to  a dia. of 3 m. These two systems use very little human element. Once the job is fixed on the machine and settings are made, it works as a fully automatic system. Welding done using these fixtures gives such an excellent finish that it requires no further dressing or grinding.

 

Preparation prior to welding:

The edges to be welded have to be beveled so that enough weld material is deposited in the joint to make it strong.  We have a semi-automatic beveling machine and this functions admirably, giving no further scope for rework.

 

2.      Refractory lining

 

The best results with refractory lining are obtained when it is put thru a series of paddle mixtures.  This ensures that the refractory is well mixed with water and is ready to be poured on to the surface of the incinerator machine.  Additionally vibrators are used to remove any air entrapped in the mix.

 

The application of refractory is manual, but in the case of cylindrical parts and certain others a mould is used and the refractory is poured between the body and the mould. When the mould is removed after sometime, the result is pleasing to the eye as one cannot see any blemish as it has taken the shape of the mould and matches well with the drawing. (Refer to our blog `What does refractory lining of an incinerator has got in common with the English channel?`.)

 

Incidentally, these kinds of moulded linings with customized refractory has made it possible for the incinerator to last for several years without re-lining as well as providing good thermal efficiency in the combustion chamber.

 

3.      Cylindrical sections require flanges and these are rolled in a hydraulic flange rolling machine.  We only need to weld the two ends.  This also gives very good surface finish with no undulation.

 

4.      Blasting and painting:

These are done using a compressor with special grit blasting equipment, followed by painting in a temperature controlled paint booth.  The vapours/air from the blasting and painting areas are treated in air pollution control equipment before being released to the atmosphere.

 

5.      Material Handling:

Three overhead cranes of 25, 5 and 2 tonnes capacity are available for handling semi-finished products from one bay to the other as well as for easy operation. They enable quick and efficient loading of the incinerator equipment on to trucks and containers without any damage.

 

6.      Working model incinerator:

What better proof is required for the performance of a Haat incinerator than a Euro-emission compliant Hazwaste Incinerator System working at our Common Facility? This is a high-end system with excellent emissions and a show piece that attracts intending buyers.

 

7.      Power and space:

A sanctioned HT connection of 200 KVA with back-up generator of 250 KVA with ample space for fabrication, refractory, paint work and storage, not to mention stores with stocks of spares and components are available to make things easy for making large-sized incinerators and thermal oxidizers.

 

We find over a period of time that the infrastructure available in HAAT is time-tested, reliable, trouble free and has created an image of Haat making good quality incinerators for supply all over the world.

 

This has been the observation made by many visitors, clients and inspectors who visit our Works.