Project Synopsis
Prepare consecutive FEL-1/2/3 process design information for a new dual train incineration system for a hazardous waste incineration company in Southeast Asia.
Project Summary
Process Engineering International LLC (PROCESS) was contracted by a hazardous waste incineration company in Southeast Asia to develop a comprehensive process design for a new dual train incineration system capable of handling a wide range of hazardous wastes. The project was executed in phases, starting with a preliminary process design (FEL-1), followed by a standard process design (FEL-2), and culminating in a detailed process design package (FEL-3). This phased approach enabled the client to thoroughly evaluate deliverables at each stage and make informed decisions on options and configurations to best meet their needs.
In addition to the design work, PROCESS visited the project site and also collaborated with local permitting agencies to provide the necessary calculations and results for preliminary construction permitting.
Initially, PROCESS prepared a heat and material balance for the incinerator system, which included:
- Liquid and Solid Feed systems
- Fuel trains
- Primary Incinerator
- Secondary Combustion Chamber
- Rotary Kiln Autoclave
- Ash Handling Systems
- SNCR
- Waste Heat Boiler
- Steam Turbine
- Steam Evaporators
- Wet Scrubbers
- Stack Gas Heater
- Required Utilities
- Other Required Equipment.
Upon completing the heat and material balance model, eleven (11) cases were identified that could impact equipment sizing. These cases were presented to and approved by the client, then run through the heat and material balance calculations to appropriately size and specify the equipment.
Throughout the project, the following deliverables were prepared:
FEL-1: Preliminary Process Design Package
- Design Basis
- Summary of Evaluation of Wet Gas Cleaning Systems
- Process Flow Diagram with Heat and Material Balance Information
- Process Description and Regulatory Description
- Identification and Quantification of Process Effluents and Emissions
- Summary of Raw Materials and Utility Requirements
- Project Risk Summary.
FEL-2: Standard Design Package Additions
- Utility Flow Diagram
- Preliminary Piping and Instrumentation Diagrams
- Process Control Philosophy
- Equipment Line and Instrument Lists with Sizing and Conditions of Service
- Equipment and Instrument Duty Specification Sheets.
FEL-3: Detailed Process Design Package Additions
- Preliminary PLC Specification
- Material Selection Diagrams
- Raw Material and By-Product Handling Requirements
- Preliminary Equipment Layout Sketches for 3 Physical Configuration Options
- Vendor Identification and Bid Packages
- Budgetary Quotes from Vendors
- Capital Cost Estimate.
Regular meetings with the client were held to discuss progress and deliverables. Ultimately, all project deliverables were submitted electronically, and the final process design package was printed, bound, and hard copies were delivered to the client in triplicate.
Industry Type
Hazardous Waste Incineration
Utilized Skills
- Thermal incinerator design
- Front-end process design development
- Environmental permitting support.