ENGINEERING

MECHANICAL CONSTRUCTIONS

& MEDIUM-HEAVY STEEL STRUCTURES

legal Address: 24122 Bergamo, Via Tiraboschi 48 p.iva/ cod. fis. 04071080164 – REA (BG) 432650

legal Address: 24122 Bergamo, Via Tiraboschi 48 Mail Address: Commercial Dept - com@femaeng.net www.femaengineering.it

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 To all Customers 

Bergamo, 15th May 2015 

 With the present communication we transmit You the data of the updated Company’s profile: 

Company’ name : FEMA ENGINEERING srl 

Legal Address (Street/House number)  :  Via Tiraboschi, nr. 48  

Postal Code/City : 24122 Bergamo (BG) ‐ ITALY 

Country : IT 

P.IVA /C.F. : 04071080164 

 

  Mail Address :  General Manager        dir@femaeng.net  Commercial Dept.       com@femaeng.net  Technical Dept.           tech@femaeng.net  Administration Dept.     admin@femaeng.net  Purchasing Dept.                       procurement@femaeng.net 

     We remain at your disposal for any further information, thanking you for the attention reserved to us we send our best regards.       

ENVIRONMENT PROTECTION PLANTS

FEMA, as a company environment-friendly, manufactures plants for:

· Incineration and recycle energetic power using waste;

· Metal recycling process.

Incineration and recycle energetic power plants The scope of work or these plants is the incineration of:

· Municipal waste

· Solid and liquid waste

· Hospital waste

· Toxic waste

Plants for metal recycling process

FEMA manufactures smelting furnaces for the waste of:

· Copper

· Aluminium

· Brass

Example : Incineration Plant with Rotary Kiln Æ 4,7 x 14 m

Example : Incineration Plant with Rotary Kiln Æ 3,5 x 15 m

Thermovalorization Plant - Singapore: F Loading Group – Charging System F Rotary Kiln for Hazardous Wastes – Ø 4,0 x 12,0 m F Load / Unload seals - “fema dragging seal” F Secondary Combustion Chamber F Wet Ahs Conveyor

Incineration Plant - UK F Rotary Kiln for Hazardous Wastes – Ø 4,85 x 13,0 m F Load / Unload seals - “fema dragging seal” F transport F installation

Site : Italy

Typology : Thermovalorization Plant –

Rotary Kiln Ø 4,7 x 14,0 m

ECOLOMBARDIA 4 is one of the major European holdings in the field of incineration of industrial waste. The plant is licensed to collect, deposit, submit and perform further volumetric adjustments and incinerate special hazardous or non-hazardous waste, generated by the activities carried out by craftsmen, traders, production and service facilities.

The plant is divided into the following main sections: F Waste management area for input waste, equipped with reception, storage and waste input area; F Combustion section consisting of a rotating drum furnace, a static chamber and a post-combustion chamber; F Power recovery section consisting of a heater for the production of overheated steam; F Power generation section consisting of the turbo group and the heating cycle equipment; F Fumes treatment line, providing soda pre-neutralization, thermal DENOX, primary dust removal with

electrostatic precipitator, thermal conditioning tower and soda neutralization, final neutralization and elimination of organic micro-pollutants in a dry reactor, secondary dust removal with a bag filter.

Waste storage section The storage of input waste consists of:

� 10 200 m3 vertical axis tanks, with a total capacity of 2,000 m3, of which 200 m3 for waste with organic chlorine content exceeding 2%;

� 6 100 m3 vertical axis tanks, with a total

capacity of 600 m3, of which 100 m3 for waste

with organic chlorine content exceeding 2%;

� 4 vertical tanks, of which 2 of 150 m3 and 2 of

200 m3, with a total capacity of 700 m3, of which

150 m3 for waste with organic chlorine

content exceeding 2 %.

All tanks are kept under nitrogen input and vents are turned towards the furnace, in order to contain emissions during vehicle unloading operations. The management of solid waste involves the storage of wrapped or bulk waste inside a closed shed, for a quantity of 1,113 tons, of which 50 with organic chlorine contents exceeding 2%.

Waste incineration section The rotating drum is mainly intended for the combustion of solid waste and a share of liquid waste, with low or high heating power, based on the type of solids that are fuelled in simultaneously. The drum is located horizontally to the axis with a 2° slope. The staying of the waste is regulated by the number drum rotations, which may vary from 0.2 to 3 a minutes, by inverter operation. The fuelling of solid waste is managed by a dosing chain installed on the loading cells, unloading into a vertical channel quenched by water where a pusher is inserter, for cleaning purposes. Two automated overhead travelling cranes load the funnel according to a recipe set by a remote PC, based on the various types of items in the tanks, and may be based on weight or volume. At the end of the drum, heavy cinder and ash fall into a quenching tank where there two redlers extract the material and unload it into a rolling bin. The static chamber installed serially to the rotating unit, for the combustion of liquid waste, consists of a refractory vertical cylinder inside which there are injection nozzles for low heating power liquids and the two effluent burners, with high heating power. Furthermore, the static chamber is equipped with two methane/gasoline burners, which provide the appropriate combustion conditions. The same structure includes, then, the post-combustion chamber separated by a narrowing that increases the speed of fumes and turbulence (favouring the mixture and, thus, the oxidation), which contains an auxiliary methane burner that controls the temperature. The combustion chambers are led up to 850°C by auxiliary fuel. If the waste to be burned exceeds 1% of halogenated organic matters, expressed on chlorine, temperatures go above 1,110°C. When entering the furnace, effluents include organic chlorine, which is lower than 2 %. Oxidation conditions for the homogenous stage are created in the post-combustion chamber, and the persistence of the fumes above 2 seconds is guaranteed. If the minimum temperatures are not reached, the post-combustion burner starts automatically, in order to restore the recommended operating conditions. The content of output free O2 going out of the post-combustion chamber is constantly maintained above 6%. Cinders are collected and discharged through the redler into a water tank located at the base.

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Power recovery and electricity production section Fumes going out of the post-combustion chamber are sent to the recovery tank. The tank has a radiating section consisting of three wide vertical channels: the first two are completely free, while the third contains a vertical exchanger that allows the deposit of flying ashes brought by the gas current and the lowering of the fume temperature before entering the superheater. The convective section develops horizontally with vertical tubes released in the lower part, for easy cleaning. An efficient hammering system allows the falling of ashes into the lower funnels, from where they are extracted by double-flap valves. Overheated steam generated in the tank, approximately 40 t/h at 380°C and 45 bars, is conveyed into the turbine, wh ose 8.9 MWe power is enough to cover the transfer of 6.5 MWe to ENEL and to meet the estimated own consumption of 1.9 MWe. The exhaust steam going out of the turbine at 54°C and 0.15 bar is then con densed by an air condenser and sent to the condensate storage tank for recirculation.

Fume treatment section The fume treatment line chosen for ECOLOMBARDIA 4 allows stack emissions lower than the limits imposed by the norms in force. In order to pre-neutralize the waste to be incinerated, according to a patented system that has been tested for the management of the first ECOLOMBARDIA 4 plant, the combustion section provides the injection of NaOH in 30% water solution, through dedicated nozzles or premixing into watery liquid effluent. Thus, the acid gases are lowered during the actual combustion. The first stage of actual elimination consists of a SNCR (Selective Non Catalytic Reduction) system aiming at reducing NOx by 50% by injecting a urea solution that reacts with the nitrogen oxides and reduces them to nitrogen and water.

Fumes go then into the primary dust removal section: it is an electrostatic precipitator consisting of three independent fields, which allows the elimination of dusts by approximately 12 g/Nmc going out of the tank at 50 mg/Nmc. Then, fumes cross the conditioning tower where, from an initial temperature of approximately 210°C, are quenched to 150°C. In the tower, the acid gas from the fumes are neutralized by NaOH in water solution. The reaction salts that are generated are discharged by a rotary valve located at the foot of the tower; the quenched and partially neutralized fumes are introduced into the dry contact reactor. It is a device consisting of two concentric cylinders crossed by the sequences of fumes that, entering from below, encounter an upcoming section where reagents, hydrated lime and active carbon are injected, being used for the final elimination of acid gases and for the absorption of organic micro-pollutants. Fumes that are no longer acid and lack organic micro-pollutants still contain the reaction salts, lime and carbon that have not reacted and part of the flying ashes that have not been eliminated by the electro-filter. The final removal of dusts is performed at a temperature of approximately 150°C, in a bag filter consisting of eight independent cells. Fumes are then sent to the FTIR analyzer located on the stack, which can monitor the composition continuously, and then they are released into the atmosphere.

Site : France

Typology : Thermovalorization Plant –

Rotary Kiln Ø 3,5 x 15,0 m

The plant can treat waste generated by hospitals (except for anatomic parts that must be cremated), clinics, laboratories, pharmaceutical industry. The waste is transported in 1,000-liter barrels equipped with a locking system. In 2006, Prociner treated 13,000 tons of waste, (43 % generated by public or private hospital structures located in the south-western part of France and 18 % generated by the neighbouring countries).

Key numbers F Capacity: 19,000 t/year F Treated waste:

o general waste o hospital and pharmaceutical waste o medical o damaged foods

F Equipment: o 1,500 ADR barrels o 1 incineration line of 2.5 tons/h o 1 auxiliary line of 1.5 t/h o collection vehicles

Plant cycle

� Barrel reception Waste transported in barrels according to ADR norms arrive at the location in special trucks. Each barrel is identified by a barcode that allows its traceability during the process stages. After radioactivity has been checked by an automatic system, the barrels are transported to the furnace, for unloading. Thus, the waste to be treated does not require handling by operators

� Incineration

Waste incineration is performed at a temperature of 850 °C in a rotating furnace, up to maximum 1,200 °C during post-combustion. When going out of the combustion chamber, unburned waste is quenched and conveyed to the Class II Technical Centre.

� Barrel washing

After being emptied, barrels are automatically conveyed towards the wash cabins, for disinfection. Water used during this stage is recycled for the furnace and post-combustion.

� Boiler

The power generated by the combustion of waste is recovered by heat exchange into the boiler. The boiler allows a production of 15 tons of steam at 40 bars, respectively 12 MWh.

� Management of environment waste (permanent control system)

Fumes generated by the combustion of waste are recovered, when going out of the boiler, and conveyed towards various units for treatment of pollutants (powders, acid gas, heavy metals, etc.).

Ø Treatment of nitrogen oxides NOx Ø Neutralization of gases Ø Injection of active carbon Ø Bag filter Ø Evacuation cycle

Site : Italiy

Typology : Thermovalorization Plant –

Rotary Kiln Ø 4,0 x 12,0 m

The “F3” incineration plant in Ravenna is authorised to treat approximately 40,000 t/year of special, even hazardous waste. The employed technology, using rotating drums, allows vast flexibility of the range of waste that can be fed into the plant, which can be fed bulk or barrel solid waste, sludge and fluid muds that can be handled by shovel, oily deposits, halogenated organic substances and compounds, hospital waste and urban solid waste. Organic and inorganic liquid waste can be fed into the rotating drum or the successive static chamber. The disposal activity of the plant is applied to industrial activities from the petrochemical sector, as well as external ones. The plant has been studied, designed and created in order to comply with the most recent Italian and EU emission standards. Special attention has been paid to the reduction of NOx, by injection of urea into the heater, as well as hot gas and heavy metals through a two-stage washing column with sub-quenching. The elimination of organic micro-pollutants and heavy metals is then completed by adding reagents, such as lime and active carbon, upstream the final bag filter.

Key numbers F Number of waste-to-energy lines 1 F Overall heating capacity of 19,000,000 Kcal/h F Combustion technology with rotating drum furnace and static chamber F Waste disposal capacity 125 t/g F Operation during one year 7680 h F Rated electrical power 4.2 MW F Disposal operation D10

Type of admitted waste

The plant can treat municipal waste and special waste of the following types: F bulk solid waste F solid and liquid waste in barrels and boxes F pumpable muds F liquid waste (organic and inorganic)

Plant cycle

Ü Acceptance and control of waste

Waste entering the plant is homologated according to a homologation procedure; the homologation must be renewed at least annually. Furthermore, an input waste control plan is in force (sampling and analysis) for checking the chemical characteristics of the fed waste.

Ü Reception and storage of waste

Bulk solid waste, dry mud and organic sludge: they are brought in by trucks or containers and are unloaded and stored into appropriate pits, which can be accessed via gates and fast packing. The pit is maintained at low pression in order to avoid the spreading of foul odours; aspirated air is used as combustion air.

The pit has an overall volume of approximately 1,200 m3, divided as follows:

• 1,000 m3 for the reception and storage of waste;

• 200 m3 for the sector of homogenous loading of solid waste ready to be fed into the furnace.

Waste is taken out of the pit by an overhead travelling crane/bucket system and is homogenised into the appropriate homogenous loading pit and then brought to appropriate incineration sizes by a rotating blade grinder. From this area, it is further taken and unloaded into the furnace feeding funnel. An extractor located on the bottom of the funnel then feeds the waste into the furnace by a double-valve vertical channel, in order to avoid the leakage of fumes during the loading. Solid waste in barrels and boxes: barrels and boxes that can be fed directly into the furnace are provided on pallets and stored into an appropriate area, with pavement and roof, with safety kerb and collection ditch. Waste is fed directly into the rotating drum furnace, between the double valves of the vertical furnace-loading channel, through an elevator located on the front head of the rotating drum. Pumpable muds: are discharged into a covered funnel with an active volume of 60 m3, in order to avoid the spreading of foul odours into the environment. Waste is brought in mainly by gully emptiers or tanker. With the help of a conveyor system and bottom augers, they are sent to an alternative pump, in order to be fed into the head of the rotating drum. Liquid waste (organic and inorganic): are transported by tankers with two discharge tanks and then sent to storage tanks appropriate for their characteristics. In order to prevent volatile organic products from spreading into the air during the emptying of tankers, a discharge system with nitrogen injection is installed into the tankers. Acid waste is discharged in the same manner; however, it does not transit the discharge tanks, but goes straight into the storage tanks. The tank park of F3 furnace has an overall volume of 550 m3. Tanks are made of carbon steel; those used for storing acids are also lined with glass inside. Organic liquids are then taken from the storage tanks and sent to two tanks for the preparation of a homogenous load appropriate for feeding into the furnace. Liquids taken from the tanks by pumps are fed to the furnace burners by close recirculation rings.

Ü Rotary Kiln

The kilns consists of the horizontal rotating drum covered in refractory material, used for incineration of solid waste, barrels, muds and liquid waste, and a static chamber, equipped with three burners for liquids and one additional methane burner, whose operation is subordinated, automatically, to the temperature controller for output fumes.

Ü Steam Generator

Fumes going out the post-combustion chamber, before being fed into the treatment section, are quenched to 220-260 °C in a recovery boiler, producing steam overheated at 350°C and 30 bars. Overheated steam produced into the boiler is fed into a turbo-alternator group for power generation.

Ü Fumes Treatment

NOx exhaust system (“DENOX”) is non-catalytic (SNCR - “Selective Non Catalytic Reduction”). The reduction of fume NOx with molecular N2 is made by injection, in front of the first vertical radiating channel of the boiler, of a reagent consisting of urea solution. For the elimination of dusts, an electrostatic filter with 2 serial electrical fields has been installed. After the electrostatic filter, a fume washing column has been installed, divided into 3 sections: o in the lower section (“acid circuits”), fumes are quenched and saturated, with the absorption of

halogenated acid gases (HCl, HF, HBr) in the bell plate.

o in the intermediate section (“sub-quenching circuit”), fumes are quenched, for the elimination of volatile heavy metals (especially mercury) and halogenated organic micro-pollutants (PCDD and PCDF); furthermore, soda can be dosed, in order to increase the absorption of SO2 and SO3;

o in the upper section (“basic circuit”), SO2 and SO3 are absorbed, and residual traces of halogenated

acid gases are neutralized by dosing soda.

Every section is serviced by a specific recirculation circuit.

Cold fumes going out of the fume washing column, at a temperature of 40, 45°C, pass through a fume/fum e heat exchanger where they are post-heated at 90, 110 °C at the expense of the hot fumes going out of t he electro-filter at a temperature of 220, 260 °C, whi ch are quenched at 175, 195 °C before entering the washing column. Fumes going out of the fume/fume heat exchanger then cross the steam/fume heat exchanger, which provides a constant temperature of fumes entering the “tertiary” treatment section of at least 120 °C, in order to avoid dust deposits on the external walls of the bag filter. Fumes are subject to a finishing treatment in the following bag filter; the feeding is dosed with a powder reagent current, composed of active carbon and hydrated lime. The reagent sediments on the external wall of the filter bag, creating a fine layer which undergoes the following operations : o elimination of residual dust traces, especially sub-micron ones; o elimination, for absorption by active carbon, of dioxins and residual traces of volatile heavy metals; o elimination, for neutralization by Ca(OH)2, of residual traces of acid gases.

Treated fumes are exhausted into the air - at 100,120 °C – through the appropriate 60-m tall stack

Ü Plant for chemical and physical treatment of waters

The F3 furnace is equipped with a chemical and physical plant for treatment of exhaust from the fume washing column. Input current is brought to pH 8.2 by lime cream, supplemented by ferric chloride, precipitate for metals and anionic polyelectrolyte for flocculation. Water is separated from mud by lamellar package settling tanks and then filtered on sand and active carbon beds. The mud extracted by the settling tanks is sent to a thickener from which it is then extracted and conveyed to drying in a centrifuge.

Ü Power recovery

Overheated steam produced by the steam generator is sent to a turbine-alternator unit, with terminal design power of 4,200 kW. The generated electricity covers the needs of the plant; the exceeding amount is transferred into the national distribution network.

Site : Italy

Typology : Tyres Thermovalorization Plant –

Rotary Kiln Ø 3,3 x 14,0 m

Car or truck tires that are fed into this plant consist of a rubber coat and a metal structure. After their reception, they are controlled, in order to ascertain a possible re-coverage and, if deemed fit, they could be reused. Otherwise, they are introduced directly into the furnace, without any preliminary treatment (chipping, grinding).

Tires are loaded via a conveyor belt and weighing system that transports the material into the furnace by a vibrating feeder. During the combustion stage, the rubber cover is separated from the steel structure, which, at the end of its stay inside the rotating drum, falls into the lower part of the discharge funnel. Metal parts are discharged via conveyor belts that transport them into scrap collection crates.

Kiln 1

(Rovereto Plant)

Kiln 2

(Anagni Plant)

Kiln 3

(Rovereto Plant)

Internal diameter : 3,0 m Internal diameter : 3,3 m Internal diameter : 3,3 m

Lenght : 12,6 m Lenght : 14,0 m Lenght : 14,0 m

Loading Capacity : 1,5 t/h Loading Capacity :

1,8 t/h

Loading Capacity

:

1,8 t/h

Discharge of treated fumes

Production of electricity

Production of steam

Discharge of metal residues and ashes

Discharge of sodium sulphate

The fumes generated by combustion pass into the post-combustion chamber and are maintained at the temperature specified by the norms in force and enters the boiler. The boiler produces approximately 16t/h of steam, sufficient to generate 2,800 kWh by a 3,500 kW turbo-alternator. The steam at the lower temperature going out of the turbine returns to the boiler in a continuous closed cycle. The boiler produces steam at 430°C and a pressure of 43 bars. Then, the fumes at the lower temperature cross the bag filter, which recovers the fly ashes, and then into a dry depurator. Here, depurated fumes can be introduced into the air.