SINCAL DRS

DRS: Biomass with moving grate

The new Sincal DRS biomass steam boilers are the culmination of all the experience acquired by SINCAL in the use of solid fuels for steam production.
During the design process of these boilers, the characteristics of the different types of biomass most commonly used in the industry (wood chips, olive pits, argan shells, etc.) have been taken into account at all times, resulting in a versatile design, suitable for a large number of fuels (*) and providing exceptional performance and emission levels.
The DRS biomass steam boilers are not an adaptation of other models of liquid or gaseous fuel boilers. It is a design made exclusively for solid fuels.
Standard models range from 2,000 to 10,000 kg/h of steam at design pressures of 9, 11, 13 and 15 bar. All our boilers are manufactured according to the German steam boiler code TRD and comply with the European Pressure Equipment Directive 2014/68/EU obtaining the corresponding CE marking.
Types of biomass
Sincal DRS boilers are capable of using even the most demanding fuels.

VERY LOW FOULING RATE

Great solutions to great problems

Fouling in biomass boilers is a major problem that affects a large part of the owners of this type of equipment, as it can involve large costs for production stoppages and costs for the personnel who must perform the cleaning manually.

The fouling or deposition of particles on the heat exchange surfaces of the boiler is mainly caused by two mechanisms:

  • The inertial impact of the particles, which depends on the particle velocity and particle mass
  • Condensation of vaporized salts, which depends on the concentration of the vaporized salts and the temperature of the metal surface of the pipe.

Thanks to the careful design of the SINCAL DRS boilers, the level of fouling is radically reduced and the boilers can be used continuously for several months without the need for manual cleaning.

 

DRS rear box
Exit of the tubes of the first pass after six months of continuous operation with olive pomace
Inlet of the first pass pipes after six months of continuous operation with olive pomace
Inlet of the first pass pipes after six months of continuous operation with olive pomace
drs CFD
Detail of the careful CFD calculation of DRS boilers

BOILER PARTS

Sincal DRS interior
The pressurized body has been designed with the objective of minimizing fouling, thus maximizing total availability.

Pressurized body

The pressurized heat exchanger body of the DRS biomass steam boilers consists of an outer laminated steel shell welded to the rear and front tube plates, which in turn are braced to the shell by means of bevels.

In the ferrule are arranged the sockets for:

  • Steam output
  • Safety valve(s)
  • Aeration
  • Level electrodes
  • Optical level indicators
  • Water inlet
  • Sludge draining and purging
  • Salt purge
  • Lifting rings

Manholes are incorporated in the ferrule to facilitate inspection of the boiler interior.

Inside the exchanger there are two tube bundles formed by a set of smoke tubes that form the fourth and fifth gas passages, joined to the tube plates by welding. The tubes are of suitable diameter to achieve optimum gas velocity and heat transfer.

The tube bundles are arranged horizontally and run parallel to the combustion furnace.

At the rear there is a gas inlet and flue gas outlet chamber for the heat exchanger.

The inlet chamber is formed by a refracted ferrule in its lower part and an intermediate partition, from this point the gases face the first tube bundle of the exchanger body. At the top of the ferrule of this chamber is the gas outlet of the exchanger from the second tube bundle, ending at the flange of the flue gas outlet.

At the front is the gas inversion chamber of the heat exchanger body.

The gas reversal chamber consists of a ring nut and access doors, where the gas direction is reversed from the first bundle to the second tubular bundle of the heat exchanger body.

Combustion furnace

The combustion furnace of the DRS boilers is located in the lower part of the boiler and serves as its support. It is where the biomass combustion takes place.

It is a long rectangular prism whose walls are cooled by water. The thickness of the water chamber is 100 mm. All this, plus the exterior insulation with high density wool (120 kg/m3) allows us to maintain a surface temperature around 20/25ºC above the boiler room temperature.

The furnace walls have two doors, one located on the rear face of the boiler and the other on the side to allow and facilitate the maintenance of the grates.

In DRS boilers, the opening of the doors is done by means of handles, which allows an easy and fast operation, and facilitates maintenance operations.

A differential pressure transmitter is placed on one of these doors, which will act on the frequency converter of the exhaust fan to keep the vacuum in the furnace constant.

The furnace will have two deflector partitions, or two empty passages, which will allow us to decant a large part of the particles carried by the combustion gases and increase the heat transfer by radiation-convection in the furnace area.

In order to properly visualize the movement of the grates and the combustion flame itself, the oven is equipped with two 114 mm diameter peepholes in the front of the oven.

Mobile grill

The boiler is equipped with an air-cooled horizontal moving grate with an inclined step and reciprocating motion to burn the fuel. All the grate passages are provided with air-cooled supports which ensure that the temperature in the grate is maintained at a constant level thus preventing the formation of slag on the grates. The walls are also air-cooled to ensure a constant combustion temperature even though it is already cooled by the water in the wall itself.

The horizontal stepped grate is equipped with moving grate sections to achieve controlled fuel distribution. The speed of movement of the moving sections is adjusted to achieve drying of the fuel at the top, allowing for subsequent combustion with complete cauterization.

DRS grid
DRS grid
The horizontal grate of the DRS boilers allows burning very aggressive fuels.

Electrical panel

SINCAL DRS biomass steam boilers are equipped with our successful electrical control panel with automaton that allows to operate the boiler in a simple and reliable way.

GAS CLEANING SYSTEM

Emissions under control

SINCAL DRS biomass boilers can be supplied with a complete gas cleaning package, including our advanced cyclones and baghouse.

Sincal DRS

RELIABLE EQUIPMENT

The DRS boilers are equipped with GESTRA® controls as standard, reaching SIL3 level in safety, allowing a magnificent robustness and reliability. They also have an ABB automaton with touch screen that allows visual, easy and intuitive access to the working conditions of the boiler, modify the working parameters or view the activated alarms among other functions.
DRS boilers can be equipped with economizer, multi-cyclone, sleeve filter, continuous feeding, indirect monitoring every 24 hours, two pumps, automatic salt purge, etc.

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(*) Subject to SINCAL’s authorization and modification of the start-up operating parameters.

IMAGES

Boiler DRS-5000, 5000 kg/h of steam
DRS 5000
Image: ACT Andalus Maroc
DRS5000
DRS5000