Benefits of the FTI, FTII and FTIII Cremators

There are three main benefits designed into the FT cremators enabling these products to be manufactured to a more competitive price while maintaining quality and performance.

1. Modular construction.

The FT I, II & III cremator’s modular construction enables the cremator to be fully assembled and tested under close supervision. Once tested, the cremator’s refractory can be baked-in and commissioned before leaving the factory. This reduces time on site and offers the client a cost saving on these high expense installation resources. Once commissioned, the cremator can be put on site, enabling the client to maximize his operating resource while minimizing down time for the crematorium.

2. High Technology insulation materials.

The FT I, II & III cremator designs utilize the modern insulation materials to reduce heat radiation from the cremator’s refractory shell, so optimizing the heat retention within the cremator.

These insulation materials reduce the overall content of the refractory brickwork, while maintaining the service life of the lining.

Reduced brickwork content means a lighter cremator with faster preheat times and lower costs for future refractory repairs.

3. User-friendly computer system for operation and commissioning.

The FT I, II & III cremators use a state of the art (up to date) control system from a recognized leading manufacturer, which provides for world wide support for spares and technical assistance. The PLC based control system is designed to provide instant access to the operator functions of the cremator without the need for expensive PC based computer systems and software. The control system also provides access for engineering staff to quickly, effortlessly configure the FT I, II & III cremators to the specific needs of the client. Once configured, the parameters can easily be installed into the control system. The control system can also be configured for a variety of languages (including all European Languages) all pre-programmed and selectable with a few strokes of the Human Machine Interface keypad.

FT I, II & III TECHNICAL ADVANTAGES

The control system fitted to the FT I, II and III cremators is based upon the use of a Programmable Logic Controller – and not outdated electrical relays and electro-mechanical timers as used by other manufacturers.

Facultatieve Technologies has utilized MITSUBISHI PLCs, and as a result we have in excess of ten years programming experience of these PLC control systems.

The use of such a control system enables infinite variability offered by the specialized “software PLC program”. Every FT I, II & III cremator is pre-installed with the dedicated PLC software. The special combustion PLC program is the result of more than forty years of Facultatieve Technologies experience.

Use of this technology enables the cremator to be either operated in the fully automatic mode (considered as normal operation), or manual mode. Even in manual mode, the operator benefits from the auto control system monitoring the process, thereby preventing dangerous situations. Safety is our number one priority.

Additional benefits of this PLC technology allow for high flexibility in the machine operator interface. As standard, the FT I, II & III come with an HMI (Human Machine Interface) controller, providing a high degree of communication between the operator and the cremator. In this format, as an optional feature, the control system can be fitted with a modem -- enabling Remote Engineering Support by our dedicated support engineers. Such PC based operator interface systems can also offer high levels of data monitoring of the cremator’s operation, requiring no computer skills by operators. They are designed to make operation of the cremators as simple as possible.

The benefits of our combustion engineering and knowledge are wide ranging:

• Fast and efficient cremation performance
• Maximum energy efficiency – minimal fuel usage
• Exceptional environmental performance
• High levels of automation – equipment requiring little or no manual intervention.
• Utilizes Best Available Control Technology (BACT)
• Equipment components meet both UL (Underwriter’s Laboratory) and FM (Factory Mutual) standards

2. ENERGY EFFICIENCY

Energy efficiency isn't just about how well the FT I, II & III cremators are controlled -- it has to be designed into the product on the drawing board. The selection of modern refractory and insulation materials make the FT I, II & III the most energy efficient products in their class. Use of high-quality insulation materials ensures minimal heat loss from the cremator – thus enabling faster preheat times and reduced fuel usage during all modes of operation.

For improved energy efficiency, the FT I, II & III cremators include Flue Gas Oxygen Monitoring equipment. This instrument constantly monitors the composition of the flue gases discharging from the cremation process, and takes “the guesswork” out of how much post-combustion air to add to ensure compliance with the emission regulations. However, putting in too much post-combustion air ensures good pollution control BUT cools the secondary chamber temperature -- REQUIRING large amounts of auxiliary fuel to heat the gases to the environmental requirements. Installation of Flue Gas Oxygen Analyzers is expensive – BUT eliminates the guesswork involved in supply air to the cremator, ensuring good environmental compliance, LOW AUXILIARY FUEL USAGE and ENVIRONMENTAL compliance.

The Average Fuel consumption varies upon the number of cremations per day made by the cremator, and we know a cremator will consume less gas (on average) the more cremations performed per day.

For example, consider FT II cremator performance:

• 5 cremations / day
• Average fuel used per cremation: 210kWh
  or 20 m3 of gas with CV 34,820kJ/m3
  or 716,520 btuh or 716.52 cfh (7.16 therms)

Note: this is approximately 75% less fuel consumption as compared to any other cremator on the market.

These figures exclude fuel necessary for preheating the cremator. The FT I, II & III cremators only require one preheat cycle per day since there is no cool down cycle between cremations. Immediately upon completion of the cremation cycle, the cremated remains are removed from the chamber and the next case can be loaded into the hot chamber.

3. BURNER INFORMATION

To ensure minimal fuel usage, the two burners fitted to the FT I cremator are configured for on/off control. The FT II & III cremators are fitted with fully modulating burners. The burner systems are protected against flame failure, thereby complying with established gas regulations set forth by FM (Factory Mutual).

The main chamber burner has an operational rating of 250 KW (853,000 btu/hr), and this enables normal operating temperature in the range of 800°C (1,472 oF) to be achieved in the main chamber.

The secondary combustion zone burner has a maximum rating of 350 KW (1.2 mbtu/hr) which will enable temperatures of 850-1000°C (1,600-1,800 oF) to be achieved in the secondary chamber as required by Environmental Regulations.

Burner Data:


• Burner manufacturer: Eclipse Thermal Systems
• Burner type: MVTA 104
• Medium Velocity Tertiary Air
• Low NOX design
• Main chamber burner rating: 250 kW (853,000 btuh) Max fire
  60 kW (204,720 btuh) Min fire
• Secondary chamber burner rating: 350 kW (1.2 mbtuh) Max fire
  150 kW (511,800 btuh) Min fire
• Burner fuel: Natural, Towns gas, Liquefied Petroleum gas (LPG), Propane
• Burner control: On / Off firing rate for FT I
  Fully modulating for FT II & III
  

4. ENVIRONMENTAL COMPLIANCE

The FT I, II & III cremators are designed to provide complete environmental compliance, for most cremation markets throughout the world. The FTI is designed to ensure a residence time in excess of one (1) second in the cremator’s secondary chamber during all periods of operation while maintaining a minimum temperature of 850 deg C (1,600 deg F) in the secondary combustion chamber, and thus eliminating visible emissions and odors.

The FT II & III cremators are designed to ensure a residence time in excess of two (2) seconds in the cremator’s secondary chamber during all periods of operation while maintaining a minimum temperature of 850-1000 deg C (1,600-1,800 deg F) in the secondary combustion chamber, and thus eliminating visible emissions and odors.

5. CONTAINER LOADING

Container Loading is a simple task, assisted by the unique design of various type loaders. Numerous loading systems are available, and are dependent upon site layout and client preferences. Our solutions include automated loaders, to simple manual types.

6. CREMATED REMAINS REMOVAL

The FT I is exclusively available in single end format (that is load front end and remove cremated remains from the same front end), such a format enables minimal facility space for an installation. The FT II & III are both available in single end and double end formats. The double end format allows loading of the body from the front of the cremator and removal of the cremated remains from the rear.

7. PERFORMANCE AND CAPACITY

The FTI process routinely completes in 90 to 120 minutes. However, our engineers suggest even better performance may be achieved depending upon varying charge weights. Times of less than 70 minutes may be possible, while complying with the Environmental regulations. The FT II & III process routinely completes in 70 minutes when performing multiple cremations in the same day. The thermal design of the cremator, the use of specialized and highly advanced refractory and insulation materials ensures short preheat times and longer refractory lives contributing to lower operating costs.

As an example of our simple, easy to use control system, the operator at the end of the operating day can program the cremator to Auto Start Up function. This feature enables the cremator to automatically preheat (unattended), and be ready (up to cremating temperature) to cremate when the operator gets to site, therefore maximizing the units productivity through a normal day.

TYPICAL OPERATIONAL COSTS FT I, II or III CREMATOR

Detailed below are the typical operational costs that may be incurred by a new cremator installation equipped with oxygen control and performing 5 cremations/day

GAS:

• Gas/ cremation: 250 kWh (8.50 ccf)
• Gas Price: $ 1.40/ccfh
• Gas cost per cremation $11.90

  
  ELECTRICITY:

• Electricity / cremation: 8 kWh
• Electricity Price: $ 0.064/ kWh
• Electricity cost per cremation $0.51

Typical Operating Cost per Cremation: $12.41

Note: above data was provided by actual customer utility bills.