Designing a Crematorium

You mean are there any hobbyists on here who...

"You mean are there any hobbyists on here who...

"

I didn't realize that this board was limited to hobbyists. This is definitely not a hobby for me. The area in which I live has no crematoria, so bodies have to be shipped to Cagayan de Oro or even Cebu (200 nm) for sanitary disposal.

First, it's a creepy thing to do.

Second, are there any local ordinances on burning bodies?

Some idea of scope, too. One body a week or ten a day?

Fuel source? Maybe something rustic like a wood fired grate above ground.

Good luck.

"First, it's a creepy thing to do.

Second, are there any local ordinances on burning bodies?

Some idea of scope, too. One body a week or ten a day?"

Is it any creepier than burying dead bodies? Death is a fact, and if you had seen the cemeteries around here you would understand the need for safe, sanitary and above all low-bulk methods of disposal of the dead.

There are no specific ordinances on the subject, that I know of. Cremation is fairly new to this mostly Catholic, mostly traditional country. There are regulations that apply to the handling and disposal of the dead, of course, and environmental rules that restrict emissions, but nothing specifically about cremation as far as I know. Which makes responsible engineering design all the more important.

Initially, there will probably be only one committal per firing of the crematory furnace, which makes thermal efficiency very important as the retort and afterburner must already be at full temperature when the casket goes in. Later, we may be fortunate enough to have several committals per startup, which will reduce the fuel cost per committal considerably and improve the life of the retort due to a reduction in thermal cycling.

Fuel will be liquefied petroleum gas (LPG) in exchangeable cylinders. One of the investment group is an executive in a major LPG distribution firm, and can guarantee supply on favorable terms.

A purely scientific approach (without regard to ethics, morality and/or regulations concerning the handling and disposal of the dead) would be to masticate the remains with what would be considered the equivalent of a wood chipper.This would reduce the amount of heat required if the remains are introduced correctly.

You could then use a modified fire tube boiler (perhaps a used one in need of re-tubing) fitted with an after-burner.

Would I need a freezer and chain saw too? This is known as divorce Conncticut Style, http://en.wikipedia.org/wiki/Helle_Crafts

google it.

http://www.google.ca/#hl=en&source=hp&q=cremation+%2Bdesign&btnG=Google+Search&aq=f&aqi=&aql=&oq=cremation+%2Bdesign&gs_rfai=&fp=638b29cdd23775ce

http://www.google.ca/#hl=en&safe=off&ei=aDz7S6HvAoO8lQfT66XpDw&sa=X&oi=spell&resnum=0&ct=result&cd=1&ved=0CBwQBSgA&q=crematorium+%2Bdesign&spell=1&fp=a962a42b56405c7b

We in India have two types of Crematoriums, one is open where in body is rested on platform and log wood is kept below and above dead body and fire is ignited on the logs. Other is Electric type where in bodies are burnt in electric furnace.Electric crematoriums are more cleaner as there is less smoke than wood type. These crematoriums are located at distance from the towns.Both types have forced draft air circulation and chimney for smoke disposal.

The retort obviously operates at a fairly high temperature. Do you have the resources to construct your own chamber lining that will withstand these temps?

Gas controls and ignition controls? Afterburner and associated limit controls? Mixing venturi and forced air blower equipment? It seems to me that you have a lot of issues that would be solved if you purchased a ready to fire retort and had it shipped in.

Your statement of the retort being up to temperature before inserting the deceased makes me believe you have no experience with the process. How would you propose to do such a feat?

Lastly, I don't know what the customs are in your country but the co-mingling of cremains would be a huge no-no here in the states. Have you ever witnessed what comes out of a retort after a cremation? It isn't ashes to ahes, dust to dust. To say that once a unit is at operating temps to cycle it with repeat cremations to keep thermal cycling down isn't realistic. How would you get the cremains out of the retort while it is running at temp?

I would seriously let this one go to those who know a bit more about the topic.

"The retort obviously operates at a fairly high temperature. Do you have the resources to construct your own chamber lining that will withstand these temps?"

In a word, yes. Refractories Corp. of the Philippines is headquartered here, and my brother-in-law is a professional refractories installer - cast, sprayed and brick. I am confident that any valid design can be built. The important thing is to have a valid design.

"Gas controls and ignition controls? Afterburner and associated limit controls? Mixing venturi and forced air blower equipment? It seems to me that you have a lot of issues that would be solved if you purchased a ready to fire retort and had it shipped in."

All industrial controls and fittings are available here, with some searching. Sometimes they have to be ordered from Manila.

No question but that buying a packaged plant is the no-brainer "solution," but it has its costs. The crematorium in Cagayan de Oro is an imported, packaged unit. For reasons of bulk, it could not be procured with any kind of heat recovery unit, so its fuel costs are going through the roof. Retrofitting is theoretically possible but would require a prolonged shutdown. My plan is to design ab initio for heat recovery, giving my group a large and growing competitive advantage as fuel prices increase.

"Your statement of the retort being up to temperature before inserting the deceased makes me believe you have no experience with the process. How would you propose to do such a feat?"

You are right in saying I have no experience, but a quick search of crematory standards worldwide will convince you that this requirement to preheat the retort exists, is universal and is non-negotiable. How to do it is simple, but costly: the whole unit has to be brought up to full temperature before the casket is inserted, just like preheating a cooking oven - only at much higher temperatures. Various tricks are used by some crematoria to reduce the thermal shock experienced by the refractory when a slug of cold air comes in with the casket, including airlocks and a kind of narrow tunnel which minimizes the entrained mass of cold air. But most seem to just open the heavy refractory-lined door as fast as possible and shove the casket in ASAP.

"Lastly, I don't know what the customs are in your country but the co-mingling of cremains would be a huge no-no here in the states. Have you ever witnessed what comes out of a retort after a cremation? It isn't ashes to ahes, dust to dust. To say that once a unit is at operating temps to cycle it with repeat cremations to keep thermal cycling down isn't realistic. How would you get the cremains out of the retort while it is running at temp?"

Good question. The procedure seems to be to gradually admit some outside air to the retort to cool it, and at the same time complete the combustion of the organic part of the bones. The cremains are then raked out, still quite hot, into some kind of bin, where they are allowed to cool further while the retort is prepared for the next committal. Once cool, the calcined bone fragments are usually ground before placement in a container for presentation, but some cultures want the bone fragments left as burnt. Some crematoria have a separate, small door for raking out the remains, while others do it from the front.

"I would seriously let this one go to those who know a bit more about the topic."

Whom would you suggest?

www.cremationassociation.org

You are missing the point. Most if not all of the points I raised would be solved by purchase of a package unit.

You need some training instead of the google research you cite. We operate a crematorium here at my facility. What you cite as international standards are not universal nor non-negotiable. The proper operation of a retort is dependent on the manufacturer and the removal of the cremains is also dependent on the specific type of retort. The removal of cremains does not happen while operating. Some cool down time is required, again dependent on the manufacturer of the retort. Why are you insistant on re-inventing the wheel?

Do they have a CANA organization there in the PI? If so I would consult with them.

Seriously, If the intent of cremation is to reduce the body to ashes, is the retort the most efficient method of doing this?

It appears as though there is a blend here, of tradition (as with a funeral pyre) and modern technology (as with automated controls).

Why is it required that a relatively large chamber (in relation to the body) be brought up to the necessary temperature?

Is optimization of this process possible, or is there a degree of "tradition" involved?

Please explain.

It is my understanding that the afterburner be brought on and the smoke chamber portion of the retort be at a minimum of 500 deg F before lighting the main burner. The reasoning behind this is to eliminate any smoke plume from the stack upon initial burn of the main burner.

We do not do a 'hot reload' on our equipment. It is brought down to a max of 200 deg F before the cremains are removed. The reasoning behind this is that the brushes used to sweep the cremains would combust, or at a minimum would be destroyed in a few uses. We also use a fine filtered vac to collect any dust or small bits of cremains to be added to the processing of the cremains before inurnment.

We may not operate as others do. We are operating our equipment as designed, which is old school technology and older equipment that is why I posted the link to CANA. If a like organization exists in the PI, then that is where the OP needs to turn for the local, expert advice.

Hell, if the OP wants to start from scratch then go for it. I cannot even begin to amass the list of required materials to construct a retort from the ground up. Get it wrong and you'll be wishing you'd gone the ready made retort route not to mention the liability of mishaps.

The package unit is the way to go.

I can see some avoidance here os the costs and duty associated with this. Contact the maker of the package unit. They may be able to sell some key components and a set of plans to make the rest locally.

There are hundreds if small details that the package maker will have worked out....thing you will have to experiment with, amid choking clouds of smoke and the risk of explosion.

Yes, explosion, a vapor of human body fat is quite capable of ignition and explosion. Not a high explosive by any means, but plenty enough to push off the roof and flatten the walls.

Can you imagine what this will do to your reputation!! It might kill the business, as people are very sensitive in these matters.

"There are hundreds if small details that the package maker will have worked out....thing you will have to experiment with, amid choking clouds of smoke and the risk of explosion."

Are you saying that this is how the packaged unit manufacturers learned their trade? I don't believe it.

Piolenc/Dlingo/Aurizon...

Thanks for all your input.

found this forum interesting as I am into gathering details on how to start the "business"

"The package unit is the way to go."

Since the equipment is part of the major expense, can you please send me quick feedback on the model I'm planning to purchase - US 100 "Classic" Cremator - priced:

$83900 (standard equipment/ 1 year limited warrantry)

$8000 freight cost (from US factory to pier/airport?)

$4950 technician fee to setup machine

www.uscremationequipment.com

I am planning to put up the crematorium somewhere in North Luzon Philippines, and equipment will be shipped from FL, USA to Manila north harbor Philippines.

Is this really "the way to go"? are there any other complications/items I need to consider?

I would really appreciate your feedback. :)

As I recall, the Phillipines has a very high import duty, maybe 20-30% and a VAT and an ad valorem tax.

http://www.chanrobles.com/republicactno1937book2title5.html

Ask an import broker. He will tell you and also tell you what invoices are needed from maker as well as certificates of origin etc

You might also need permits and locate in an industrial area.

This is very helpful!

Many thanks, chief. /