CHOICES FOR YOUR PLANT WELL PROVEN TECHNOLOGIES VERY HIGH REILABILTY

Ash&otherbulkmaterialhandling

SHORTHISTORYOFMBEEWBLTD
MBEEWBLtdisoriginatedfromErtervPowerPlantEngineers.ItwasinitiallyaGovernment company,entrustedwiththesettingupofpowerplantsonturnkeybasisinHungaryand otherEuropeancountries.AshHandlingDivisionofErtervstartedworkinginaroundyear 1955.Sinceinceptionthisdivision,executedmanyashhandlingplantsofdifferenttypesin majorthermalpowerstationinHungary,Germany,Austria,Czechoslovakia,Greece,Turkey, Yugoslavia,Bulgaria,etc. Intheyear1990,WaagnerBir,AustriaawellknowncompanyofEuropeacquired50% equityoftheashhandlingdivisionofErterv.Fromthisyearthenameofthecompany changedtoErtervWaagnerBirLtd.Sincethen,ErtervWaagnerBircontinuedash handlingbusinessbyimplementingmanymoreashhandlingprojectsinEuropeandAsia. GraduallyWaagnerBir,Austriaincreasedtheirstakeinthecompanyendingupwith90% holdingofequitybytheyear2000. From1997McNallyBharatEng.Co.LtdwasinexclusivecollaborationwithEWBforthe IndianMarketuptheyear2000.In2001,whenWaagnerBirputupitsequityforSale, McNallyacquiredthesamethroughaglobalcompetition. BeingsatisfiedMcNallyBharatincreaseditsequitiesto100%witheffectfrom24Sept.2003. AtthismomentMBEEWBLtd.isoneofthefewcompaniesintheworldabletosupplyall kindofAshHandlingtechnologiesandotherBulkMaterialTechnologies. WearereadytosupplysystemsonturnkeybasisorgiveEngineeringandsupplythekey componentsoftheashhandlingsystems. ThisbrochureinthenextpagesisgivinganoverviewaboutEWBtechnicalcapabilityand referenceshowingnumberoftechnologiesdevelopedandexecutedbyusinthefieldofAsh HandlingandotherBulkMaterialHandling. KarolyHorvath ManagingDirector MBEEWBLTD

EWBASHHANDLINGTECHNOLOGIESCANCOVERALLREQUIREMENTS
MBEEWBLtd.hasdevelopeddifferentkindofAshHandlingtechnologiessuitablefor PulverizedCoalFiredBoileraswellasFluidBedBoilerapplication. Theselectedtechnologyweareofferingforthecollection,transportationandstoringofthe ashdependsonmanyfactorssuchas: - Typeofboiler - NumbersofUnits - SizeoftheUnits - Typeofcoalorotherfuel - Quantityofash - Particlesizeandchemicalcompositionofash - NumbersofESPhoppers - Plantarrangement - Requirementsagainstashdisposalside - Distanceofashdisposalarea - SilodistancefromtheUnits - Specialrequiremente.g.utilizationofflyash Fortheflyashcollectionandtransportationwecandesignandsupplydifferentpneumatic transportationsystemsuchas: - AirslideAirliftsystem - Densephasepneumatictransport - Vacuumtypepneumatictransport - Mechanicalashcollection&transport - Highconcentrationashslurrydisposalsystem - Positivepressureleanphasepneumatictransport. - Silotechnologies Weofferalwaysthemoresuitabletechnologyortheircombinationdependingonfactors listedabove.

AIRSLIDEAIRLIFTSYSTEM
TheAirslideAirliftmaterialtransportisusuallyusedtogether. Itisasimpleandwellprovendesignandsuitabletotransportlargequantitiesforshort distances. TypicalapplicationwhentheflyashhastobecollectedfromthelargenumberofESP hoppersandhastobetransportedintoanearbyflyashstoragesilo.

Airslidechannel
Technicalparameters: - Standardtransportcapacity - Standardtransportdistance - Specificairdemand 1500t/h 10200m 100500m3/h/m2

Advantagesoftheapplication Lowinvestmentandoperatingcosts,operationalsafety,simplicity,flexibilityandhigh transportcapacitydependingonchannelsize.Ithasnomovingpartandtransportsthe materialwithlowspeed,inaprotectingoperatingmode. Thereisastableworkingpointinwiderangeaccordingtochangeoftheloading,thatis,the samechannelisabletooperateevenforaconsiderablychangedmaterialquantities.

1.pictureAirslidedistributionunderfly 2.picture Flyashcollectionwith ashsilosObrenovac,Serbia airslidesunderESPAgiosDimitrios, Greece Themostfrequentapplicationfields: - flyashtransportsystemsofpowerstations - aerationanddischargeofsilos - transportationofbulk,fluidizablematerialsinindustriessuchas: - cementworks - limeplants - chemicalindustry

Airlift
TheAirliftisusedforverticaltransportationofflyash,cementandfinegrainedmaterials. Technicalparameters - Standardtransportcapacity 10150t/h - Standardverticalliftingheight 1080m Advantagesoftheapplication TheAirlifthassimplestructuralconstructions,containsnomovingpart,itsoperatingcostis lowandcanbeoperatedsafetyinwideoperatingrange.Theairlifthasastableworking pointandtheequipmentisselfadjusting.

3.picture Airlifts AgiosDimitrios,Greece

Themostfrequentapplicationfields Inflyashhandlingsystems,cementworks&chemicalplants verticaltransportationofbulkmaterialinlargequantities intolargesizesilos,intermediatestoragetanks. Theflyashcollectionwithairslidecanbecombinedwith densephasetransport. EWBofferthisversionforbigUNITS(largeNos.ofESP hoppers)whentheflyashstoragesiloisfarfromESP. TheflyashcollectedfromESPhoppersviaairslideiscollected inasmalltransferbin.Underthebintransportvesselisput andthematerialisconveyedbydensephasetransportation modustothestoragesilowhichcanbelocatedupto1500m farawayfromtheESPareas. EWBhasnumerousreferencesforthisarrangementwith verygoodexperience.

4.pictureFlyashairlift Kangal, Turkey

DENSEPHASEPNEUMATICTRANSPORT
Inthelast1520yearsitisatrendworldwidetousedensephasepneumaticconveyingfor flyashcollectionandtransportation. EWBhasdevelopeditsowndensephasedesignandwehaveawellproventechnologywith manyreferences. Whydensephase? - Highmaterialtoairratio,bigquantitiescanbetransportedforlongdistances withlessair. - Duetolowervelocitylesswear - Longconveyingdistanceinonestageupto1500m - NostorageinESPhoppers,flyashiscollectedinthetransportingvessels - Nosuckingoffluegas,thereforedangerofcondensationisminimizedwhilefilling andduringconveyingnodangerofplugging - Duetodensephasesmallertransportpipesrequired,consequentlylessstructure anderectionworks - Lowerpowerconsumptioncomparedtoothermethods.

Technicaldescriptionofthesystem DependingontheUNITsize,theNos.ofESPhoppers,ashquantitiesandplantarrangement (storagesilodistancefromESParea)wecanofferdifferentarrangementmostsuitableand economicalfortheactualrequirements. Typicalarrangementsweareusuallyoffering: - Direct,multidensephasetransportfromeachESPhopperstostoragesilo.This simplesolutioncanbeusedforsilodistanceupto500m.Forthisdirect transportationsystemwehavedevelopedpairandgroupoperationofthe transportvessels.Itmeansthatupto4Nos.ofvesselscanbeoperated simultaneouslyissuchawaythatthetransportvesselsareworkingontoone commondeliverypipeline.Itresultssimplerandmaintenancefriendlyoperation 6

5.picturePressurevesselunderESPhoppers Banjarmasin,Indonesia

6.picture Aluminadustpneumaticconveying vesselsIndia

sincethenumberofvalvesisreduced.Thisarrangementisusuallyrecommended underthe3rd,4thand5throwoftheEprecipitatorhoppers. Twostagedensephasetransport.Inthefirststagetheflyashiscollectedby individualvesselsintoatransferbinandthelongdistancetransportationfrom transferbintostoragesilo(upto1500mdistance)ismadebyJumbotransport vessel. Twostagetransportation,wheretheflyashcollectionisdonebyairslide, mechanicalorvacuumsystemandthelongdistancetransportbysingleJumbo transportvessels.

7.picturePressurevesselunderESPhoppers LeykamGratkorn,Austria

Technicalparameters - Standardtransportcapacity 2150t/h - Standardtransportdistance 101000mhorizontal - Standardverticalliftingheight 1080m Advantagesoftheapplication Theequipmentcanbeoperatedinwideoperatingrange.Mainoperatingparametersof workingpointbelongingtoquantitativeandqualitativechangesofthematerialtobe transportedcanbechanged,resp.,adjustedflexibly. Lowpowerconsumptionandoperatingcost. WithPLCcontrol,fullautomaticoperationofthetransportequipmentoftransportvessel canberealized.Becauseofthelowdeliveryairdemand,onventingofthereceivingsiloswe needfiltersofsubstantiallylesssizeinsteadoffilterscustomarytotheconventional,thin phaseflowpneumatictransportequipment. Additionaladvantagesagainstvacuumtypesystemsincaseofbigflyashquantities:Thefly ashiscollectedinthetransportingvessel,thereforeESPhoppershavenostoragefunction, consequentlythepluggingofhopperoutletiseliminated. Severaltransportvesselscanbeconnectedtoacommonpipeline,therebyapossibilityis affordedtoconstructmorecomplexsystemsaswell.

Themostfrequentapplicationfields - Flyashtransportationinpulverizedcoalfiredpowerstations. - Flyash,bedash,limestone&sandtransportationforfluidbedboilers. - Transportationofcementandclinkerdustincementworks. - Transportationoffoundrysand. - Transportationofdustymaterialsinchemical,foodindustryandagricultural plants,aswellasinpharmaceuticalfactories.

8.pictureTipicalarrangementofflyashpneumatictransportwith individualpressurevesselforeachESPhopper

9.picturePressurevesselsforKlinkerdust Lbatlan,Hungary

10.picture Pressurevesselforboiler ashDaeGu,Korea

COMBINATIONOFAIRSLIDESANDPRESSUREVESSELSYSTEM
Forpowerplantsover300MWwherebigsizeESPswithlargenumberofhoppersare requiredandsilosarefarfromunitsthereisanalternativesolutiontoindividualpressure vessels.Thisiscombinationofairslidesandpressurevessels. Atypical600MWunitwithtwoESPincluding32NOSofcollectinghopperseachworkingas follows: - Fromthefourhoppersbelongtoonepath,flyashisconveyedbyairslideintobig sizeconveyingvesselsinsteadof4NOSofsmallerones.Resultingeight(8) pressurevesselsinsteadofthirtytwo(32). - Outofthetotaleight(8)pressurevesselstwo(2)orfour(4)canevenreceive boilerashviashortdistancepneumaticconveying,makingeasiertotransportthe boilerashtolongdistancebymixingitwiththefinerflyashfromESP. - MoreoverfourpneumaticconveyingvesselsbelongtooneESPcanbeconnected toonecommonashconveyinglineinsuchawaythattwotwovesselscanbe coupledandconnectedtoonecommonashoutletvalveformingconveyingpairs.

11.pictureTipicalarrangementofairslideandpressurevesselcombinationundertheESPhoppers

12.pictureVesselundertheairslides Obrenovac,Serbia

13.pictureCoupledvesselsunderthe ESP Obrenovac,Serbia

10

14.picture CollectingairslidesundertheESP Kolubara,Serbia

15.pictureCoupledvesselsundertheESP Kolubara,Serbia

11

VACUUMTYPEPNEUMATICTRANSPORT
Vacuumtypepneumatictransportwidelyusedforflyashcollectioninpowerplants. EWBhasdevelopeditsownvacuumtypepneumaticashhandlingsystem. Vacuumsystemispreferredtouseinthefollowingcases: - LargeNos.ofESPhoppers - LowelevationofESPhoppersoutlets - Relativeshortconveyingdistanceandonecommonreceiversilo - Light,lowbulkdensitymaterial

16.pictureVacuumsystemunder ESPforoilashShoaiba,SaudiArabia

17.picture VacuumsystemunderESPforoilashShoaiba, SaudiArabia

Vacuumsystemhaslimitationintheconveyinglength,thereforethissystemisusually combinedwithpressuresystem. FlyashiscollectedfromESPhoppersintotransferbinwithvacuumsystemwhilelong distancetransportisdonebydensephasepressurevessels. VacuumsystemisverysimpleattheashintakepointsthereforeonlylowESPhopper elevationissufficient. Criticalitemsofthesystem: - Ashintakevalves - Ashsegregatingvalves - Cyclonefilterseparatorwithdoublefeedertosilo - Vacuumgeneratingequipment EWBhasdevelopeditsownequipmentlistedabovewhilevacuumgeneratingequipmentare commercialproducts. Twotypesofequipmentareusedforairdelivery: - Rootstypeblowerforlowvacuumdemand - Waterringsealvacuumpumpsforhighvacuumdemand

12

Technicalparametersofvacuumtransport: - Standardtransportcapacity: 250t/h - Standardtransportdistance: 10150m - Standardverticalelevation: 1040m Specialapplication Vacuumsystemspecialapplicationispneumatichandlingoilash. FluegasofHeavyFuelOil(Busteroil)firedboilerscontainsrelativebigamountofflyash. ESPisrequiredtoinstalltokeepemissionlimit.OilashcollectedbyESPhasaveryspecial property. EWBhasdevelopedcompleteashhandlingsystemforoilashhandling.

13

POSITIVEPRESSURELEANPHASEPNEUMATICTRANSPORT
IncaseofsmallermaterialquantitiesandshortertransportationdistancesEWBcanoffera moresimpleashremovalmethodswithlowerinvestmentcostcomparetodensephase.

Pneumaticjetpump
Thepneumaticjetpumpisanequipmentsuitableforleanphasepneumatictransportoffly ashandfinegrainedbulkmaterialsupto10mmgrainsizerange. Abovethejetpumpasimplerotaryfeederisarranged,orincaseofhightemperature materialapneumaticoperatedgatevalveoffeederisput.

18.pictureBoilerashconveyingwithpneumatic jetpumpSteyrermhl,Austria

19.picture Perlitconveyingwithpneumaticje pump Martf,Hungary

Technicalparameters - Standardtransportcapacity - Standardtransportdistance - Standardverticalliftingheight - Suitableforhightemperatureoperation. Advantagesoftheapplication Theequipmentissimple,hassmallspace requirement,andcontainsnomoving part. Ithaslonglifeiffittedwithwearlining elements. Itsinvestmentcostislow. 18t/h 10100mhorizontal 030m

20.picture Perlitconveyingwithpneumaticjepump Martf,Hungary

14

Themostfrequentapplicationfields Itcanbeusedexcellentlyatseparatedustcollectingplacesofpowerstationflyash transportingsystems,forexample,understack,forremovalofflyashbeingproducedat Ljungstrm,resp.,ECOhoppers,inadditionatfluidbedboilersforinjectinglimestone necessaryfordesulfurisationoffluegasintothefurnacecombustionchamber.Firstofall, thisequipmentiscompetitivewiththeconventional,mechanicaltransportequipmentfor lowtransportcapacities. Asaspecialapplicationfield:transportationofhightemperaturedusts.

21.picture Boilerashconveyingwithpneumaticjetpump AgiosDimitrios,Greece

Feedingshoewithrotaryfeeder
Alternativesolutiontojetpumpisasimplefeedingshoe.Advantageisthatthepressureof theblowerisfullyutilizedforthematerialconveyingbutformaterialfeedingintotheair streamaspecialrotaryfeeder(airlockfeeder)isrequiredwhichisabletofeedthematerial againstoverpressure.

22.pictureLimestonefeedingwithrotaryfeeder&feedingshoe intoCFBcombustion chamberChangShu,China

15

Oneofthemostfrequentapplicationislimestonefeedingintocombustionchamberforflu gasdesulphurizingpurpose.Therotaryfeederisequippedwithfrequencyconverter.The injectedlimestonequantityisadjustedtotheactualSO2quantity.

23.pictureLimestonefeedingwithrotaryfeeder& feedingshoeintoCFBcombustionchamberChang Shu,China

24.picture Limestonefeedingwithrotary feeder&feedingshoeintoCFBcombustion chamber Hodonin,CzechRepublic

16

HYDRAULICASHDISPOSALSYSTEMS
EWBcandesign&supplydifferentkindofhydraulicashhandlingtechnologiessuchas: - thinslurrymixingandtransportwithhydraulicjetpumpforflyashandbottom ash - thinslurrytransportflyashandbottomashwithcentrifugalslurrypumps,mixing ratio1:31:10 - denseslurrymixingtechnologyforflyashandbottomashandconnecteddense slurryconveyingwithseriesofcentrifugalslurrypumps,mixingratio0.91.1kg solid/kgwater Thethinslurrymixingtechnologywaswidelyusedforcoalfiredpowerplantsinthepast, butduetohighwaterdemandforthehydraulicconveying,thistechnologyhas disadvantagessuchas: - largepoundarearequired - pollutionofgroundwater Thisthinslurrytransportnowbasicallyusedforbottomashtransportonly. Thereisatrendworldwidethatthethinslurrytransportingsystems(flyash+bottomash) arereplacedbydenseslurrydisposalsystems. Forbiglignitefiredplantswithunitsizeover 300MWlargeamountofashisgenerated. Utilizationofflyashispreferablebutlimited. Fortransportationofashtodisposalarea therearetwopracticalsolutions:

Flyashconditioningandtransportto disposalareawithbeltconveyors
Thisisverymuchusedinmanypowerplants, butifdisposalareaisover2.0kmitis 25.picture Branchingpipe&topofpremixer becominguneconomical. Obrenovac,Serbia Anotherdisadvantageofthistransport methodisthatonthedisposalsidenumerousmachineriesarerequiredforspreadingthe ash.Maintenancecostisveryhigh.

Highconcentrationashslurrydisposal system
Thisistheonlypracticallygoodsolutionin caseoflargeashquantitiesifdisposalareais morethan3.0kmawayformunit(s). EWBmixingtechnologyconsistsofpremixer andconnectedconditionertank. Thepropermixingisensuredbytwoways: - continuousrecirculationofthe 17

26.pictureTopofconditionertank Obrenovac,Serbia

slurryfrombottomofconditioner tothepremixer continuousmixingbymechanical stirrerinsideconditionertank

Forpumpingofdenseslurrynormally23 slurrypumpconnectedinseriesarerequired. Maintechnicaldata: - Mixingratio: 0.91.1kg ash/kgwater - Capacityrange: 100300 27.pictureConditionertank&recirculationpump t/h (dry ash) Obrenovac,Serbia - Conveyingdistance: 310km

28.pictureLongdistanceslurrypumps Obrenovac,Serbia

29.picture Hydraulicashdisposalsystem

18

SILOTECHNOLOGIES
Flyashsilo
EWBcansupplycompletesilotechnologies includingventing,aeration,levelmeasuring equipmentanddifferentkindofdischarging facilities. Wecanprovidecompletedesignfromsmallsteel silosuptobigstoragesiloswithcapacityof5000m3 madeofconcrete. Wehavedifferenttypedesignforsiloaerationto ensuretheproperflowoutofthesilos.Thetypeand capacityoftheaerationsystemcanbedifferent dependingonthesizeofthesiloandtheshapeof thesilobottomsuchas,traditionalconicalbottom, flatbottom,insideconebottometc. Thedischargingarrangementcanbealsodifferent dependingontheshapeofthesilobottomportion furthermorehowmanyoutletsarerequired. Ofcoursetheflyashstoragesiloshavetobe 30.picture FlyashstoragesiloNeyveli, equippedwithlevelswitches,levelmeasuring India equipment,safetydevices (overpressure/underpressurevalves)etc.

Silodischargefacilities
Forsmallerdischargingcapacitiesrotaryfeederiswidelyused.Butfortheflyashsiloswe prefertoofferourfluiddischargingsystem. Thisfluiddischargingsystemisaverysimpledesignconsistsofpneumaticallyoperatedcut offgateandmanualormotorizedflowcontrolgate.

31.pictureFlyashhopperfluiddischargesystem Suralaya, Indonesia

Themainequipmentforsilodischarging: - dryunloadingchuteequippedwithventingsystemfortheproperdustfree loadingoftanktrucks,usualcapacityrange80150TPH 19

- conditioningunloaderfordustfreeloadingofopentrucksorbeltconveyor Intheinletchuteoftheequipmentthereisaweightbalancedfeederarrangedtoprevent thevaporgoingcounterdirectionofflow.Insomecasesiffromtheaerationsystemtoo muchairisforcedtotheconditioningunloadertheunloaderhastobeequippedwith additionalsuction.Inthiscaseanadditionalsuctionfanandawettypedustcollectorhasto beprovided. Normaldischargingcapacityrange: - fortwinshafttypeconditioningunloader: 40300TPH - forrotarydrumtypeconditioningunloader: 40450TPH

33.picture 200TPHdoublescrewpaddlemixer Suralaya,Indonesia

32.pictureFlyashdryunloading Steyrermhl,Austria

20

Largeashstoragesilostation
Forbigpowerplantslargeashstorage capacitiesarerequired. ThebiggestEWBreferenceisanash storagesilocomplexincluding2x5000m3 flyashstoragesiloanda2x500m3bottom ashsilowiththeengineeringandsupplyof thefollowingtechnologicalparts: - flatbottomflyashsilowith expansionchamberequipped withaerationpanelsand ventingpipes - ventingsystem 34.picture AshsilocomplexObrenovac,Serbia - flyashsilodischargefrom centraldistributionboxtomixingequipmentanddryunloadingviaflowcontrol device,flowmeasuringdeviceandairslides - bottomashsilowithvibrationfeederdischargingfacility

35.picture Bottomofsilo Obrenovac,Serbia

36.pictureBottomashsilodischargewithvibrationfeeder Obrenovac,Serbia

21

LIMESTONEHANDLINGSYSTEMSINPOWERPLANTS
LargequantityoflimestoneisusedfortheFlueGasDesulphurization(FGD)ofcoalfired powerstations. Incaseofpulverizedcoalfiredunits(PC)inmost caseswetFGDtechnologyisusedwhere desulphurizationtakesplaceinsprayingtowers. Forthisproposefinegrindedlimestone(below 90micron)isusedforslurry. Incaseoffluidbedboilers(CFB)the desulphurizationtakesplacemainlyinthe combustionchamberoftheboiler.Thegrinded limestoneisinjectedpneumaticallyintothis chamber.Particlesizeoflimestonerequiredfor thistechnologyisbiggercomparedtowetFGD systems. LimestonehandlingtechnologyforPCunits mainlyincludes: - Wagonortruckunloadingstation - Limestonestoragesilo,itsaeration andventing - Limestonedischargetoslurry 37.picture Limestonewagonunloading preparationtank Rybnik,Poland Limestonehandlingtechnologyfor CFBunitsmainlyincludes: - Wagonortruckunloading station - Limestonestoragesilo,its aerationandventing - Limestonedischargeand pneumaticconveyingto dailysilo(s) - Pneumaticlimestone injectionintocombustion chamber EWBhasexperienceandreferncefor 38.pictureLimestonewagonunloading&storagesilo bothsystemlistedaboveuptopower Mtra,Hungary stationssize1000MW.

22

39.pictureLimestoneunloading Rybnik,Poland

40.pictureLimestoneunloadingstation Mtra,Hungary

23