Hitachi Power Europe Service GmbH

Mills and Components

Hitachi Power Europe Service is an independent

subsidiary of Hitachi Group and bundles the service
activities of Hitachi Power Europe GmbH.
About Hitachi Power Europe Service

Hitachi Power Europe Service GmbH (HPES), with about 300 employees, is an inter­nationally
active company in the field of power generation, steam generator construction, as well as
for environmental technologies and firing equipment. The company’s head office is located
in Duisburg (Germany), with the departments of engineering, boiler and firing technology,
mills and components, erection and commissioning and flue gas cleaning. In addition,
Hitachi Power Europe Service GmbH operates a centre of excellence for surface engineering
(cladding) with a cooperation partner.

With service centres throughout Germany and branches in Europe, Middle East and Asia,
Hitachi Power Europe Service GmbH operates as closely to its customers as possible, provid-
ing its products and specialist skills.

Hitachi Power Europe Service GmbH

˜ Head office in Duisburg, Germany
› German locations
› International locations

Contents
Components in Typical
Coal Power Plants 3
Mill Feeders 4
Pulverisers 6
Burn-Out Grate 13
Ash Removal 14
Other Ash Removal Components 15
Bevel Planetary Gear 16
Replacement Parts Service 17
References 18

2
Components in Typical Coal Power Plants

Lignite
a

A Steam generator
B Steam lines
C Coal bunker
D Mill feeder
 E Coal mill
F Burn-out grate

 G Ash removal

H FD fan

Bituminous coal
a

A Steam generator
B Steam lines
C Coal bunker
 D Mill feeder
E Coal mill
   F Ash removal
G PA fan
H FD fan

Mills and Components  3

Mill Feeders

Reliability even under demanding requirements

Designed as coal bunker dischargers, the mill feeders supply the pulverisers with raw coal –
evenly dosed and in keeping with boiler load requirements.

Gravimetric coal feeder

Even when faced with demanding requirements, the mill feeders designed by HPES operate
both reliably and safely.

Experienced HPES staff determine the optimum feeder in keeping with the requested
fuel quantity, design directives (including DIN EN 12952-9, NFPA 85 F) and customer
requirements (for instance, volumetric and gravimetric metering).

Other selection factors are the various bulk material properties, such as coal flow and erosion
behaviour.

4
In hard coal boiler units, gravimetric coal feeders are used to discharge the raw coal from
the bunker. In lignite plants, drag-chain conveyors together with belt conveyors are used
to discharge the raw coal from the bunker.

Gravimetric coal feeders

The gravimetric coal feeders with corrugated edge belt ensures high outputs, uniform bunker
discharge and continuous mill charging – even at low conveying rates. This design permits volu-
metric / gravimetric metering and quantities conveyed of up to 180 t / h. During normal operation
no conveyed material can fall to the bottom of the feeder due to the design of the corrugated edge
belt. Nevertheless a cleaning device is installed in the bottom section of the feeder to guarantee
the removal of dust deposit. The belt speed is determined by the quantity conveyed. Purge air is
supplied to the housing to stop condensate forming and, in turn, to stop corrosion.

 c



A Discharge of coal from the bunker
 B Conveyance of coal
C Bed depth limitation
D Weighing of coal
E Discharge to the mill

Drag-chain conveyor
Drag-chain conveyors are meant for limited conveyed quantities of up to approx. 40 t / h – this
can, in special cases, be raised to 120 t / h. The fuel is discharged opposite to the direction­
of conveying. The drag-chain conveyor principle allows both a compact design with minimum
spacing between bunker discharge and conveyor dumping as well as a possible large s­ pacing
between material charging and dumping.




 A Discharge of coal from the bunker

B Conveyance of coal
e
C Bed depth limitation
D Conveyance of coal
E Discharge to the mill

Mills and Components  5

Pulverisers for Bituminous Coal

Excellent results

In the mills, the raw coal is simultaneously pulverised, dried and evenly distributed to the
coal burners. Hot air or flue gases transfer the pulverised fuel to the burner and reduce the
moisture in the coal.

MPS® mill

Bowl & roller mill type MPS®

The MPS® bowl & roller mill by Hitachi Power Europe Service grinds and dries hard coals and
difficult-to-grind lignite with a low moisture content to pulverised fuel and distributes them
evenly directly to the burners.

Mills of various sizes for throughputs ranging from 10 t/h to 200 t/h can be supplied. Constant
refinements and improvements have led to excellent crushing results with high fineness
grades from raw coal found throughout the world. The positive operating properties and low
energy requirements have contributed in no small measure to the success of these mills.

6
The performance of vertical spindle mills depends on the geometric dimensions, revolution
speed of the grinding table and the grinding force itself.

a
MPS® Mill
b

c A Rotary classifier
B Classifier drive
e
f C Grinding rollers
g
D Hydro-pneumatic system
d E Grinding table
F Gear
G Motor

By suitable measures at existing plants capacity increase and adaption of the load change
behavior are possible. For example for changed coal characteristics.

As a prerequisite for these mill upgrades, it needs to be ensured that sufficient primary air is
available and that the mill primary air pressure as well as the mill drive power have the required
margins. This necessitates also investigating the mill motor, PA fans and pf-piping in detail.

Implementation of the above measures for variable adjustment of dust fineness during op-
eration, by use of dynamic classifier (type SLS), also secures higher flexibility during load
changes and a temporary increase of pulverised fuel outlet capacity.

SLS classifier Particle Size in µm

30 50 63 70 90 150 200 300 500 700
99.99
V3 V1 V5 0.01
rpm

pm

pm

99.90 0.1
r
85 r
110

100

99.00 1.0
V6
pm
0r

Residue R (%)
Passing (%)

90.00 10

80.00 20

70.00 30

60.00 40

50.00 50

40.00 60
400 270 200 140 100 70 50 30

U.S. Standard Sieve

Mills and Components  7

Pulverisers for Bituminous Coal

Long service life

RKD mill

Tube ball mill type RKD

The Hitachi Power Europe Service RKD tube ball mill grinds and dries difficult-to-pulverise
hard coals (particularly low-volatile coals such as lean coal and anthracite). This mill type
can deal with approx. 150 t / h of coal. Depending on size and space, the tube ball mill
can be designed with drum or neck bearing and be of the single or double pass type.

a
g

b d e

f
A Rotary classifier
B Oversize return
C Neck bearing
D Drive gear rim
E Grinding ball filling c

F Feed spiral conveyor

G Classifier riser

8
Maintenance of tube ball mill

The maintenance work at tube ball mills includes activities which are carried out while the
mill is in operation and work which requires shutdown of the mill.

Installation of wear plates

Replacement of screw spirals

Maintenance work during mill outage

■■ Inlet screw conveyors

■■ Inside lining of the inlet and outlet housing
■■ Grinding space armoring
■■ Air sealings

Mills and Components  9

Pulverisers for Lignite

Low energy requirements

Pulverising lignite is particularly challenging in view of its high moisture content and the
considerable throughputs involved.

DGS® mill

Distributor fan beater mill type DGS®

HPES supplies DGS® mills of various sizes up to a 240 t / h throughput for drying and pulver-
ising raw lignite coals.

DGS® technology involves the raw coal and flue gases being initially put through the pre-
crushing beater section of the beater wheel. This ensures excellent air and coal dust distribu-
tion into the beater wheel. Crushing in
the DGS® mill is u
­ sually so intensive
that adequate grinding fineness can be
a
obtained in one working operation –
c without the need for an additional clas-
sifier. This both raises the pressure
f g
balance and cuts back on energy re-
b
quirements. The DGS® mill has stood
g
the test of time particularly with
d
A Flue gas gate valve ­difficult-to-work lignites – something
B Inlet housing
that explains its c
­ onsiderable lifetime
C Beater shaft
and unrivalled properties.
D Beater wheel
E Coupling e
F Motor
G Bearing

10
Easy maintenance

NV mill

Wet fan mill type NV

The NV mills ranging from 10 t/h to 140 t/h throu­ghputs are for crushing high moisture
­content lignites for direct injection into the furnace.

Together with the flue gases, the raw lignite is brought for crushing purposes into the beater
wheel. It acts as a fan impeller fitted with beater plates. Baffle-type classifiers ensure that
the required fuel fineness for combus-
tion is ­fulfilled.
e

The high-tech NV mill more than meets a

the ongoing demands worldwide of op-

erational availability and low costs. f g

A Gate valve housing

B Grinding chamber door
C Grinding chamber
d
D Beater wheel
E Baffle-type classifier
c
F Double bearing
G Motor

Mills and Components  11

Pulverisers for Lignite

The grinding system –

key component with huge refurbishment potential

Optimised grinding in terms of throughput and grinding fineness and in parallel

minimisation of wear is the target of mill rehabilitations. Even without any firing upgrades,
HPES has attained remarkable plant improvements which mainly have a positive impact
on boiler operation efficiencies.

As a specialist for mills with its own technology, HPES possesses enormous competence in
all kinds of mills and coals for new installations and upgrades – the latter also for “Non OEM”
mills. HPES’ comprehensive knowledge on grinding and fluid dynamics within the mills / 
classifiers and their optimisation potential allows the company to improve matters through
simple design measures backed up by CFD simulation.

DGS® mills, NV mills, N mills for lignite

The main challenge behind a lignite mill upgrade is to optimise the contradictory targets of
fuel throughput and grinding fineness in such a way that the increase of fuel throughput –
mostly in connection with improved grinding fineness – can be obtained with a minimum
of wear with consideration given to the permitted conditions (temperature, oxygen content).

Efficient constructive measures either in the preheater section (for DGS® mills), classifier
(NV, N mills) or in the mill housing are HPES’ specialty for tapping the full potential of the
mill – again supported by cfd simulation.

Exemplary for HPES’ competence is

the upgrade in Nicola Tesla A at fan mill
DGS100S. Instead of the requested
contractual throughput increase of almost
10 %, the reasonable measures which HPES
took resulted in a 30 % increase

12
Burn-Out Grate

High efficiencies

In lignite coal or peat-fired plants with a high proportion of xylite or fibers in the fuel,
the proportion of unburnt residue in the boiler hopper ash can be extremely high and this
impairs firing efficiency.

The optimum designed burn-out grate ensures that the ash burnout in the boiler hopper is
improved to over 80 % – thus substantially raising the overall efficiency of the boiler plant. In
addition, afterburning results in additional heat input into the boiler hopper, which would
otherwise be relatively cold. This leads to an even distribution of temperature in the furnace.

Burn-out grate diagram Ash

a n b c

f
d

e A Boiler furnace hopper

B Refractory jacket of retarded
combustion reactor
C Water seal gasket
g
D Firmly fixed grate supporting bars
E Grate carriage
F Grate surface
G Hydraulic system for grate
i k carriage and deashing flap
h
l H Ash hopper
I Cooling and combustion air
j J Deashing flap
K Ash discharge chute
m L Shutoff gate valve in ash
discharge chute
M Deasher
N Monitoring system

Mills and Components  13

Ash Removal

Stable in the extreme and long lasting

Ash removal systems have been part of HPES’ range of products and supplies for many
years now. This applies to bottom ash removal as well as to the transfer of ash accumulat-
ing in the course of air heater and electrostatic precipitator ash removal.

Submerged scraper conveyor

Submerged scraper conveyor functions:

■■ Air sealing to the boiler hopper
■■ Ash cooling
■■ Ash conveying
■■ Inlet for furnace inspection

Submerged scraper conveyor for hard coal-fired systems

e

c a b i f

A Bottom ash
B Transfer chute with immersion piece k g j k d k g
C Expansion joint
D Submerged scraper conveyor Submerged scraper conveyor for lignite-fired systems e

E Drive station frequency controlled

F Tensioning station i c a
G Idler stations
H Discharge chute h
I Cooling water inlet
J Overflow
K Travelling rails

➞
➞
Conveying
direction
f k g j k d k g k

14
Other Ash Removal Components

HPES provides a broad range of ash handling systems. These systems apply to ash handling
for furnace bottom ash removal and also to the ash removal from all downstream ash
accumulation points.

Our systems offer a lot of benefits: they are stable in the extreme, wear parts are long lasting
and both the energy requirements and operating / upkeep costs are low. HPES provides the
entire range for utility steam generators with pulverised hard coal and lignite firing: from
design, manufacturing and erection up to commissioning the complete ash disposal systems
including loading systems for transport by truck, rail and ship.

Components
■■ Ash silos and dewatering bunker
■■ Single-strand chain conveyors
■■ Apron conveyor
■■ Screw conveyors
■■ Single and double roller crushers
■■ Hammer crushers
■■ Rotary feeders
■■ Single and double pendulum flap
■■ Shut off gates
■■ Ejectors
■■ Bucket-type conveyors
■■ Sluice ways

Ash removal systems

■■ Dry mechanical ash removal systems
■■ Hydraulic ash removal systems
■■ Pneumatic ash removal systems
■■ Mill reject systems
■■ Re-cooling systems for submerged conveyor overflow water

Mills and Components  15

Bevel Planetary Gear

Highest availability

KPV gear unit

Gear unit type KPV

The HPES gear unit type KPV, for vertical spindle mills, is a two-stage planetary bevel gearing
with a bevel wheel stage and a planetary gear stage. The driving shaft is arranged horizontally,
the bevel wheel shaft, planet wheel set and output flange are mounted vertically. The bevel
wheel stage is connected with the planetary gear stage by a toothed coupling. To sustain the
static and dynamic axial forces from the mill a tilting pad thrust bearing is installed in the upper
casing section.

a

A Output flange

B Tilting pad thrust bearing
C Planetary wheel  
D Tooth coupling  
E Bevel wheel
F Hollow wheel Carrier

G Planet 
H Sun wheel

I Driving shaft
J Casing

16
Replacement Parts Service

As a designer and manufacturer of original components, HPES is the ideal partner to

­contact when modernization or replacement parts are needed.

Our extensive expertise derived from designing and delivering utility steam generators
with the associated components over many years enables our HPES experts to provide
­professional solutions matched to customer requirements in the matter of plant design and
operations. Optimized plants ensure that performance and availability are raised and that
­efficient operations are attained as far as possible. As a competent and flexible partner,
HPES’ expertise is available in the fields of process engineering, plant optimization, measuring
technology, plant-internal inspection, component installation and commissioning. At the same
time, HPES supports customers in the design and configuration of their future plants – from
the technical point of view (planning, design, optimizing) and in the matter of operating
­economy analyses.

Rapid servic
e from
a competent
partner
Manufacturi
Ash submerged ng from
Mill Feeders Pulverisers Burners a single sour
scraper conveyors ce
As stakeholde
Pulverised fuel r in Babcock
Belts Wear parts Chains Ferti-
line elbows gungszentrum
GmbH in Obe
rhau­
sen, we are in
Chains Linings Pulverised fuel lines Scraper bars the closest po
ssible
contact with
our partners
Drives Nozzle rings Impact plates Wear plates and,
as such, are
flexible and
quick
in ha nd lin g
Bearings Shaft seals Housings Drives yo ur en qu iri es
an d
can provide yo
Feeding screw u with depend
Gate valves Adjusting mechanisms able
conveyors solutions.
Conveyor-type
Beater sections Bearings
weighers

Expansion joints Gear units

Drives

Hitachi Power Europe Service GmbH

24h Hotline + 49.172.2608481

Mills and Components  17

References

Projects / products of Hitachi Power Europe Service (selection)

Project Technology Capacity Design
Kusile Unit 1 – 6 Bituminous 6 x 800 MW Belt conveyor, according to NFPA 3.5 bar
South Africa coal fired boiler 117 t/h 6 x 5 MPS® mill, size 265 incl. gear box
Submerged scraper conveyor
Medupi Unit 6 – 1 Bituminous 6 x 794 MW Belt conveyor, according to NFPA 3.5 bar
South Afric a coal fired boiler 114 t/h 6 x 5 MPS® mill, size 265 incl. gear box
Submerged scraper conveyor
Maasvlakte Bituminous 1,100 MW Belt conveyor, according to TRD 1.0 bar
Netherlands coal fired boiler 84 t/h 5 MPS® mill, size 255 incl. gear box
Submerged scraper conveyor
Duke Cliffside Bituminous 900 MW 6 MPS® mill, size 235 incl. gear box
USA coal fired boiler 72 t/h
Datteln 4 Bituminous 1,100 MW Belt conveyor, according to TRD 1.0 bar
Germany coal fired boiler 84 t/h 5 MPS® mill, size 255 incl. gear box
Submerged scraper conveyor
Moorburg Unit A + B Bituminous 2 x 820 Belt conveyor, according to TRD 1.0 bar
Germany coal fired boiler MW 76 t/h 2 x 4 MPS® mill, size 245 incl. gear box
Submerged scraper conveyor
Rotterdam Bituminous 800 MW Belt conveyor, according to TRD 1.0 bar
Netherlands coal fired boiler 65 t/h 4 MPS® mill, size 225 incl. gear box
Wilhelmshaven Bituminous 800 MW Belt conveyor, according to TRD 1.0 bar
Germany coal fired boiler 65 t/h 4 MPS® mill, size 225 incl. gear box
Walsum 10 Bituminous 750 MW Belt conveyor, according to TRD 1.0 bar
Germany coal fired boiler 68 t/h 4 MPS® mill, size 225 incl. gear box
Genesee Power Generation Bituminous 495 MW 6 MPS® mill, size 225 incl. gear box
Station Phase 3 Canada coal fired boiler 58.9 t/h
Shentou II Power Plant Bituminous 2 x 500 MW 2 x 6 MPS® mill, size 225 incl. gear box
Phase 2 China coal fired boiler 60.5 t/h
Kogan Creek Bituminous 750 MW Belt conveyor, according to NFPA 3.5 bar
Australia coal fired boiler 80 t/h 6 MPS® mill, size 255 incl. gear box
Mid American Energy Bituminous 830 MW 6 MPS® mill, size 255 incl. gear box
Company USA coal fired boiler 80 t/h
Shanxi Wangqu Thermal Bituminous 2 x 600 MW 2 x 6 MPS® mill, size 200 incl. gear box
Power Plant China coal fired boiler 51.6 t/h
Paroseni Co-Generation Bituminous 180 MW Belt conveyor, according to NFPA 3.5 bar
Power Plant Romania coal fired boiler 39.5 t/h 4 MPS® mill, size 212 incl. gear box
Iskenderun Sugözü Power Bituminous 2 x 605 MW Belt conveyor, according to TRD 1.0 bar
Plant Turkey coal fired boiler 77.8 t/h 2 x 4 MPS® mill, size 255 incl. gear box
Boxberg R Lignite coal 660 MW 8 NV mill, size 110
Germany fired boiler 113 t/h Submerged scraper conveyor
Boxberg Q Lignite coal 900 MW 8 NV mill, size 130
Germany fired boiler 140 t/h Submerged scraper conveyor
Lippendorf III Lignite coal 933 MW 8 NV mill, size 110
Germany fired boiler 116 t/h
Megalopolis IV Lignite coal 850 MW 6 DGS® mill, size 180
Greece fired boiler 956.4 t/h (steam) Submerged scraper conveyor
Elbistan B Lignite coal 4 x 360 MW 4 x 6 DGS® mill, size 180
Turkey fired boiler 4 x 1,037 t/h (steam)
Schkopau Lignite coal 2 x 450 MW 2 x 8 DGS® mill, size 65
Germany fired boiler 2 x 1,365 t/h (steam)
Dezhou Unit 2 + 1 Special fuels 70 t/h 2 x 6 RKD mill, size 420 x 650
China fired boiler Submerged scraper conveyor
Lausward Unit D + B Bituminous 46 t/h 2 RKD mill, size 340 x 500
Germany coal fired boiler
Lausward Unit A1 Bituminous 28 t/h 1 RKD mill, size 340 x 500
Germany coal fired boiler
Herne 4 Bituminous 500 MW 3 RKD mill, size 500 x 700
Germany coal fired boiler 85 t/h
Herne 3 Bituminous 300 MW 2 RKD mill, size 440 x 650
Germany coal fired boiler 55 t/h

18
Service / retrofit activities for grinding and firing systems
Project Technology Capacity Work carried out
Kostolac B2 Lignite coal 330 MW 8 N270.45
Serbia fired boiler Retrofit / replace of classifier, coal change,
capacity increase, improved classifier outlet
fineness
Mega IV Lignite coal 650 MW 8 DGS® 180
Greece fired boiler Retrofit / replace of classifier, coal change,
capacity increase, improved classifier
outlet fineness
Nicola Tesla A5 Lignite coal 330 MW 6 DGS® 100
Serbia fired boiler Retrofit / replace of burners and mills,
revolution grinding desk / beater wheel,
coal change, capacity increase, improved
classifier outlet fineness, low NOx firing
Weisweiler F / E Lignite coal 2 x 300 MW /  2 x 6 DGS® 60 / 2 x 6 DGS® 60
Germany fired boiler 2 x 300 MW Retrofit / replace of mills, coal change,
capacity increase
Mehrum Bituminous coal 650 MW 3 MPS® 190
Germany fired boiler Retrofit / replace of classifier, coal change,
capacity increase, improved classifier
outlet fineness
Nicola Tesla A4 /A3 Lignite coal 330 MW /  6 DGS® 100 / 4 DGS® 100
Serbia fired boiler 330 MW Retrofit / replace of mills, revolution
grinding desk / beater wheel, coal change,
capacity increase, improved classifier
outlet fineness
Weisweiler D / G + H Lignite coal 300 MW /  8 N80.75 / 8 DGS® 130
Germany fired boiler 600 MW Retrofit / replace of mills,
coal change, capacity increase
Mega IV Lignite coal 650 MW Bottom ash
Greece fired boiler Retrofit / replace of bottom ash handling,
higher unit availability
Buschhaus Lignite coal 650 MW 6 DGS® 90
Germany fired boiler Retrofit / replace of classifier,
coal change, capacity increase
Wilhelmshaven Bituminous coal 720 MW 4 MPS® 225
Germany fired boiler Nozzle ring, higher unit availability
Kiel Bituminous coal 320 MW 4 MPS® 180
Germany fired boiler Retrofit / replace of classifier,
coal change, capacity increase
Heyden Bituminous coal 900 MW 4 MPS® 255
Germany fired boiler adjustable grinding force,
revolution grinding desk / beater wheel,
retrofit / replace of P.F. pipes,
coal change, capacity increase
Amer Biomass fired 600 MW 6 MPS® 235
Netherlands boiler Retrofit / replace of mill, biomass grinding
Veltheim Bituminous coal 330 MW MPS® 150
Germany fired boiler Retrofit / replace of classifier and mill,
coal change, capacity increase,
reducing of unburnt carbon,
improved classifier outlet fineness
Reuter Bituminous coal 320 MW MPS® 170
Germany fired boiler Retrofit / replace of burners, classifier,
p.f. pipes and sealing air system, low NOx
firing, reducing of unburnt carbon,
improved classifier outlet fineness
Milliken Bituminous coal 150 MW MPS® 150
USA fired boiler Retrofit / replace of mill air fans, classifier,
mill, P.F. pipes and sealing air system,
coal change, capacity increase,
low NOx firing, improved classifier outlet
fineness

Mills and Components  19

 © Hitachi Power Europe Service GmbH / 05.2013 / Printed on chlorine-free bleached paper

Hitachi Power Europe Service GmbH

Friedrich-Ebert-Straße 134
47229 Duisburg, Germany
Phone +49.2065.4221-0
Fax +49.2065.4221-677
info@hitachi-power-service.com
www.hitachi-power-service.com

24h Hotline +49.172.2608481