Marine Terminals 04/04 - IBAU HAMBURGcdn.ibauhamburg.com/pdf/ibau-hamburg-dry-product-handling.pdf · Information 4 5 Dry product handling for flue gas cleaning and ash removal systems

Your efficient partner for modern and effective bulk material handling

PLANT DESIGN - ENGINEERING - EPC-CONTRACTING

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I BAU HAMBURG

CEMENT - THERMAL POWER - MINERALS

Single silos. Ring silos.

Multicompart-ment silos. From 2 to

22 chambers,diameters:

14 to 27 m.

Advanced technology for

self-discharging Cement Carriers

including the Midship tunnel.

Marine Cement Terminals

Central Cone Silos EPC-Contracting

Silo Conversions

Components

Spare Parts

Cement Carriers

Ship Unloaders

Floating terminals.

Mini terminals.Silo systems.

Dome systems.Flat storage

terminals.

Stationary ormobile types:

From the5,000 class

up to the60,000 class.

Piling. Civil works. Steel structure, supply/erection. Electrical/mechanical supply and erection.

Economic modifications with advanced cutting-edge technology.

The key for a well functioning plant: Components, all made to measure.

High stock availability:Just-in-time supply of spare parts.After-sales Service.

I BAU HAMBURG

for flue gas cleaning and ash removal systemsin thermal power plants

I BAU HAMBURGDry Product Handling

A HAVER & BOECKER Company

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InformationDry product handling for flue gas cleaning and ash removal systems in thermal power plants

Storage and conveying solutions for dry bulk material

Main IBAU Components

Pneumatic conveying installations:� Fluidslides� Pressure vessels� Screw pumps� Rotary air locks� Jet conveyors� Pneumatic conveying with Fpipe� Medium pressure conveying

systems

Silo, storag, loading technology:

� I BAU Large-storage silos� Steel silos with aerated bottom� Bulk loading systems

for pressure vessel trucks, rail wagons and ships

� Discharge systems for pressure vessel trucks, rail wagons and ships

� Wet ash loading systems

Fly ash handling for coal-fired Power Plants

The fly ash is separatedfrom the flue gas byESPs or fabric filters.

I BAU HAMBURG findsthe best economical andtechnical solution for thefly ash removal system,the storage silo systemand the loading facilitiesby taking important layout data into consid-eration.

Fly ashremoval systems:

Depending on the ESP-height and the distance to the storage facility,I BAU HAMBURG isable to choose betweenseveral different techni-cal solutions.

Fly ash removal systemwith fluidslides

The fly ash is fed fromeach filter hopper byrotary feeders or pendu-lum flap valves to fluid-slides. The fly ash is conveyed by theses fluid-slides to an intermediatebin from where the ash istransported pneumatical-ly either by I BAU Pumps

or pressure vessels to thestorage silo. These sys-tems are very economicalthanks to the low energyconsumption and also100% reliable in service.

Fly ash removal system with fluidslides and conveying by I BAU Pumps to an I BAU Storage siloLimestone and fly ash storage silos for RWE STKW Westfalen, Germany

IBAU Fluidslide

I BAU LoadingIBAU Screw Pump

IBAUFlow Control Gate

IBAU Two-Way Valve

I BAU HAMBURG is one of the worldwide leading companies supplying storage and conveyingsolutions for dry bulk material pro-duced and used in flue gas cleaningsystems of thermal power plants.

I BAU HAMBURG not only sup-plies systems and components forpower plants, but also completecustomised solutions for handlingfly ash, pulverised limestone,quicklime and gypsum.

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Dry product handling for flue gas cleaning and ash removal systems in thermal power plants

Fly ash removal system with multi-pressure vessel system

Under each hopper of the ESP, a pressure vessel is installed pickingup the fly ash.

In case the vessel of a group of vessels is full, the group of vessels in one row is emptied simultaneously.

Pressure vessel conveyors:Pressure vessels functionaccording to the dense-phase flow principle withlow conveying velocitiesof the material. Severalvessels are connected toone conveying line. Fordifferent conveyingquantities different pressure vessels sizes canbe combined. The energyconsumption is relativelylow.

A multi-pessure vesselsystem is the ideal solution in case of a lowheight underneath theESP hoppers and a longconveying distance to thestorage silo.

Low material velocitiesinside the conveying pipewill cause low abrasion.

Pneumatic fly ash conveying system with I BAU Pressure vessels Pneumatic conveying of FGD-Product by pressure vessels

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I BAU Fpipe for a fly ash removal system of an ESPFpipe Conveying system

Fly ash removal system with IBAU Fpipe

The fly ash is fed from each filter hopper by rotary feedersto the Fpipe. The Fpipe conveys the fly ash either tothe storage silo or to an inter-mediate bin in case there is agreater distance to the silo.The advantage of this systemis a low height of the ESP anda low energy consumption.

Material transport viaIBAU Fpipe

So far, there are mostly twomethods set for the pneumatictransport: the energeticalfavourable fluidslide transportand the flexible pneumatictransport through conveyingpipes.

The new Fpipe methods combine the advantages ofboth conveying systems andeliminate the disadvantages of e.g. the downward fluidslide slope at the fluid-slide transport or the relativelyhigh energy consumption for a conventional pneumaticconveying system.

With the Fpipe method, the material is conveyed in adense flow with conveyingspeeds of 3-10 m/s. In order toavoid plug forming in the conveying line, the material is fluidised in the conveying linejust as it is done in a fluidslidesystem. The system allows aconveying capacity of up to 400 t/h with an air speed of 3 m/s at the beginning ofthe conveying line.

The conveying air is beingreduced by factor 2 in compar-ison to a lean-phase conveyingas well as the pressure loss inthe conveying line and theenergy consumption for theconveying.

Advantages

� Flexible pipe routing� Horizontal and

vertical conveying� Dust-tight� Low conveying

velocities� Low wear / abrasion� Low energy

consumption

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Information

I BAU Fly ash storage silo in a coal-fired power plantTypical discharge section of an I BAU Silo


Loading terminal with steel silos

Fly ash storage silos:Depending on therequired storage capacity,I BAU HAMBURGchooses the best technical and economicalsilo system.

I BAU HAMBURGsupplies pneumatic sys-tems for the storage offly ash, pulverised limestone, burnt lime,hydrated lime and FGD-products at power plants.They function accordingto the "first-in/first-out"principle.

Lower capacities of up toapprox. 2,500 t, usuallyare stored in steel silos.

I BAU Central cone silos:These silos have proventheir worth time andagain and are the industrial standard forstorage volumes of up to 30,000 m³.

They are equipped with a pneumatic dischargebottom and provide for metered and maintenance-free material discharge.

The advantages of this silo system are:

� Less concrete works� Cost and time saving

by using prefabricatedcone elements

� Less energy consumption

� Emptying rate of up to 99%

� Less maintenanceworks

� Trouble-free operation

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I BAU storage silos with I BAU Ship loader for fly ash

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Combined dry ash and movable wet ash loading system

Mobile truck loading system for dry fly ash

Humidifier for a wet ash loading system

Ship loading system for dry fly ash

Fly ash loading systems:The loading system canbe stationary or mobile.I BAU offers a wide variety of fly ash loadingsystems. The fly ash canbe loaded dry into truckvessels, rail waggons orships.

The wet ash loading sys-tem consists of a humidi-fier and a downstreamarranged open type load-ing chute for dispatchingthe material onto opentrucks, open railwaywagons or ships.

I BAU has delivered suchloading systems forGemeinschaftskraftwerkMannheim, RWE, E.ON,Austrian Energy andmany other customers inthe Power Plant Industry.

These loading systemsallow the Power Plant customers to distributethe fly ash to furthermarkets and to reduce thedeposit of a valuable by-product.

Ship loading systemsBulk material such as flyash, gypsum or FGD-product can be loadeddirectly onto ships bymeans of pneumatic conveying systems. This technical solutionrequires separate dedust-ing equipment on theships.

Higher loading capacitieswill be reached specialship loading chutes. Thebulk material will bestored in a separate bin,which will be dischargedpneumatically byairslides. A loading chuteat the end of the airslidecharges the ship with thebulk material.

Ship loading systems caneither be moveable orstationary.

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Unloading station for trucks Unloading station for rail wagons

Pulverised lime-stone, burnt limeand hydrated limehandling for dryand wet FGDPlants

I BAU HAMBURGsupplies the material handling system for dryand wet FGD plantsincluding unloading fromrail wagons, trucks orships, the silo storageand the dosing system tothe slurry tanks.

Unloading systems:

The Lime is unloadedfrom trucks, rail wagons or ships.

The unloading capacitycan be increased byinstalling a separate conveying air compres-sor.

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I BAU HAMBURG is oneof the worldwide leadingsuppliers for storage andconveying systems fordry FGD plants for coal-fired, biomass and waste-fired power plants.

Usually, the burnt lime is hydrated and thehydrated lime then fed tothe scrubber.

The dry FGD product isrecirculated back fromthe bag filter hoppers tothe scrubber while a cer-tain percentage of theFGD product is dis-charged and fed into thestorage silos.

Bulk materials, such ashydrated lime and FGD product, require aspecial treatment due totheir special characteris-tics.

I BAU HAMBURGprovides the perfect technical solution toguarantee a troublefreeoperation.

Storage and conveying systems for dry FGD plants

Feeding system of hydrated lime into the flue gas scrubber

The pulverised limestone or hydrated lime isdischarged from the siloand dosed volumetricallyby rotary feeders orscrew conveyors into theslurry tank.

The accuracy can beimproved by using special flow meters suchas weigh feeders or solidflow meters.

The density of the suspension inside theslurry tank is measured.

In case a certain densityis reached, the dosingprocess is stopped andthe suspension of waterand lime is fed into thescrubber.

Silo discharge and dosing system to slurry tanks:

Dosing system to a slurry tank by weigh feeders

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Silo discharge with loading chute for FGD product

Recirculation system from filter to the flue gas scrubber

Medium pressure conveying system in a FGD plant

RecirculationThe dry FGD productincludes a high amountof hydrated lime whichhas not yet reacted withthe sulphur dioxide.

Therefore, the productfrom the filter dischargeis recirculated back to thescrubber in order toreduce the consumptionof hydrated lime.

A certain percentage ofthe product is dischargedand conveyed pneumati-cally to the FGD productsilos.

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InformationHighly qualified service and maintenance personnel

Installation of an I BAU Mixer

Maintenance

Components and systemsperform best when theyare in ideal operatingconditions.

Our supervisors areaware of the sensitivepoints and mechanicaldetails of our equipment.

In order to keep yourequipment in best condition, we recommendfrequent inspections byI BAU HAMBURG sitetechnicians, and the appropriate preventivemaintenance.

• Visual inspection• Functional testing• Optimum adjustment of

process parameters

Adjustment of the settings

Supervision

After system equipmenthas been delivered byI BAU HAMBURG, ourspecialists travel to theplant site in order to perform the relevantplant services.

Commissioning is theprocess of ensuring thatour systems are installed,functionally tested andoperated in conformance

with the design. A systemthat has not been properlycommissioned oftencauses problems later on. Our skilled engineers areexperienced in providingcommissioning and supervision services fornew as well as existingsystems. We can be onsite during configurationand test, start-up, operation, shutdowns,trouble shooting andmaintenance.

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InformationHighly qualified service and maintenance personnel

I BAU – Warehouse and assembly shop on more than 5.000 sqm, pre-assembled components and spare parts for fast delivery – the real just-in-time solution

Documents

Marine Terminals 04/04 - IBAU HAMBURGcdn.ibauhamburg.com/pdf/ibau-hamburg-dry-product-handling.pdf · Information 4 5 Dry product handling for flue gas cleaning and ash removal systems