KOPAR EXPERTISE IN ASH HANDLING FOR POWER PLANTS

Kopar is a leading manufacturer of ash handling systems for the power industry and utility plants. The technology behind Kopar ash handling systems is based on the years of knowledge and experience of Elmomet and Site Teollisuus. The company is specialized in mechanical and pneumatic conveying of ash and is able to offer flexible solutions in assessing the need of the individual customer. In many cases the delivery is based on tailor-made projects of which Kopar also has a long tradition based on the expertise gained from numerous deliveries all over the world.

In addition to the conveying systems for handling of ash, lime and sand, Kopar has a vast variety of other solutions suitable for power plants. It includes equipment for storage, screening, dosing and dust removal. A further particular Kopar expertise is the raw-water intake and filtration equipment. Kopar equipment is being used within many different types of power generating plants extending from nuclear power plants to bio energy plants.

 

PNEUMATIC SOLUTIONS

Pneumatic conveying is one of the most efficient and economical ways of handling dry ash. Four different pneumatic conveying systems can be utilized depending on the material to be conveyed, the conveying distance, the conveying volume and the process in question. By using one or any combination of these systems it is possible to solve almost all problems of fly ash conveying in power plants.

As far as Kopar is concerned, the systems are based on the dry ash principle, which offers an effective solution to environmental problems in handling of fly ash.

The four methods are called pulse dense phase, dense phase, fluidised phase, and diluted phase.
 

 

THE PULSE DENSE PHASE SYSTEM

Most of Kopar customers have selected the pulse dense phase system as the most efficient, competitive and reliable solution. Kopar pulse dense phase systems are in use in hundreds of power plants all over the world. They cover the handling need of ash in volumes from 2 tph up to 20 tph and conveying distances up to 1,000 m (3,350 f).

The pulse dense phase conveying system operates in a batch mode. The batch then travels as high density pulsed plugs through the pipeline to the receiving silo. The system is easy to operate since it is fully automated and integrated with the plant’s control (DCS) system. The system offers such benefits as low energy consumption and low wear of components.

 

RELIABILITY

    There are several features that make Kopar ash handling systems reliable and trouble-free. Foremost it is the result of automation and the non-clogging principle. Kopar equipment is truly factory and field-tested and consequently, they establish a reliable frame of reference.

    The reliability of Kopar ash handling equipment is based on the following:

• The non-clogging feature ensures disturbance-free operation
• Long distances can be handled reliably; Kopar deliveries include distances up to 1,000m (3,350 f)
• Low velocity and wear-resistant materials result in a long lifetime
• Easy operation and full automation due to the integration with plant’s DSC system
• Kopar systems meet the needs of the most demanding clients and offer easy integration with existing processes

 

ECONOMY

    Kopar ash handling equipment is economical due to low energy consumption and consequent low operating costs. This is achieved by

• Manufacturing know-how combined with research and development over the past twenty years
• Low wear and tear through low conveying velocities
• Special ceramic coatings reducing the need for spare parts thus lengthening the system’s lifetime
• Less maintenance and lower costs due to a minimal number of moving parts
• Kopar pneumatic conveying systems are clean and dust-free; pneumatic conveying is a dry method, which means that there is no waste water problems

 

MECHANICAL SOLUTIONS

For transportation of various types of powdered and dusty materials Kopar offers a range of heavy-duty drag chain conveyors. They are suitable to transport ash, lime and solid fuels. The key is the continuous and efficient material flow, which ensures high availability and first-class profitability.

Kopar forged conveyor chain is especially suitable when the material is very abrasive or when the working conditions are very hot (up to 600º C; 1112º F). Kopar drag chains are usually made of case hardened steel (20MnCr5) or tempering steel (27MnCrB5), also known as boron steel. In special cases links and pins are made of hardened stainless steel or heat resistant steel.

There are three main flight types of drag chains. T-flight chain is suitable for horizontal conveying and up to conveyor width of 630 mm (2’ 1”); P-flight chain is used in inclining or vertical conveyors up to the grade of 90 degrees; I-flight chain is a double strand chain, which is used in wide conveyors (500 to 1,200 mm; 1’ 8” to 3’ 11”).

CRUSHERS AND BUCKET ELEVATORS

Further Kopar products are crushers and bucket elevators.

There are two types of crushers, rotor crushers and roller crushers that process cloddy or lumpy materials in order to make them more suitable for conveying. The capacity can be up to 30 tph, and when placed consecutively, they process the material from 300 mm (1’) down to final product size of 5 x 5 mm (0.20” x 0.20”).

There are two types of Kopar bucket elevators, either belt or chain elevators. They efficiently transport the materials from ground up to the silo. Belt elevators are mostly used in this type of processes but when the material is hot, chain elevators are the right machines.
 

RAW WATER TREATMENT

Kopar offers a variety of equipment for raw water intake and filtration. The range includes automated bar screens, and travelling basket and drum basket filters. All are based on over 20 years of experience in power generation and many other industries where water screening is needed to produce cooling water.

The screens and filters are made of stainless steel (AISI 304L), acid-proof steel (AISI 316L) or Duplex (2205). They also feature a module type automation supervising the functions. Because of the module structure, it is easy to enlarge the system and/or add more automation.

Bar screens
Kopar bar screens are used to make sure that larger objects do not get into the system. The grid of the screen is designed to prevent clogging. The trash collected on the grid is automatically removed at intervals by a cleaning rake. The function is switched on by pressure sensors or timers.

Travelling basket filters
Kopar travelling basket filters are suitable for treating the intake water when the water is taken directly from a river or a lake or from open sea by gravity flow. Travelling basket filters are particularly recommended when there are large fluctuations in the water level. The filter screen has a mesh size from 015 mm to 5 mm (0.006” to 2”) depending on the application.

The screen is made of stainless steel or plastic material. The filters supplied by Kopar have a capacity range from 1,800 to 50,000 m³/h (from 2,355 yd³/h to 65,400 yd³/h).

Drum basket filters
Kopar drum basket filters are used when a high degree of mechanical purification is needed. These filters have proven their reliability in a large number of installations worldwide. They are able to separate particles down to 50 μm. The largest drum basket filters supplied by Kopar have had a capacity of 4,800 m³/h (6,280 yd³/h).

When drum basket filters are used, it is essential that the water level is kept stable, i.e. water is pumped to the filter in and out. The filter is installed in a concrete base or in a separate tank made of steel.

KOPAR SERVICES FOR POWER PLANT CLIENTS

There are quite a few services Kopar is able to offer to its clients of energy and power. In order to maintain the high availability of power plants, services offered by Kopar include:

• Pilot tests
• Engineering
• Project management
• Erection
• Start-up
• Training
• Annual maintenance check-ups
• Modernizations
• Spare&Wear parts

 

KOPAR PRODUCT RANGE FOR POWER PLANTS

Kopar manufacturers and supplies a whole lot of equipment related to ash handling and other functions in power plants. Kopar equipment is designed for high availability and low operating costs. The equipment is based on field-proven ash handling technology of Elmomet and Site Teollisuus.

They include:

• Pneumatic conveying equipment and systems
• Cupola valves
• Cast basalt elbows
• Feeders for solid fuels
• Mechanical conveying equipment and systems
• Vacuum transport equipment
• Silos
• Silo filters
• Bag filters
• Dry and wet silo dischargers
• Screens and screen shakers
• Rotor and roller crushers
• Screw and rotary feeders
• Paddle mixers
• Bar screens for raw water intake
• Travelling and drum basket filters
• Spare and wear parts