hardox: coal power - damatech · process of coal power plants hardox is useful in crushing :...
TRANSCRIPT
Hardox: Coal Power
1
2
Process of Coal Power Plants
Hardox is useful in crushing : •coal•limestone•ash
3
A Success Story at Kangal Power Plant, TURKEY
•Their maintenance time before using HARDOX 400 is about 60 days.(Including controls of the liner plates + changing all of them)•They were stopping during maintenance.• After using HARDOX their maintenance last 25 to 40 days. (Includingcontrols of the liner plates + changing some of them)• Their income for 1 day is app.. USD 1,000,000.
A state-run Power Plant at East Side of Turkey, with 457 MWatt Capacity
Coal powerstation = mechanical processing of raw materials and
by-products
• Raw materials:
• - Coal (ca 7800 ton coal/year for 1 MW of the elektric power)
• - Limestone for flue gas desulfurization. Coal contains ca 1% -5% sulfur. (Ca 390 ton limestone/year for 1MW)
• By-products:
• - Slag. Coal contains 10% - 35% ash. After burning the coal the ash is distributed to slag and fly-ash. Ca 1/3 goes to slag, 2/3 goes to fly-ash. (Ca 500 tons slag/year for 1 MW)
• - Fly-ash (ca 1000 tons/year for 1 MW)
• - Gypsum (hydrogen calcium sulphate) - ca 670 tons/year for 1 MW
All above mentioned data are aproximately valid for brown coal powerstation and theoretical 100% production during an year..
• For black coal powerstations are the values ca half.
400 MW BROWN COAL POWERSTATION
ANNUAL CONSUPTION / PRODUCTION
(roughly):
• 2.000.000 tons coal
• 112.500 tons limestone
• 94.000 tons slag
• 188.000 tons fly-ash
• 169.000 tons gypsum
Hardness reduction due to tempering
250
300
350
400
450
500
550
600
650
100 150 200 250 300 350 400 450
Su
rface H
ard
ness (H
BW
)
Tempering temperature (C)
Surface Hardness vs. Tempering temperature
HARDOX 600
HARDOX 500
Above 200°C to 250°C HARDOX starts losing hardness!
The Quarry - loaders
Part Steel grade
Cutting edge HARDOX 500
Bucket Shell HARDOX 450
Side sheets HARDOX 450
Side cutters HARDOX 500
Main wear plates HARDOX 500
Outer wear plate HARDOX 450
Floor reinforcement HARDOX 450
Strip Mining of Coal
Bucket wheel ReclaimersMine Soft Coal in Large Open Cuts
Hardox 400-500
Dead bed liner concept
• Low weight
• Favorable flow reduces wear
• Dead bed liner at selected areas
• Advanced to produce
• Easy to handle and quick to bolt on
Crusher Feeder & Chute
Feeder and Hopper to the primary crusher.
Liner plates in HARDOX 400-600
Wear plates in vibrating feeder
Wear plates in vibrator: Hardox 400 10 mm
Grating to lignite conveyor made by Hardox 450
Crusher at a limestone quarry and cement plant
• Segments for the grate basket and the perpendicular wear bars are made of HARDOX 500. The wear bars are 75 mm.
suspension
Stone
rubber Breakage is common in both segments and wear bars, both usually made out of 12 %Mn-steels. With the HARDOX 500, breakage is minimized and wear life increased.
Gryzzly bars in the secondary crusher
Wear plates in hammer millWear plates
HammersBeaterarm
Coal processing – the crushers
• Hammer crusher. The hammers are
usually from 12%Mn cast steel. Thickness
50 mm – 120 mm. It is supposed that
HARDOX 500 will have aproximately the
same lifetime as 12%Mn. HARDOX 550
will be better.
• Ventilator mill. It works at higher
temperatures (200 – 400 °C). Erosion
instead of abrasion. For the impact desks
is used everything (from S355 to high Cr
cast iron). HARDOX 500, 15 mm were
successful as liner plates.
• Ball mill. Coal is crushed by balls which
are run up by special wear resistant cast
lining. Just entry part is potential aplication
for HARDOX. (HX500, 12 mm)
Hardox 450-500
Hardness vs Temperature and timeFrom previous information that we have we know that the crushers in East Europe
is working at the temperature is between 180 and 200 degrees Celsius, temporary the temperature can reach 300 degrees.
The hardness after 2000 hours can be calculated according to Holloman Jaffe in which the temperature and time gives the annealing dose. The result is usually quite conservative and the temperature has a much bigger impact then the time. The estimation, according to Holloman Jaffe curve and 2000 hour working time, is.
HARDOX 400 325 to 350 HBHARDOX 500 375 to 390 HB
Hardox 550-600Hardox 450
Ventilator mill- impact desksPresent life time of impact desks is to 2200h in a Turkish plantThe improvement to 2500 is considered as a sucessPictures showing worn out 13% Mn steel ready for replacement
20
A Test at Elbistan A-Power Plant, TURKEY
IMPACT LINER PLATES
Current Version Test Version
Erdemir 3995 (Mild Steel)90 & 110 mm thicknessMaksimum 4000 h life time
Lamella Solution (HX500 + HX400)Same thicknessSingle plate design (HX500) is planned for serial production
Test is is ongoing, has started in Jan 2010
21
Hammers made by Hardox 500-600 for longer service life
Lamella hammer
Segments of wheel to smash lignite made by Hardox 600
• Segments of wheel to smash lignite before the coal will be transported to the fire.
22
Breaking wings in a lignite coal crusher
Description:For crushing the funded lignite before being transported on a conveyor.
Technical data:
HARDOX 550th The rotational speed in the crusher is
about 230U/min. Originally from St 37 and some hard
facing.
Dimensions and quantity:Thickness 30 mm. The crusher has 2 x 6 pairs of wings. Dimensions: 700 mm x 450 mm for each wing.
Operating Condition:Wing with armored St 37 950 h were in use before they had to be replaced. The HARDOX 550 wings must be replaced after 1100 hours in use.
Kontakt person:Detlef Semar, Senftenberg, Deutschland
Bild hier einfügen
HARDOX 550
Hammers by hardox 600
New hammer sultions with hardox
Makes it easier to replace and
tailor make the hammers in the míll.
Ball mill
Wear protection at inlet and outlet chutes
HARDOX 500
HARDOX 550
Hopper• Bottom part made in
HARDOX 400 or HARDOX 450
Lignite cyclone
Lignite is separated under high water pressure in a cyclone. Hardox 450 is used in the cylinder and cone
Lignite cleaning cyclone
It is used to wash coal and the main abrasive is iron powder.
The service life was max 6 months with 10 mm S235. The target is to reach 1 year with Hardox 400.
They will try 6 mm Hardox 450 in the chutes as well.
New Hardox cyclone Old worn out made by S235
Material flow - burning
Coal bunker
Ventilator mill
Coal crusher
Slag crusher Air
ventilator
Chimney fan
Slag conveyer
chain
Fly-ash separator
Wear plates in cleaning knivesThe oven doors evolves a coating of graphite material while processing.This graphite is machined off by the pressing box vessel.
Hardox 500 15 mm
Coal processing
• Grain size of the input coal is ca 30 mm
– 100 mm. All coal has to be crushed to
final granulity 0 – 2 mm.
• The crushing is normally provided in 2
stages (2 different types of crushers). First
stage is usually hammer crusher. Second
stage is normally ventilator mill or ball mill.
• Coal is not just coal! Coal contains ca
30% of another minerals (quartz, pyrit, illit,
ortoklas, plagioklas, chlorit ....). These
minerals are responsible for wear.
Material flow - desulfurization
Limestone stock
Conveyer
Limeston bin
Limestone crusher
Mixer
Pump
Inlet of flue gas
Chimney ventilator
Pump
Outlet of gypsum
chimney
Water inlet
By-products processing
• Slag has to be crushed to enable
useing it for another processing. Before
crushing is slag cooled down by water, so
the temperature is normally under 100°C.
• Slag contains SiO2 (quartz), Al2O3,
CaCO3, Fe2O3. Majority is quartz.
• For the crushing are used roller
crushers (see pictures). They are also
called teeth crushers. For the teeth rolls
can be used HARDOX 500, 550 or 600.
Thickness ca 20 mm.
• Because of high content of quartz
HX600 should be used. But we have also
good experiences with HX500.
By-products processing
• By-products from desulfurization
(gypsum) have to be also processed.
Substantial part of the process is in wet
condition, but also here could be HARDOX
used. We have positive experiences with
blades of compouder (HARDOX 500, 8
mm).
• Fly-ash is fine enough – no crushing.
Newerless it has to be transported, mixed
(with slag, gypsum ....).
36
The use of Our ProductSynergies Strip Plate
ELECTROSTATIC FILTERS
Domex 355 W
Raw meal conveyors
• Bucket elevator• HARDOX 400, 450
Raw meal conveyors
Other possible applications for HARDOX:
- Sprockets in HARDOX 500
- Reinforced chain parts in HARDOX 400 and 450
- Wear protection on elevator housing
Sprocket wheels
conveyor
Plates
Mild steel
HARDOX 450
chute
• Often made in hard faced material
• To compete with this we have try HARDOX 550 or maybe even HARDOX 600
HARDOX 550
HARDOX 600
Conveyor scrapers
• Chain of scrapers
• Sliding wear
Scrapers
HARDOX 400
HARDOX 450
Screw conveyors
Flanges made in
HARDOX 400
HARDOX 450
Flanges made in
HARDOX 400 or 450
Could also have wear protection plates on the centre axle
43
Damatech d.o.o.
Cesta Franceta Prešerna 63SI-4270 JeseniceSlowenien
T +386 5 923 55 00F +386 5 923 55 01E [email protected] www.damatech.com
Damatech GmbH
Wolfernstraße 20bA-4400 SteyrAustria
T +43 7202 70041F +43 7202 70042E [email protected] www.damatech.com
Damatech – certified Hardox Wearparts Partner