Since 2008 ABB helps Magaldi in developing reliable systems and solutions for bulk material handling

Magaldi Group and ABB.A partnership for growth and profit.

Success Story

The Magaldi Group, founded in 1929 in Salerno, is a leading manufacturer of industrial systems and plants for bulk material handling at high temperatures, particularly used for coal-fired power plants, cement industries, steel plants, foundries and metal refining plants. In recent years, Magaldi has also been producing large plants for generating electricity from solar photovoltaic. Magaldi Group's mission is to design,

manufacture and market reliable, high quality systems which are able to provide environmentally sustainable industrial solutions worldwide.

Since 2008 ABB helps Magaldi in developing reliable systems and solutions in bulk material handling, by supplying top quality control products and ensuring high level training of technical personnel.

Torrevaldaliga Nord, (Civitavecchia - Roma)

At the beginning of 2008 Magaldi won a “turn key” project from Enel SpA for the mill reject handling system thanks to its patented, well proven and dependable Magaldi MRS (Mill Reject System) technology.The MRS is a patented system designed for dry conveying of pyrites and other rejects from coal mills.The new plant of Torrevaldaliga Nord, owned by Enel Produzione SpA, includes three coal fired supercritical units (Unit #2,#3,#4) each rated 660 MW (gross capacity).

Each system is based on ABB 800xA Extended Automation, with one combined aspect-connectivity and operator station on one PC, connected to a redundant controller PM861 with approx 400 I/Os.

Systems startup completed in 2009-2010.

Ratnagiri J.S.W. Energy Ltd.Vill Nandiwade, Post-Jaigad, dist. Ratnagiri, Maharashtra (India)MAC for 4 x 300 MW thermoelectric power plants.

Magaldi developed the MAC - Magaldi Ash Cooler - a dry system to handle bottom ashes of solid fuel fired boiler without using water for the cooling process. This system allows to save millions tons of water and ensures a reliable operation of thermoelectric power plants.

Each system is based on ABB 800xA Platform for control of 2MAC, with redundant servers, two operator station, connected to two redundant controllers PM861 with approx 400 I/Os.

Project realization: 2010-2011.

An overview of the most significant projects

OPG1OPG Power Generation Pvt Ltd Gummidipoondi - Tamil Nadu (India)MAC dry bottom ash system for 80 MW thermoelectric power plant

System is based on ABB 800xA Platform, with one combined aspect-connectivity and 2 operator stations, connected to a redundant controller PM861 with approx 400 I/Os.System startup completed in early 2010

SMAL - Sarda Metals & Alloys LtdAPIIC, Industrial Park, Kantakapalli, Kothavalasa, Vizianagaram, Andhra Padesh (India)MAC dry bottom ash system for 1 x 80 MW thermoelectric power plant

Each system is based on ABB 800xA platform with one combined aspect-connectivity and operator station on one PC, connected to a redundant controller PM861 with approx 400 I/Os.System in commissioning phase.

GELAGela Refinery (a company belonging to ENI group).Site: Gela (CL)Pet coke handling system and MAC systems for three boilers

The system is handling all transportation and handling processes of pet coke up to the boiler storage silos.

In particular, the following activities are fully automated:

1- Extraction and drying of pet coke coming from hydrobins2- Loading of the storage house and dehumidification3- Picking up of the pet coke and transportation to the bunkers loading belts 4- Extraction and cooling of boiler bottom ash

PKS - Palm Kernel Shell E-ON Fiume SantoSite: Cabu Aspru (SS) Sardegna

PKS handling system for transporting the material from the storage house to the mill, consisting of belt conveyor, crushing and injection through 4 pneumatic ducts into the boiler, as a calculated percentage of the main fuel (coal), determined with a Magaldi special regulation algoritm.

The system is controlled with a ABB 800xA Platform with redundant servers (combined aspect-connectivity) and 2 operator stations, connected to a redundant controller PM861 with approx 700 I/Os.

System in final phase of commissioning.

Also used in this plant: FDC (flow dynamic conveyor). For transportation of pet coke at a given height, the FDC technology is applied, which consents to eliminate any type of emission to the environment of dust.

The control system is based on ABB 800xA Platform and in particular: redundant combined servers, 4 operators station, 3 redundant controllers PM861K02, totaling more than 1500 I/Os.System in commissioning phase.

For more information please contact: ABB SpALBU Control TechnologiesVia L. Lama, 33 20099 Sesto S. Giovanni (MI)E-Mail: controlsystems@it.abb.com www.abb.com

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