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Putzmeister High Tech for clean coal technology

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In 1989, Putzmeister supplied the Värtan heating and power station in Stockholm with 17 high density solids pumps of the KOS series as well as 1,050 m stainless steel conveying line with Putzmeister ZX flange systems. Among these pumps were 3 KOS 2180 which are the world's largest oil-hydraulically driven high density solids pumps for the transport of coal from the coal preparation plant to the power station ­ over a distance of 350 m and a difference in height of 50 m. 14 KOS 1070 pumps were also needed for the charging of the coal into the pressure-charged incinerators. The three pipelines (cross-section 200 mm, stainless steel) which run parallel from the coal preparation plant in the harbour to the power station, were supplied turn-key plus assembly. In spring 1991, the commissioning of the heating and power station was completed on schedule. Until then each of the Putzmeister pumps had worked for up to 4,000 operating hours.

The large models of the high density solids pumps are preferably used. The KOS 2180 has, for example, a stroke length of 2,100 mm and a delivery cylinder diameter of 280 mm. Approximately 130 l are conveyed with every stroke. With the output set at 46 m3/h, the frequency of switch-over is so low that the planned continuous operation of 6,500 operating hours during one heating period is possible. Even greater reserves are present with the injection pumps KOS 1070 to guarantee greatest availability. The switch-over frequency was halved once again in comparison to the transport pumps KOS 2180. The pumps as welll as the pipelines are of course monitored and controlled fully automatically by the control centre. Special demands on the dosing accuracy and also on monitoring had to be met. Especially with regard to mechanics and hydraulics, Putzmeister can also provide economical and special tailor-made

Pump hopper housing KOS 2180 with material inlet, service opening with flap and outgoing pipeline

Similar system: PFBC power station TIDD, Ohio River US with KOS 1070

solutions for its customers thanks to the extensive modular system. With its thorough planning and reliable technology, Putzmeister has proved again that thick pasty and abrasive media can be pumped over large conveying distances and differences in height. Furthermore, thus Putzmeister was able to contribute to the further development and success of new types of power stat-

Heating and power station Värtan with the two power station blocks in the middle of the picture (1) and the coal preparation plant in the harbour of Värtan (2)

No considerable wear has been determined so that Putzmeister kept its promise to ABB Carbon, the constructor of the power station, that operation would be maintenance-free for a complete heating period. Such a heating period in Sweden lasts 6,500 hours. The confidence placed

in Putzmeister high density solids pumps of KOS series was more than worthwile. At the end of 1991, Putzmeister received a larger follow-up order for a similar power station with 200 MW in Japan. 2

ions. Due to Putzmeister's comprehensive know-how in conveying and preparing coal and limestone mixes, Putzmeister is now offering complete coaling plants consisting of 2-stage mixer plants: for the correct pumpable mixes of coal, limestone and water as well as the coal charging pumps. Reliable Putzmeister technology pays for itself in every respect. The complete solution to the problem from just one source.

Reference list with technical data: pressure-charged fluidised bed incinerators

KS 64296, version August 1991 Project name / unit Heating and power station RWTH Aachen Customer Country Year of delivery Therm. performance Pressure charging Coaling pumps MW bar Steinmüller GmbH Germany 1986 40 max. 3.8 2xKOS 720, HA 30 Germany 1988 15 16 1xKOS 1040, HMC-R, HA 45 1,000 x 150 17.6 5 110 25 30 + 11 Sweden 1989 2 x 200 12 2x7 KOS 1070, HA 30 HMC-S Stroke x del. cylinder Stroke capacity Max. output2 Max. del. pressure2 Min. stroke time Performance of drive

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Experimental plant for fluidised bed incineration Friedrichsfeld Deutsche Babcock

Heating and power station Värtan, Stockholm ABB Carbon TIDD

Power station ABB Carbon US, Ohio. 1989 200 12 3xKOS 21801, HA 90 2,100 x 280 130 60 40 8 90 6xKOS 1070 HA 30 HMC-S 1,000 x 230 41.5 7-15 40 42 30

Pilot plant Karhula

Pilot plant Wakamatsu

Power station

Ahlström Finland 1988 10 max. 18 1xKOS 1030 HA 30 HMC-S 1,000 x 120 11.3 4 60 20 30

Babcock/ Hitachi Japan 1992 2 ­ 1xKOS 1020 HA 22 1,000 x 100 7.8 3 60 ­ 22

IHI/EPDC Japan approx. 1992 200 12 6xKOS 1070 HA 30 HMC-S 1,000 x 230 41.5 12 45 35 30

Coal injection pumps 2 x (6 + 1), KOS 1070 HA 30

mm l m3/h bar s kW

700 x 100 5.5 4 70 10 30

1,000 x 230 41.5 9-15 40 33 30

Coal conveying pumps, over a distance of 350 m and a difference in height of 50 m Design values, ratings depend on the consistency

Coal conveying system 2 + 1 KOS 2180, HA 90

PM pipe system ZX 200, stainless steel, ready for use, difference in height 50 m, distance 3 x 350 m Layout of the heating and power station Värtan with the coal preparation plant and the two power station blocks. Three KOS 2180 are conveying IP 1544-3 GB

Putzmeister Products and Services Concrete Pumps · Industrial Technology PIT · Telebelt · Mörtelmaschinen GmbH · Dynajet High Pressure Cleaners · Services · Concrete Project Division CPD · Consulting and Data Technology · Academy

Putzmeister AG Max-Eyth-Str. 10 · 72631 Aichtal P.O.Box 2152 · 72629 Aichtal Tel. +49 (7127) 599-0 Fax +49 (7127) 599-520 www.putzmeister.de E-mail: [email protected]

IP 1544-3 GB

Right to make technical amendments reserved · All rights reserved · © by Putzmeister AG 1999 · Printed in Germany (10710RR)

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In the Swedish capital of Stockholm, the plant constructor ABB Carbon have further extended the already existing power station by a further two blocks. After commissioning, this plant is to supply the major part of the heat needed for Stockholm. It is scheduled to heat 240,000 tonnes of coal a year. The plant is situated in a densely populated city area of Stockholm. Despite a considerable expansion in capacity, the Värtan works will not burden the environment any more than before the alterations. This has been made possible by the fluidised bed incineration which is noted as being especially environmentallyfriendly. By adding limestone to the coal, the sulphur is already bound during the burning process. The low calorific intensities possible with fluidised bed incineration keep the emissions of nitrogen oxide far below the legally admissible limit values. It is also possible to burn almost all qualities of coal in a fluidised bed incinerator ­ also fuels of lower quality. The pressure-charged fluidised bed incineration provides further combustion technical advantages. As the combustion is carried out under pressure the volume of the burning chamber ­ and therefore also the investments ­ can be reduced. The combination with the gassteam-turbine process additionally results in an even higher efficiency of combustion in comparison to traditional atmospheric combustion processes. The greater efficiency means that the fuel

required and the emissions of carbon dioxide are reduced by 10 ­ 15 %. The coal is not prepared in the power station itself but in the port of Värtan nearby (see fig. 1). It is stored in an underground with former oil store. At the quay it is prepared with limestone and water to form a pumpable mix. Different crusher stages, screening devices and mixing devices are necessary for this. Two large-volume high density solids pumps KOS 2180 pump the coarse grain coal limestone water mix into a pipeline, laid in a pipe bridge and an underground tunnel, to the power station. A third pump of the same type is at "stand by" and with the help of an hydraulically operated transfer tube can fully automatically take over the work of one of the other two within a very short time. For the conveying of coal to the power station, the KOS 2180 must not just cover 350 m horizontally but also a difference in height of 50 m. They are designed for an effective output of 46 m3/h respectively in continuous operation under a delivery pressure of 40 bar. The whole system consisting of pipelines, flange couplings and transfer tubes made of stainless steel was installed in situ by Putzmeister. It was handed over turnkey along with the pumps. Six smaller high density solids pumps KOS 1070 inject the coal, limestone and water mix into the two pressure-charged fluidised bed incinerat3

Sectional drawing KOS 1070 with HMC-S shut-off valve and main components such as control box, oil-to-water heat exchanger, oil tank, oil pump block in inline version, material feeding, slide frame

Putzmeister High Density Solids Pumps ­ well-proven technology: High Tech for power stations The technical concept suggested by Putzmeister ­ the combination of the KOS pump already proven 10,000 times with its S-transfer tube and the postpiloted shut-off organ HMC-S, has proven itself completely at Värtan. It combines the well-known advantages of the Stransfer tube pumps such as the excellent material suction behaviour ­ (the full diameter of the delivery cylinder opening is always available) ­ with the necessary security that flow-back of the medium during switch-over of the transfer tube is prevented. To prevent the return flow, the hydraulically actuated HMC-S-valve is shut off just for a short time at the decisive moment. Hardening of the material of the sharpgrained coal and thus increased wear are thus safely avoided. If coal with even coarser grain is to be pumped, as necessary at other power station projects, a HMC-R valve with rotary segment valve is used and an agitator is

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installed in the hopper housing for improved suction of material (see fig. 7). This combination has also proven itself in the meantime in continuous operation for over several thousand operating hours. At the same time it was proven that hydraulically controlled valve pumps are hopelessly overcharged for this type of work.

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File under: A 1.00, A 4.00, IP 4.05

One of the three KOS 2180 HA 90 which pumps the coal mix from the preparation plant to the power station

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Coaling pump KOS 1070. The special HMC-S-valve positioned after the pressure outlet prevents a back-flow of material is delivered surge-free

ors (max. 12 bar). Two further KOS 1070 pumps can be used at short notice when, for example, inspection work has to be carried out. In such cases the pumps are

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placed on the wheels supplied and driven out of the slide frame. This is carried out between switching off and on again ­ just a matter of two hours.

3 hydraulic power packs HA 90 (90 kW) for the drive of the KOS 2180 coal transporting pumps. Sound protection hoods for max 85 dB(A) at limit load 7

Coal samples with different grain sizes and contents of dry solids ("Värtan coal" at the front, on the left)

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coal

limestone

pressure-charged fluidised bed incinerator 4 ­ 20 bar

flue gas

Coaling of pressure-charged fluidised bed incinerator

High pressure ZX-type

gas turbine steam turbine

ZX

water pre-mixer

steam

air

post-mixer shut-off valve fluidised bed ash

turbocharger district heating

ZXS

HMC-R KOS

condenser

compensator

KOS

high density solids pumps hydr.-drive

S Version Screw

HMC-S

pre-heating Flow chart, combined gas-steam turbine process, pressure-charged fluidised bed incinerator (ABB Carbon)

Flow chart for combined gas-steam turbine process and central heat supply IP 1544-3 GB

Putzmeister transfer tube GBH/4-2, ZX 200 stainless steel, oil-hydraulically driven. The third stand-by pipeline is automatically switched to the power station blocks 1 or 2

Combination of KOS with HMC-R Valve (rotary segment valve) for coarse coal mixes with reduced share of fine grain

The Putzmeister ZX coupling system with spigot couplings, projection and groove, and the O-ring seal which has proven itself so well IP 1544-3 GB

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