For a long time, and well into the future, coal will remain an important source of energy. This is especially the case in an era when nuclear power has once again become a political focus. Therefore, it is important to transport and handle these large quantities of dry bulk goods as efficiently as possible. For many years reputed German crane manufacturer Ardelt, with its headquarters in Eberswalde near Berlin, has specialized in this task.
Ardelt is the pioneer in this field with its double jib level luffing cranes ‘Tukan’ and ‘Tukan Kangaroo’ with an integrated bunker. In both versions, the Tukan demonstrates top productivity with enhanced energy consumption and minimal maintenance costs. The company’s products are the result of decades of experience in goods handling — as more than 4,700 cranes supplied worldwide prove. Continuous technical development, using top-quality, reliable components, leads to consistent improvements and higher through-put in handling capacity.
Site conditions and requirements dictate whether ship unloaders or double jib cranes are the best option technologically. At the moment, in inland terminals and seaports, double jib level luffing cranes are generally used with a capacity up to 1,500tph (tonnes per hour). Typical examples are the cranes supplied by Ardelt in 2011 for Microca in Lu¨nen, Germany. These cranes will be used to supply coal to a new power station. However, double jib level luffing cranes tend to be used in a performance range close to ship unloaders. For example, in December 2011, two Tukan Kangaroo cranes were delivered to Rhenus-Logistik AG in Wilhelmshaven, Germany, one of Europe’s leading logistics companies. They were installed for
unloading coal ships on the unloading pier (Niedersachsenbru¨cke), right next to the Jade-Weser Port currently under construction. These machines are deployed to supply coal from abroad to two coal-fired power plants. Based on the discharge of a 230,000dwt Capesize vessel, the free- digging capacity is 1,750tph, while peak capacity is more than 2,000tph per crane.
The design of these Tukan cranes ensures optimum energy efficiency. Unloading is via the shortest load path with the lowest energy consumption, the lowest maintenance and repair costs and noise emission.
Minimum energy consumption is based on purely electric operation with the associated high energy-efficiency. The jib geometry provides a balanced system and the pivot points are fitted with anti-friction bearings. Energy losses from the movement of dead loads, which occur in the jib system of single- jib cranes and the trolley of ship unloaders, are avoided. Energy recovery units are installed on Ardelt cranes as standard. The energy to be recovered when lowering the grab is available for other users of electricity on the crane and any surplus power will be fed back into the main power grid.
Wear and tear is minimized due to the controlled electrical drives and gentle, solely electrically-controlled acceleration. Rope guidance on double jib level luffing cranes is optimized so that ropes usually only need replacing every two to three years, or after handling more than three million tonnes. All in all, these factors lead to low maintenance and repair costs.
Customized solutions are becoming more and more important, especially for dry bulk-goods handling. In addition to focusing on crane efficiency,Ardelt spent years concentrating on reducing emissions (noise and dust) from these machines. The kangaroo crane’s method of operation is almost noise-free. Resonance in the supporting structure of the ship unloader, caused by the trolley movement, cannot occur. In addition, the hoisting gear is virtually noise-insulated through the machinery house. Externally mounted drives, such as the luffing gear or travelling gear, do not operate in the field-weakening range. Therefore, with double jib level luffing cranes, stringent noise prevention requirements can be complied with.
Growing environmental regulations demand intelligent solutions for reducing dust emission in dry bulk-goods handling. Ardelt offers a comprehensive range of dust prevention solutions. Depending on the requirement (determined by the dust properties of the goods handled) this product portfolio includes solutions from entirely mechanical dust prevention to vacuum extraction systems. The total energy consumed does however play a pivotal role in which dust prevention measure is selected.
Ardelt supplies bunker systems with high, specially designed dust prevention walls. Due to their shape, these walls prevent or minimize dust emission only by mechanical means. The discharge height above the bunker grating is optimized via the semi-automatic control system. As a result, any uncontrolled dust generation is excluded. In addition Ardelt recommends using closed grabs. These measures reduce dust emission without incurring an additional energy cost. Ardelt designs the bunkers so that other dust prevention measures can be retrofitted at any time and at minimum cost.
The Tukan Kangoroo cranes in Wilhelmshaven have grab depth optimization which has been patented by Ardelt. This feature allows optimal utilization of the lifting capacity over the whole outreach range of the crane, using just a single grab. Grab depth optimization controls filling grab, depending on the outreach. Grabs with a greater capacity, designed for the crane’s main operating range, can be used over the whole outreach of the crane. The handling capacity can be increased without any additional cost to the customer.
Grab depth optimization offers even more benefits. This system will prevent overloading the grab due to a higher density of the bulk good. While working near the floor area in ships or wagons during cleaning, damage to the floor is also prevented.
The Tukan double jib level luffing cranes are state-of-art goods-handling machines that offer high performance and operate efficiently and dependably. Due to their optimum energy consumption and their low emissions, in terms of environmental protection they tick all the boxes. Even though they are operated mainly in dry bulk-goods handling, these slewing cranes offer the very decisive additional benefit of flexibility. They are multi-purpose cranes, which can also be used at any time for handling many different types of general cargo.
Wherever bulk material — including coal — is handled, Sandvik Mining is present. In addition to meeting the needs of the mining industry, the company also excels in meeting the needs of downstream operations, such as power plants and mills, ports and terminals with an approach tailored for each application.
Reclamation, stockyard storing, sizing, homogenization and transportation are all materials handling processes Sandvik supports. The offering for turn-key projects, individual new equipment or upgrades and modernizations includes consulting, systems design, engineering, procurement, erection and support. Sandvik applies materials handling and automation technologies to help customers best utilize their assets. Additionally Sandvik designs and manufactures a full range of conveyor components like idlers, pulleys, belt cleaners, etc. used in materials handling equipment, whether for new systems or replacement parts for any existing system. The goal is to make the customers more successful through long-term cooperation and partnerships; success comes from efficient process design, innovative engineering and a dedication to reliability. Through the well developed Sandvik Mining organization, global parts logistics and local services keep the continuous materials handling processes running.
BULK MATERIALS HANDLING SYSTEMSSandvik Mining’s Materials Handling business offers all services related to bulk materials handling, including feasibility studies, conceptual plant layouts, design, engineering, and the entire execution of complete systems to handle coal, ore, bauxite and other different materials — a vast range of equipment for applications such as the following:
y conveying, stacking, reclaiming and blending of bulk materials; y loading bulk materials into ships; y unloading bulk materials from ships; and
y crushing, sizing and feeding of bulk materials. This offering supports the continuous transfer of the material
in various fields of materials handling solutions, whether as individual machines or as complete turnkey installations. The classical application of these systems and machines relates to stockyard facilities at mines, at export and import ports and in stockyards of power stations, steel works and processing plants. According to the requirements of the downstream consumer, Sandvik’s systems can reach output rates up to more than 10,000tph (tonnes per hour).
COMPLETE HANDLING SYSTEMS FOR PORTSAll around the world, sea-going and coastal vessels are constantly being loaded or unloaded with different bulk materials. In order to ensure a thriving international sea trade, to load the material at the export terminal and unload the vessels in the import terminal, to store the material at the ports continuously and in a very short time, a high standard of perfection in port-handling methods is needed — an area where Sandvik has a vast experience.
Sandvik ensures a smooth transfer to and from bulk terminals with a complete offering of reliable ship unloading and shiploading equipment.
Many different developments for all capacities and applications are included in Sandvik’s range of shiploaders which provide traveling, telescopic, luffing and/or slewing as well as radial functions. The ship unloading of high-density bulk material at fast flow rates is conducive to the company’s offering of grab-type unloaders of gantry or level luffing design. For the intermediate storage of bulk materials in ports, Sandvik’s complete range of stockyard equipment and systems incorporates stackers, reclaimers and stacker/reclaimers.
The equipment can be supplied with various modes of operation, including manual operation by onboard operators, semi-automated and fully-automated operation integrated in a central, remote control system.
SHIPLOADERS (PL SERIES)Sandvik linear gantry and quadrant bridge type shiploaders are constructed in proven, eco-friendly designs with a wide range of sizes to service vessels from 5,000dwt to 250,000dwt. Central to the Sandvik philosophy is minimal disruption of the port during installation of the shiploader and its supporting equipment. Sandvik’s process for off-site construction, assembly, testing, commissioning and heavy-load transportation is highly advanced, resulting in installation of fully operational shiploaders with capacities up to 20,000tph in just a few days. The range includes a variety of shiploaders which provide travelling, telescopic functions, luffing and/or slewing installed onto longitudinal jetties, or radial shiploaders which incorporate a fixed pivot point.
SHIP UNLOADERS (PU SERIES)Sandvik ship unloaders of the linear gantry and level-luffing types
are constructed in proven designs and a wide range of sizes to service vessels from 5,000dwt to 250,000dwt. Focusing on grab technology, they offer efficient, rational solutions to demands for quayside flexibility and are the perfect rigs for unloading materials with different bulk densities.
As with continuous ship unloaders, they can be constructed, assembled, tested and commissioned off-site if necessary, then shipped to site and installed with minimal disruption to port activities.
AUXILIARY EQUIPMENTSandvik’s product portfolio of standard equipment for bulk materials handling applications covers HC-series belt conveyors and HF-series belt feeders, both having fixed and mobile units. With a wide range of standard modules and components these devices can be tailored exactly to meet the needs of the application. The advantages of the mobile equipment make them ideal and cost-effective in conveying and stockpiling materials.
COMPLETE HANDLING SYSTEMS FOR STOCKYARDSStockyards, either as a circular or longitudinal layout incorporating particularly feed
conveyors, stackers and reclaimers, have a central function in the fields of materials handling as they serve as material buffers, reserve or blended storage between incoming and outgoing materials. As buffering, composing and homogenizing performed by a stockyard can vary quantity as well as quality fluctuations can be balanced out with the correctly chosen system. As the priorities for each application and stockyard operations are different, it is necessary to consider various questions before selecting type and size: throughput required, characteristics of the materials to be handled, homogenizing effect required, open or roofed storage and importantly, the future upgrading of the storage. Sandvik offers a complete range of products to provide customized solutions for each customer’s specific requirements. The equipment comprises:
- reclaiming technology for bucketwheel boom type-, bucketwheel bridge type-, scraper type-, drum type units;
- stacking technology for the most commonly used stacking methods: chevron, windrow and coneshell;
- combined stacking/reclaiming technology for bucketwheel or circular units;
- conveying technology including transfer stations; and
- auxiliary equipment with hoppers, feeders, crushers, etc.
Covered storage is used where environmental aspects require the full enclosure of the stockpiles and stacking and reclaiming activities. It can either be arranged in the form of a longitudinal/rectangular configuration or in a circular configuration covered by dome-type structures.
STACKERS (PS SERIES)
Sandvik stackers effectively stockpile bulk materials in an efficient and orderly manner. Stationary or traveling, borne on rails or crawlers, they can be supplied in fixed, luffable or luffable-and- slewable boom designs, with capacities from 150tph to 20,000tph. The choice of design depends on factors such as the stacking method and size of the stockpile, the type of material, the required throughput and the demand for mobility. Tripper cars or tripper systems for transferring material from the yard conveyor to the stacker are considered part of the stacker.
RECLAIMERS (PR SERIES)Sandvik reclaimers are designed to reclaim bulk materials from stockpiles at mines, ports, steel plants, power stations, etc. in a quick, efficient and orderly way. They are available in several main types, including bucketwheel, scraper and drum-type reclaimers, and in many configurations and sizes, with capacities from 500tph to 20,000tph and more. The choice of design
depends on factors such as the size and shape of the stockpile, the type of material to be reclaimed, the required reclaiming rate and the need for blending or homogenization.
STACKER/RECLAIMERS (PD SERIES)Sandvik stacker/reclaimers come in two main types: bucketwheel models for alternate stacking and reclaiming, and circular units, which normally stack and reclaim the material alternately but can be designed to do so simultaneously if required. The bucketwheel models, normally supplied complete with tripper cars, are compact and economical for longitudinal stockyards where simultaneity is not required and where there can be large variations in the demand for stacking and reclaiming capacity. Standard circular units, which build a ring-shaped stockpile and are normally housed inside a covered dome because of environmental aspects, both continually stack the stockpile at one end of the ring and reclaim the material simultaneously from the other end.
TRANSPORTATION SYSTEMS (PC SERIES)Sandvik has a highly skilled projects division specializing in the design, manufacture, installation and commissioning of conveyor systems for a full range of applications. The company also upgrades and modernizes systems and supply a comprehensive range of its own quality components and spare parts.
ABOUT SANDVIK MININGSandvik Mining is a business area within the Sandvik Group and a leading global supplier of equipment and tools, service and technical solutions for the mining industry. The offering covers rock drilling, rock cutting, rock crushing, loading and hauling and materials handling. In 2010 sales amounted to about 27,200 MSEK, with approximately 12,800 employees (pro forma rounded numbers).
Maintaining material quality from truck to vessel with Superior Industries
One key objective for any handler of bulk material is to minimize or eliminate material degradation. Degradation occurs when there is a breakdown in the integrity or quality of bulk materials. The
problem is expensive to fix and can generate unwanted and unpopular dust and debris.
“One of the chief triggers of material degradation is multiple handlings,” says Bob Domnick. Domnick is the vice president of engineering at Superior Industries. The Minnesota, USA-based conveying equipment manufacturer builds a variety of solutions for bulk material handlers including telescoping conveyors, portable truck unloaders and tripper conveyor systems.
“It is important to avoid degradation, especially when loading finished product onto a ship,” he says. “In coal applications, degradation comes in the form of fines and it is no secret that coal contaminated with fines is enemies to power plants.”
In 2005, Superior engineers developed the RazerTail
® Truck Unloader, a portable machine to help shiploading companies and other bulk material handlers move product from truck to vessel or stockpile via a single feed point.
“Traditionally, trucks dump material onto the dock and then transfer it to a feed hopper with a loader,” says Domnick. “In this common scenario, the chances of significantly contaminating material are pretty high.”
Apply a RazerTail truck unloader into this same application and belly or end dump trucks simply position themselves over the hopper and empty their loads. Superior says the machine can handle a 20-tonne dump truck in a cycle time of less than one minute. From there, the material is transferred to a portable ship loader or stockpiling conveyor like Superior’s TeleStacker
® conveyor.
“Historically, portable truck unloaders transfer small amounts of material at low rates, but the RazerTail truck unloader is designed to handle considerably higher production rates,” says Domnick. “We have manufactured units to move material up to 1,650tph (tonnes per hour).” Superior manufactures a wide range in this product line including belt widths of 48-inches and 72-inches with grate openings to accommodate material sized from 2-inch minus to 8-inch minus. The company says a popular trend is to include a power- folded, adjustable height discharge conveyor to control the height of the head pulley or transfer point elevation.
“Our engineers designed a very practical, low-profile machine,” says Domnick. “It allows for liberal truck movement on docks and uses limited real estate in the tight environment.”
Domnick says it is quick and easy to move the machine in and out of production as well. Simply pull into place with a truck and equip the unit with supplied steel ramps to allow truck traffic to enter from one side of the hopper, unload and then exit straight ahead.
“There is still a lot we can do to make the machine even more mobile,” Domnick says. “Some ports that may
benefit from self-contained, track-mounted units that move laterally along the ship. Our TeleStacker conveyor moves laterally, so it makes sense to equip RazerTail truck unloaders with the same abilities for added portability.”
Basically, Domnick reports that Superior is eager to explore new ideas with potential customers who can benefit from the features of the RazerTail truck unloader.
ABOUT SUPERIOR INDUSTRIESEstablished in 1972, Superior Industries
has a reputation of engineering and manufacturing groundbreaking, bulk material handling conveyors and cutting-edge components. From its headquarters in Morris,
Minnesota, the American manufacturer serves a diverse group of industries with portable stackers, transfers and feed systems; material processing plants; plus idlers, pulleys and accessories to lower operating costs and increase material production.
Partnership and long-term business in an expanding world
Uno Sundelin, Bosch Rexroth AB, Industry Sector Director for Mining and Materials Handling, gives details about origins, trends and growth at the company.
Bosch Rexroth is a global supplier of solutions and services in many different business areas, for example bulk materials handling. The company has a strong presence in most parts of the world, and particularly in rapidly developing areas such as China, India and Brazil. Thanks to the extensive expertise and worldwide coverage, the group can offer efficient co- ordination of operations, provide technical engineering and project and service support to customers anywhere in the world.
Bosch Rexroth’s bulk handling equipment can be used to handle a variety of commodities, including coal.
“We’re easy to reach for our customers, providing systems and solutions, knowledge about equipment and products as well as technical support and service. We basically offer local access all around the world,” says Sundelin, who has many years of experience with the industry from his days at Ha¨gglunds Drives. Ha¨gglunds has been part of Bosch Rexroth since 2008 and the responsibility for supporting and developing bulk materials handling business now rests in Mellansel, Sweden.
MARKET TRENDSBosch Rexroth expects a strong growth in the demand for materials handling equipment and machinery over the coming years. Present handling capacity for coal, iron, copper and gold ore, for instance, is clearly below the required level. The additional capacity that is needed to meet the increased need for handling of materials will drive the demand for systems and solutions, an area where Bosch Rexroth has a strong position on the market.
“Many countries and regions show a growing need for more efficient infrastructure with a much greater capacity. In India, China and South America, for example, they are expanding ports, railways, urban underground systems and roads to cope with the growing transport needs for people and goods. This, in turn, means rising demand for cement and steel for concrete and other constructions, and consequently demand for the systems and solutions that produce these materials,” says Sundelin.
Another trend is the market’s growing interest for extended partnerships. Customers are more and more looking for suppliers who can not only deliver reliable equipment, but also provide feedback, take an active role in development and supply new products and solutions.
“It’s all about being truly interested in the everyday work of our customers and finding the right solutions for their business. We have lots of good experience from working closely and openly with our customers, which means paying close attention to the needs of the customer, and we have good examples of such partnerships, all over the world, for example with end users in Australia, Brazil and Sweden.”
Bosch Rexroth actively provides support to consultants and customers to ensure the best possible design, performance and process, which has led to increased interest from a growing circle of customers. According to Sundelin it’s exactly this that has given the company the strong market position it has today.
“The many benefits that our solutions give the user has lead to that customers often request and specify us as a supplier in their tenders. We see this particularly in situations where reliability and up-time are of high priority,” says Sundelin. “Our global network of expertise and long experience of the market is of course also an important contributing factor,” he says.
REFINED SOLUTIONSTo satisfy customers’ needs even more fully, Bosch Rexroth offers its materials handling customers optimized application solutions, by using all the knowledge and experience of the group and by truly knowing the needs of the customers. This experience is further used to develop solutions and products that are helping customers to improve processes and machinery so that they operate as efficiently as possible.
“We’ve worked very successfully with solutions for bucket wheel reclaimers for several years, focusing on using Ha¨gglunds drive systems for the bucket wheel. By exploiting all the resources of Bosch Rexroth, we can now supply solutions for all the primary functions of these machines, including slewing, lifting and lowering the boom, rotating the bucket wheel rotation as well as moving the machine itself. We develop package solutions that integrate all these functions in collaboration and consultation with end users and OEM customers,” says Sundelin.
Several other package solutions are also popular with users and OEM’s. The Bosch Rexroth solutions for active tensioning of long conveyor belts and complete systems for railway car tipplers are other examples of solutions that are often requested.
“The ability to provide good service is very important to fulfill a good partnership. We will continue to deliver the best possible support by installing equipment, optimizing users’ processes, maintaining equipment and assisting with reinvestment and upgrades. Our strong service organization can, with its global set up, deliver comprehensive service to our customers, wherever they are.”
N.M. Heilig B.V. equipment suitable for many commodities including coal
N.M. Heilig B.V. is a specialist in designing, developing, producing and building bulk handling systems.
N.M. Heilig B.V. organizes and executes all project activities in accordance with ISO 9001 quality system and is as contractor VCA-certified as well as for assembly.
Due to its extensive experience and expertise, it can customize its equipment to guarantee the precise material handling properties and output required by its customers. Many of Europe’s major companies have called upon the expertise of N.M. Heilig B.V. to supply, maintain or inspect their bulk handling installations. The company’s scope of work begins at concept development, and continues right through to installation.
Among the heavy duty coal handling equipment offered by N.M. Heilig B.V. are: y long distance belt conveyors (within tripper systems if
requested); y slat conveyors; y chain conveyors; y screen machines; y storage and dosing bunkers; y coal-drying installations; y shiploaders; y railcar loading systems; y truck loading systems; y loading bellows; y mobile loading equipment such as conveyors and screens
(on tracks or wheels).
N.M. Heilig B.V.’s major clients are mainly made up of major European coal handling companies and dry bulk terminals in the bigger ports. The company’s European competitors are mostly German multinational corporations which also deliver major turnkey systems.
N.M. Heilig B.V. prides itself on high levels of customer service. It always strives to offer customer-tailored solutions, with all parameters considered and studied by the highly skilled engineers of N.M. Heilig B.V. The company believes that its strength lies in the fact that it has greater flexibility than some major suppliers, and less bureaucracy, without any shortcomings in quality assurance and quality control. It does not have a ‘9 to 5’ mentality. It is cognizant of the fact that its clients need high-quality, well-designed, durable equipment in order to be able to make money. It therefore supplies mainly custom-made equipment and installations while at the same time also maintaining its own standards in its delivery programme.
N.M. Heilig B.V. has just opened a new (100% owned), major production facility with state-of-the-art machinery in Slovakia, with a home grown Dutch/German management. This new set-up enables the company to manufacture its equipment at low production costs while maintaining the high standards and certifications that the
company always adheres to. N.M. Heilig has several subsidiaries in the Netherlands, Germany, Poland and Slovakia, so it is always close to the market and able to serve its customers.
Among recent contracts are several mobile loading systems for a coal terminal in Rotterdam (the Netherlands), together with a long distance conveyor. N.M. Heilig B.V. has also received a contract award for a large mobile screen machine for a coal handling company in Northern Europe.
Deals currently being negotiated include the delivery of new shiploaders, railcar loading systems, long-distance belt conveyors and mobile equipment for other clients in Germany, the UK, Bulgaria and Russia.
The company has in recent years garnered more interest in, and respect and enthusiasm for, its mobile equipment, and many of its customers use its mobile equipment for their bulk handling operations.
Liebherr four-rope ship cranes chosen for offshore coal transshipment project
One of the world’s leading logistic companies has selected ten Liebherr heavy duty four-rope grab cranes type CBG 350 for installation on its two new tailor-made 55,000dwt offshore transhipping vessels. A well-known and highly successful Italian company won this offshore coal transhipment project, which is one of the biggest ever awarded and foresees the handling of approximately 11mt (million tonnes) of coal per year off the shores of Mozambique. The first vessel has just been put into operation and the second will be completed during the first half of this year.
Offshore transshipping facilities are the ideal solution when port infrastructure does not allow for the direct loading of large Panamax or Capesize vessels. This may be due to limitations in the port itself or draught restrictions in access waters, as is the case in this project. Depending on tidal depths the average load for the transshipper will be 44,000 tonnes of coal, which will then be transshipped to open waters, where it will be transferred to ocean-going vessels of up to 180,000dwt using the five Liebherr four-rope grab cranes (one for each hold). The transshipper will be loaded using onshore conveyer belts. During this time the Liebherr cranes are parked towards the aft of the vessel, whereby an interlock device is installed in the slewing column and the jib is rested on a console positioned to the side of the pedestal of the next crane.
This locking system allows for the jib to be parked (or locked) without having to dismount the four-rope grab and so saves valuable time when putting the cranes into operation and/or when storing the cranes for the short journey between port and ocean going vessel and return.
The Liebherr CBG 350 is a dedicated heavy duty high performance four-rope grab crane. Designed for high speed continuous operation, these CBG cranes incorporate specific features for heavy duty conditions and operation in open water, including compact slewing column design, specially designed heavy duty hoisting winches, heel trim alarm systems and emergency operation functions. Additionally, an extended cabin ensures optimum visibility of the hold for the operator leading to safer and more efficient operation.
Safe and precise crane operation is further supported with Liebherr’s own Litronic
® crane control and management system. Litronic® facilitates smooth and high speed operation as well as
preventative maintenance. Amongst other information the load indication and limitation as well as the load recordings are displayed. The machine data is recorded, including alarms and failures, and service and inspection intervals can be determined. Optionally, modem access is available for remote fault-finding through skilled Liebherr engineers. The software is available in several languages.
With the design focus on maximum operating capacities and minimum maintenance and life-cycle costs the Liebherr cranes are ideally suited to this round-the-clock working cycle.
CoalTek wins first Sino–US clean coal joint venture approval in China
CoalTek/Yijian partnership’s next generation clean coal processing facility has now been approved and is fully licensed by all required People’s Republic of China provincial and municipal authorities.
In November last year, CoalTek Inc., a Massachusetts-based clean energy company that uses proprietary technology to create highly efficient and environmentally friendly clean coal from low-value brown coal, announced that its clean coal processing facility in Inner Mongolia has received final approval from all requisite regulatory and governmental authorities in the People’s Republic of China (PRC).
CoalTek’s approval marks the first successful completion of the rigorous PRC environmental review and engineering examination by a clean coal technology company. Total investment in the Joint Venture (JV) project is expected to exceed RMB 2.4 billion — more than US$350 million. The facility will initially produce 10mt (million metric tonnes) of processed high quality fuel per year, transforming low-grade brown coal into high-thermal value coal that burns more efficiently and produces lower emissions. In anticipation of future demand, the facility has been designed with infrastructure that will allow for seamless expansion beyond the currently planned scale.
CoalTek will own the facility in a 50:50 JV with Yijian Group Co., Ltd., a Chinese corporation with wide ranging energy and asset holdings. Cynergy-Global, LLC served as International Advisor and played a key role in leading the CoalTek efforts to identify prospective JV partners, structure the JV partnership, prove the technology to both the commercial and scientific communities, and meet all financial and regulatory requirements. These collaborative efforts ultimately led to the successful approval of the CoalTek/Yijian JV.
CoalTek’s approval comes only after a comprehensive review of the CoalTek technology by the Chinese government, whereby the company was required to demonstrate industrial-scale capability that is also compatible with the Central Government’s focus on energy efficiency and ‘environmental friendliness’. After clearing the energy and environmental hurdles, CoalTek also had to demonstrate the project’s financial viability and overall positive economic impact on the Inner Mongolia Autonomous Region.
The CoalTek-Yijian JV represents the first fully licensed Sino–US commercial partnership since the 2009 signing of a bilateral Strategic Partnership Agreement by Chinese President Hu Jin Tao and US President Barack Obama. The bilateral agreement is comprised of several far-reaching measures to strengthen co-operation between the two countries on clean energy research, development, and implementation. The Chinese government has pointed to the agreement as a reflection of the country’s eagerness to share with and learn from its US partners regarding the application of commercially viable clean tech and green tech solutions.
“This approval by the Chinese government is a testament to the strength of the CoalTek-Yijian partnership. Through the support of the PRC, the Inner Mongolia Autonomous Region and the Erdos and DeLaTe District governments,this example of the growing China–US collaboration on energy technology enables an environmentally friendly platform to better utilize indigenous resources such as low-thermal value brown coal,” said Chris Poirier, CEO of CoalTek. “The PRC has demonstrated its commitment to the very highest
environmental and efficiency standards, and we look forward to meeting those standards while delivering value on this project through the deployment of our unique and proven technology.”
“We are very proud to be the first, and thus far only, Sino–US joint venture approved in the clean coal arena, which is one of the top areas targeted by the US-China Strategic Partnership Agreement signed by President Hu Jintao and President Obama in 2009,” said Mdm.Yang Shaolin, managing director of Yijian Group Co., Ltd. “We are very excited about the strong support we received from all levels of government and industry leaders in the PRC. This endorsement, after such a rigorous and thorough approval process, confirms what we have always believed: CoalTek’s technology offers unique advantages that enable industrial-scale projects to come to market and help meet the growing global demand for cleaner, more efficient energy.Through our strong relationship,CoalTek andYijian will deliver on this commitment to protect the environment and natural resources in Inner Mongolia.”
“CoalTek andYijian partners have chosen to work closely with all PRC experts and regulatory agencies to ensure this project aligns with the government’s stated goal of meeting growing energy needs while being responsible global partners,” said GeFei Li, co-founder and PRC Managing Partner of Cynergy- Global, LLC.“CoalTek’s technology received strong support from Chinese government partners throughout the approval process because the company proved that it could bring a well-tested, industrial-scale, environmentally friendly technology to the market. The CoalTek-Yijian partnership is looking forward to delivering the promise of clean coal and increased efficiency in China.”
ABOUT COALTEKCoalTek uses proprietary, commercial-scale technology to create highly efficient and environmentally friendly clean coal from low- value brown coal. The technology, originally developed in-house by co-founder Dr. Jerry Weinberg, is owned and patented by CoalTek. The company’s microwave-based processing system offers the only proven solution that can cost effectively convert low-cost, clean-burning brown coals into low-emission, high- energy coal. CoalTek commissioned its first commercial-scale processing facility in Calvert City, KY in 2007 and has executed and received regulatory approval for a joint venture in the People’s Republic of China. The company has several additional large-scale partnerships in the PRC and other coal-dependent geographies poised for near-term execution. CoalTek is headquartered in Marlborough, MA.
Mining industry solutions: Beumer moves coal with curved belt conveyors
Modern mining technologies require belt conveying systems that are capable of moving increasingly large volumes on growing centre distances across impassable and mountainous terrain, particularly in the branch of coal mining. The Beumer Group, a major international manufacturer in the field of conveying technology, develops and installs such systems.
Companies require effective options for transporting bulk goods such as coal from the mine to the power plant. Transportation by truck is expensive and has a negative impact on the environment. An economical alternative is a continuous conveyor, such as troughed or tubular belt conveyors. With the
right design, these conveyors can be optimally adapted to the environmental conditions. Pollutants such as dust, noise emission and exhaust gases are minimized or even eliminated. By comparison to transportation by truck, large mass flows can be transported. Even in difficult environments, the construction work for these systems is minimal.
INDIVIDUAL ADAPTATION TO THE MATERIAL
The Beumer Group designs and implements such conveying systems. Beumer belt conveyors are used as closed tubular belt conveyors or as open troughed belt conveyors. The open troughed belt conveyors are especially used for robust and coarse material.
Due to their routing, the belt conveying systems negotiate rugged terrain and other obstacles, such as rivers, streets, buildings or train tracks. This reduces the costs of moving earth and expensive transfer points are significantly reduced. Horizontal and vertical curves can even overlap.
Beumer can offer an appropriate solution for every challenge. Tubular belt conveyors are particularly suited to negotiate steep slopes or inclines. They are suited for high quality or powdery materials. Inside the closed system, the material does not fall backwards and the excellent sealing allows the material to be transported dust-free. Beumer’s tubular belt conveyors are used for particularly tight curves, as they are able to better negotiate curves than troughed belt conveyors. The troughed belt conveyors transport larger volumes and mass flows and consume less energy. Beumer has already implemented belt conveying systems with centre distances of more than 10km.
FOCUS ON ENERGY EFFICIENCYThe motors in these systems can be controlled, making optimal load distribution in the belt possible in all operating conditions. Depending on the terrain and loading condition, the systems can also operate as generators. The generated electric energy is fed to the mains by a regenerative feedback unit. This reduces the energy costs of operating the whole system.
MADE FOR A LONG SERVICE LIFEBelts on Beumer systems reach long service lives of up to 20 years. The reason for this is the optimal design of the routes, drive technology, the take-up station and the arrangement of belt-guiding idlers. Exact calculations of the idler positions enable the belt conveyor to negotiate curves. If the system is designed optimally, an even stress on all components is ensured and the overall strain on the belt is minimized.
CONSULTING AND DESIGN COMPETENCE INCLUDEDBeumer engineers, together with the customer, optimize the route of the belt conveyor on-site.They also develop the entire construction and design the static requirements for the bridges and belt conveying systems. Using their design competence, they make sure the investment and operating costs, as well as the required energy, are minimized.
Bedeschi equipment for the Dominion Energy Virginia City Hybrid Energy Center
Coal is a fossil fuel that has been in use since the beginning of time. In the 19th century, coal was the fuel that boosted the Industrial Revolution: in the 20th century, it was the engine for the expansion of electricity and was responsible during the first decades of that century for supplying more than half of the energy needs of the planet. Currently, coal is still a vital source, supply almost a quarter of the world’s energy demands. It is the primary source for the generation of electrical power, and is responsible for supplying approximately 35% of the world’s electricity consumption.
Even as many industrialized countries are discussing long-term exit strategies for coal- fired power generation, coal will remain the most important source of energy for the foreseeable future.
Coal handling is part of the larger field of bulk material handling, and is a complex and vital part of the coal preparation plant.
Italian company Bedeschi has gained wide experience over the course of countless coal handling projects, and has developed coal handling equipment that contributes to maintaining this raw material as a sustainable and efficient source of energy.
In 2009, Bedeschi won a contract to supply a key coal handling facility to Dominion Energy Virginia City Hybrid Energy Center.
Dominion is one of the US’s largest producers and transporters of energy, with a portfolio of approximately 28,200 megawatts of generation, 11,000 miles of natural gas transmission, gathering and storage pipeline and 6,300 miles of electric transmission lines.
The contract called for the supply of two identical coal storage facilities, with twin linear STK 31/1200 coal stackers, and one PAL P 260/22+12 portal reclaimer for each section. The stacker and the tripper move together along the piles and travel on the separate runways.
The material is stacked continuously during the longitudinal traveling of the stacker.
At each end of the pile the machine reverses its travelling direction; the pile end is signalled by limit switches on the machines operated by cams on ground.
The reclaimers are portal ones with double boom blade type formed by rigid strong steel portal structure.
Commissioning of the plant was successfully completed in the last few weeks and production operation will start very soon.
ENEL BRINDISI ITALYAnother great success for the Bedeschi company was achieved in the second half of 2011.
Enel is Italy’s largest power company, and Europe’s second listed utility by installed capacity. It is an integrated player, active in the power and gas sectors. Enel today operates in 40 countries worldwide, has over 97,000MW of net installed capacity and sells power and gas to more than 61 million customers
Bedeschi will supply three circular coal stockyards systems (combined CSR coal stacker reclaimer stacking and reclaiming) to Enel (Brindisi Sud power plant).
Material stockpiling will be realized by a STKR 35/2000 stacker type. The material will be reclaimed using a PAL P300/36+240/24 portal reclaimer.
The stacker and reclaimer machine, will comprise the following main equipment:
- the stacker and reclaimer machine will perform a circular coal and non homogeneous stacking and reclaiming.The stacker will be a lifting type.
- the stacker will be fed from the hopper located on top of the central column by means of an inlet belt conveyor. The coal will be reclaimed into the hopper located on the bottom of the central column for outlet belt conveyor feeding.
- the stacker and reclaimer machine structure will be self- standing type. Only the external loads from the inlet belt conveyor gallery will be supported by the stacker and reclaimer machine column.
GENERAL DESCRIPTIONThe stacker is formed by one tripper and one stacker, connected by means of tie rods. The tripper, which lifts the belt for incoming material to feed the stacker belt, is formed by a ramp with idle drums for the belt and by supporting bearings. The stacker and the tripper are complete with service walkways and stairs.
The stacker, which has the function of stocking the material and to form the pile, is made up of one supporting trolley and one boom.
The belt towing drum is in the back part of the boom and it is driven by a motor with a reduction gear unit. Located at the end of the boom there is the belt idle drum.