Edition 1 | 2017 · 2 NEWS 1 | 2017 NEWS 1 | 2017 3 CONTENT Publisher: Clyde Bergemann GmbH,...

www.clydebergemannpowergroup.com

Successful

Implementation

of Dust and SO2

Reduction Systems at

Będzin Power Plant

RPT Shanghai

Environmental Equipment

– A Focus on Clean

Emission of Flue Gas

Measurable Results

with SMART CleanTM

for Fuel Switch

Project

Page 4 1 Page 14

Edition 1 | 2017

2 www.cbpg.com NEWS 1 | 2017www.cbpg.com 3NEWS 1 | 2017

CONTENT

Publisher: Clyde Bergemann GmbH, Schillwiese 20, D-46485 Wesel (Germany)

Responsible for content: Dr. Christian Mueller

Editorial: Claudia Denniger, e-mail: [email protected], Andre Engelmann,

e-mail: [email protected]

Graphic design: TEMA Technologie Marketing AG

Reprints are permissible only after consultation with the editorial offices.

Dr. Christian Mueller | President & CEO

Our newly appointed CEO, Dr. Christian Mueller has been with our company since 2006 and is an established member of our senior management team. Today’s interview is about getting to know more about our new CEO and to allow Dr. Mueller to share some of his beliefs and vision for our company’s future.

You were born and raised in Dortmund, just an hour from Wesel. You also completed your studies in the region, at the Ruhr-University in Bochum. What was the focus of your education?

In 1993 I graduated with a mechanical engineering degree focusing on “energy technology” and received my doctorate degree in Bochum in 1998. My doctoral thesis dealt with “numerical simulation of industrial combustion processes“. I went on developing the same tools and applying them industrially while working as a scientist at Åbo Akademi University in Turku, Finland. My principal focus was on ash deposits and their formation based on various fuels. Process simulation and modeling was an important field of activity in the 1990s and 2000s academically and within the industry. Clyde Bergemann recognized the importance of this topic and subsequently became actively interested in this work.

... and so began your relationship with the engineering team at Clyde Bergemann?

Exactly. I started working for Clyde Bergemann August 1st, 2006 as “Head of New Technologies”. Together with Manfred Frach, we built up a team of young engineers. We developed and launched FACOS – a “Furnace Ana-lyzing, Cleaning and Optimization System”. The system

allows for an “intelligent” cleaning of the furnace, by synchronizing current process data and stored operational events. And, where necessary, the “FACOS” system would initiate the activation of the respec-tive cleaning devices in response to a de-termined or required cleaning event that help to optimize the effective cleaning and operation of the furnace. Over the years, FACOS has undergone continuous reviews and has been subsequently improved to con-sider both process and fuel specific param-eters. Today, FACOS has been rebranded as our “SMART CleanTM” product and compris-es of different sensor and software systems offering tailor-made solutions to meet the many varied requirements of the power in-dustry, pulp & paper plants or with “SMART Clean Compact” – a version for smaller in-dustrial or biomass boiler. Currently, SMART CleanTM technology is regarded as the world leading product in its field.

How did you further develop within the Clyde Bergemann group?

In 2007 my field of responsibilities was ex-tended and I became the head of „Technol-ogy and Products“ at Clyde Bergemann Wesel. In the following year I additionally took responsibility for all research and devel-opment activities in the group. I got to know the technologies and colleagues of the different companies worldwide. By 2010 my tasks were again extended and I was able to step more into operational activities. As “Head of Technology and Project Management” I was additionally responsi-ble for the execution of projects of the Ger-man Clyde Bergemann GmbH. In 2013 I was appointed Managing Director of Clyde Bergemann GmbH working conjunction with Ralph Ludwig.

And now: The big step forward. March 1st, 2017 you took over the position as President & CEO of the Clyde Bergemann Power Group. What will change?

First of all, I have decided to address the fu-ture strategic orientation and steering of the company in the “Executive Committee (ExCo)” team. This team consists of Caren Borges as Chief Financial Officer, Ralph Ludwig, Adam Liu and Dominick Garton as Chief Operating Officers for Europe, South-east Asia and North and South America and Mark van der Moolen as our legal advisor. By

bringing different disciplines and regions together we will ensure that all interests are competently represented and that they are appropriately coordinated and communicat-ed. We will put more emphasis on communi-cation. It is our goal to let the employees participate in the „where and how“ and make sure that they are fully engaged with this executive team.

Do you have some vision or direction in the area of our products and services?

I would like to accelerate the development of the digitization of our internal processes, products and services and vision that Clyde Bergemann takes a leading role in our in-dustry. While at the same time maintain-ing a strong drive towards standardization of components, products and solutions still play an important and critical objective for our business. Our focus is on a review of our current and established portfolio of prod-ucts and services to ensure we make any necessary adjustments in order to meet our customers’ needs and to be open to the op-portunity of potentially viable new business fields.

Politicians sometimes are being judged on their “first 100 days in office”. The idea is to analyze what the new leader did in this period and if he is already able to report on initial successes. What is your desired result?

The focus is to develop a reliable Execu-tive Committee that enjoys the trust of the employees. In this context, we have al-ready been successful in a very short time and want to keep an eye on strengthening the cohesion between all members of the Clyde Bergemann family. Additionally we are going to review various units and busi-ness fields with regards to their processes and structures, while maintaining and supporting all things that are good and improving less ideal situations. This is in progress and I am confident that we will be able to show the first good results after 100 days. Last but not least we want – as mentioned before – to encourage open communication, thereby not only ensuring all employees are “in one boat”, but also to keep us all pointed in the same direc-tion and “rowing” together.

Thank you very much Dr. Mueller for your first indication of our future direction and for sharing some of your plans and your vision for Clyde Bergemann.

We will continue to use this publication to present the latest news and developments from the ExCo.

The new Executive Committee: (from left to right) Dr. Christian Mueller, Dominick Garton, Caren Borges, Ralph Ludwig, Adam Liu, Mark van der Moolen

Interview with our new CEO Dr. Christian Mueller

Claudia Denniger, CBPG [email protected]

Interview with our new CEO Dr. Christian Mueller ..................... 2

Clyde Bergemann Successfully Implements Dust and SO2 Reduction Systems at Polish Power Plant Będzin ........................ 4

Clyde Bergemann’s Bottom Ash Handling System DRYCONTM Gains a Foothold in Japan ........................................ 6

Clyde Bergemann Equips New Build Power Plant Turów (Poland) with Boiler Cleaning Equipment .................................. 7

European Pulp & Paper Mill Utilizes RS Steam Saver Low Pressure Drop Sootblower for their Newly Rebuilt Recovery Boiler .......... 8

Clyde Bergemann Environmental Technologies Rotary Valves Provide a Reliable Method for Dry Sorbent Feeding .................. 9

Clyde Bergemann Environmental Technologies (CBET) Replaces Competitors Fly Ash Mixers .....................................................10

Clyde Bergemann Environmental Technologies (CBET) Passes Factory Acceptance Test for Submerged Scraper Conveyor .......10

Measurable Results with SMART Clean™ Technology for Midwestern Utility Fuel Switch Project ......................................11

Shanghai Clyde Bergemann Machinery Co., Ltd. .......................12

A New Addition to Our Group of Companies: RPT Shanghai Environmental Equipment Co., Ltd (Clyde Bergemann RPT).......14

Clyde Bergemann presents DRYCON Compact at “Power Plant Components Workshop“ in Germany .................15

“Navigating Change“: New Young Talent Program Kick-Off ....16

Events Diary & Personnel ..........................................................16


PollutantGuaranteed Emission Mg / Nm3 Dry @ 6 % O2

Achieved Emission Mg / Nm3 Dry @ 6 % O2

SO2 ≤ 130 10 to 75

HCl ≤ 5 3

HF ≤ 2 0.3 to 0.6

Particulate Matter ≤ 15 0.5 to 1

The system achieves very high removal rates of Sulfur Dioxide (up to 99 %) on medium to high sulfur fuels. The fluidized bed provides a buffer for spikes in emissions at the inlet to the CDS/Fabric Filter system.

The subsequently installed Pulse Jet Fabric Filter is a high efficiency collection device ca-pable of collecting fine particulate (> 99.99 % efficiency) from the gas stream. In a pulse jet fabric filter, particulate in the flue gas stream is deposited on the outside surface of the fil-ter bag, which then builds up to form a dust cake layer. When the dust cake accumulation reaches a level where gas flow is restricted, cleaning is initiated by the system. The dust cake is removed from the bags by the injection of a pulse of clean compressed air down the inside of the bag. The collected dust cake is dislodged and falls down into the hopper for collection by the material handling system.

The Clyde Bergemann inlet manifold design reduces pressure drop, improves ash and gas flow distribution, and promotes longer bag life. In addition, the patented system of hop-per vanes minimizes dust re-entrainment af-ter cleaning, thereby lowering the number of cleaning cycles, which, in turn, has a very fa-vorable impact on emissions and bag life.

Included were also complete lime discharging with redundant feeding systems with total ca-pacity of 4400 t/hr along with 504 m3 silo, as well as 3500 t/h by product conveying system with associated 480m3 storage silo equipped with discharge unit.

The table below outlines the emissions tar-gets that were guaranteed and the system emissions performance that was achieved after installing the flue gas desulfurization system.

Ziemowit Słomczyński, President of SBB En-ergy comments: “SBB ENERGY is a company with many references in the area of DeNOx technology. The Będzin project was a good opportunity to perform the complement project in the area of environment protec-tion. Having Clyde Bergemann as a part-ner we were able to offer both DeNOx and DeSOx technologies and to become the gen-

Clyde Bergemann Poland (CBP), part of the globally operating Clyde Bergemann Power Group (CBPG), completed the execution of its $9M USD order for an air pollution control system at the Będzin power plant in Poland. As a result of well coordinated working processes and committed teamwork, the project was finished within the planned time frame and the plant, now operating since October 2016, fully complies with the set emission limits.

Clyde Bergemann Successfully Implements Dust and SO2 Reduction Systems at Polish Power Plant Będzin

The Będzin power plant, 2 × 40 MWe and 1 × 81 MWt cogeneration facility, started operating in 1916. Situated in the south west of Poland next to Katowice, it is one of the main sources of heating, warm utility water and technological heat for the region. The plant has gone through different stages of renewal and modernization projects to date, with the latest one in order to meet the new-ly defined Emission Limit Values (ELV) that are part of the European Industrial Emissions Directive (IED). The IED entered into force in June 2011 and requires existing large combustion plants to meet minimum stan-dards for the emissions of toxic air pollutants such as acid gases and particulate matter in a short-term timeframe.

eral contractor. The good, mutual and com-plementary cooperation during the project is a perfect foundation for future projects. Achieved results have given us good refer-ences and proved that together we are able to fulfill the requirements of clients in the energy market.”

Piotr Zarmutek, General Manager of CBP adds: “The Będzin DeSOx project is a very important step towards the expansion of Clyde Bergemann environmental technolo-gies in Europe and confirms that our com-mon partnership is beneficial for both SBB Energy and Clyde Bergemann. We are very happy and look forward to working togeth-er in future projects.”

Piotr Zarmutek, [email protected]

Partnering to Supply Turnkey Solutions In order to comply with the defined limits, the operator, Elektrociepłownia Będzin S.A., assigned SBB Energy (SBB) to provide turn-key solutions for DeNOx and DeSOx plants. SBB is a Polish engineering company that has already cooperated with CBP in the past in the field of boiler cleaning and ef-ficiency solutions. SBB Energy is an industry expert for the execution of DeNOx projects for power plants, but lacked DeSOx tech-nology capabilities. Their need for a DeSOx partner is how the Clyde Bergemann Power Group came into play. Together with the experienced specialists of Clyde Bergemann Environmental Technologies (CBET), part of the Clyde Bergemann Power Group Ameri-cas and core center of competence for air pollution control solutions, CBP was able to fill the gap. Additional support was provided by Clyde Bergemann Doncaster (UK) who supplied all associated material handling systems.

Air Pollution Control SystemsCBPG’s scope included the engineering and delivery of a Circulating Dry Scrubber (CDS) reactor, a Pulse Jet Fabric Filter (PJFF), water humidification system, lime feeding system, lime silo, by-product silo, material handling systems and the commissioning.

The Circulating Dry Scrubber combines hydrat-ed lime (as a reagent), water, sulfur dioxide and particulate laden flue gas in an entrained fluid-ized bed reactor. The sulfur oxides in the flue gas react with the lime in the fluid bed. The reaction products (calcium/ sulfate), unreacted lime, and fly ash are carried into a Pulse Jet Fabric Filter to be collected on the filter bags.

Clyde Bergemann designed and delivered a water humidification system that atomizes the water in order to coat the lime in the fluid bed for improved reaction kinetics.


Together with three consortium partners, Mitsubishi Hitachi Power Systems Europe (MHPSE) is setting up a highly efficient lignite fired 450 MW power plant in Turów, Poland. MHPSE awarded German Clyde Bergemann GmbH with the supply of the boiler cleaning and efficiency systems. Turów is now the second new construction project in Poland where MHPSE relies on process technology from Clyde Bergemann. The first being unit 11 of Kozienice power plant.

Presently, Turów power plant consists of six units with a total output of 1,320 MW. The new power plant is designed to replace the three oldest units. Being equipped with ultra-supercritical steam technology, the plant will not only be considerably more efficient but also environmentally friendly.

When selecting a partner for the delivery of the boiler cleaning equipment, MHPSE again chose Clyde Bergemann.

Clyde Bergemann Equips New Build Power Plant Turów (Poland) with Boiler Cleaning Equipment

nozzles. These are aimed optimally at the reactor heating surfaces.

The combination of the various cleaning devices for the different application areas guarantees a safe and efficient removal of all deposits.

Commissioning of the plant is scheduled for 2019.

“For us, this repeat order by MHPSE pro-vides both recognition and further motiva-tion. We are pleased to be a preferred sup-plier for one of the few European projects“, states Dr. Christian Mueller, President & CEO of the Clyde Bergemann Power Group.

The scope of supply includes 12 SMART Cannon and 36 F149-wall blowers for clean-ing the furnace. SMART Cannon uses a concentrated water jet and different nozzles to clean the side and opposite wall of the furnace with precise, reproducible cleaning patterns. Additionally, F149 wallblowers are used in the lower part of the furnace, the burner belt. They are primarily applied in areas with heavy fouling, which is a typical occurrence in lignite-fired boilers.

For cleaning the flue gas return suction duct six SMART RSG with variable feed and variable rotation are utilized, the heating surfaces in the superheater and reheater areas make use of 48 PS-H retractable sootblowers and 45 PS-HB part retractable sootblowers.

The SCR is cleaned with the help of 10 PS-AR rake sootblowers. The blowers envis-aged feature a longitudinal variable blowing rake equipped with cross-arms having

Bernd Koester, CBEU [email protected]

©Mitsubishi Hitachi Power Systems Europe

Clyde Bergemann’s Bottom Ash Handling System DRYCONTM Gains a Foothold in Japan

After winning several contracts in its home markets, German Clyde Bergemann GmbH has now secured its first order for the supply of a dry bottom ash handling system in Japan. DRYCONTM will be deployed to automatically convey and cool the bottom ash of the new-build 1,070 MW coal-fired power plant Taketoyo 5, situated in the middle eastern part of Japan.

Chubu Electric Power Co., Inc., the owner and operator of the plant, is one of the biggest power generating and electric-ity supplying companies in Japan. The new highly efficient ultra-supercritical (USC) plant Taketoyo 5 is supposed to replace three old oil-burning units. Chubu awarded Japanese Sumitomo Heavy Industries, Ltd. (SHI), Clyde Bergemann’s long-term partner in Japan for dry bottom ash handling solutions, with the delivery of all ash handling systems.

For handling and cooling of the bottom ash, Clyde Bergemann’s patented DRYCONTM technology will be deployed. DRYCONTM is a pan belt conveyor, an eco-friendly system that eliminates water usage completely uti-lizing ambient air for cooling the bottom ash only. The air streams along the conveyor and in counter flow to hot ash, transferring heat back into the boiler.

The DRYCONTM technology makes it possible to easily transport the bottom ash to the silo top over a distance of 75 m at an inclination of 40° with a single stage conveyor. Other commercially available dry bottom ash han-dling systems have to apply a second con-

veyor for inclines of more than 35°. That not only increases the cost of purchase but also has a negative effect on additional costs, like spare parts and service provision.

Alongside environmental compatibility and low operating and maintenance costs, DRYCONTM also delivers a by-product – dry bottom ash – that can be sold to other in-dustrial markets.

“Securing this order is based on exceptional collaboration with SHI. With Chubu Elec-tric Power´s acceptance, DRYCONTM now also gains a foothold in Japan”, states Christian Mueller, President & CEO of the Clyde Bergemann Power Group.

Andre Engelmann, CBW [email protected]

The Taketoyo and Clyde Bergemann team successfully cooperate in Wesel, Germany


European Pulp & Paper Mill Utilizes RSMP-H Steam Saver Low Pressure Drop Sootblower for their Newly Rebuilt Recovery Boiler

One of the biggest producers of bleached softwood kraft pulp and bleached kraft paper in Central and Eastern Europe came into contact with Clyde Bergemann’s Boiler Efficiency specialists to help supply equipment and solutions towards rebuilding their recovery boiler. With nearly 400 people they generate an annual turnover of 252 Mio. Euro (2016), selling 430 000 t of pulp and paper.

Steam Saving Technology for Recovery Boilers Steam Saver Sootblowing Technology is one of the key advancements that Clyde Bergemann Power Group (CBPG) has intro-duced to the Pulp and Paper industry within the past few years.

Conventional sootblowers utilize valuable high pressure steam. The source of this high pressure steam can either come from

the 900 – 1500 psig (62 – 103 bar) steam produced by the recovery boiler or the 400 psig (28 bar) steam from the first turbine extraction.

RS Steam Saver Technology uses less expensive steam from the second turbine extraction steam (generally 150 psig or 10 bar) for sootblowing. The technology was first implemented in 2007, since then there are four successful installations in the USA, three in Brazil, one in India, and two in Europe.

The European Recovery Mill was the latest installation, commissioned in early 2016, and has been in operation for one year with no interruption due to heavy fouling and plugging. It is estimated that with this tech-nology the mill will be able to generate ad-ditional 1 – 2 MW (valued about 1 million per year) from its turbine.

Danny Tandra, [email protected]

Silo with feeders

Rotary valves are used to meter flow of materials. With Dry Sorbent Injection (DSI) systems, a rotary valve meters the sorbent into a pneumatic conveying pip-ing system. In this application the rotary valve meters and acts as a seal for the pressure in the pneumatic conveying air stream.

The Clyde Bergemann Environmental Tech-nologies (CBET) arm of Clyde Bergemann Power Group Americas has recently com-pleted the start-up and commissioning on DSI systems for PPL (Pennsylvania Power and Light) at their Brunner Island Station.

CBET’s scope included two new complete Dry Sorbent Injections system for Units 1 & 2 as well as an upgrade for the existing DSI feed equipment for Unit 3. United Conveyor Corporation originally supplied the Unit 3 DSI system in 2011.

Upon review of the existing Unit 3 feed equipment, it was apparent that the design suffered multiple issues that were causing unreliable feed control of hydrated lime into the DSI conveying piping. Hammer marks on the silo spool, above the rotary valve, indicat-ed that additional flow aides were needed. Also the size of the rotary valve required a reducing transition that was made with a very shallow angle. This shallow angle and rotary valve design also hampered with the flow of the hydrated lime into the system.

To correct these issues, CBET supplied their Heavy Duty (HD) rotary valve. This rotary valve has several design features that will greatly improve the reliability of the DSI feed system.

The CBET HD rotary valve is specifically de-signed for handling abrasive materials due to the following unique features: • Separate inlet shoe provides precision

ground surface for mating with rotor• Rotor is adjustable, in place, to maintain a

tight seal as normal wear occurs over time

• Rotors can be easily adjusted to maintain factory settings many times before replacement is required. Other rotary valves are nonadjustable and therefore thrown away when wear occurs

• Bearings are outboard and self-aligning away from product dust

• HD Rotary valves incorporate air purge connections to introduce sealing air thus preventing dusting at the shaft seals

Clyde Bergemann Environmental Technologies Rotary Valves Provide a Reliable Method for Dry Sorbent Feeding

The adjustable rotor feature is most valuable in a rotary airlock system. It is important to maintain close tolerances between rotor and sealing surface, in order to maximize throughput. Abrasive powders will erode this critical area of the rotary valve through wiredraw wear. These new CBET rotary valves provide a reliable method for dry sorbent feeding that will serve the plant for many years to come.

Ron Grabowski, CBET [email protected]

Modular SSC Concept


Measurable Results with SMART Clean™ Technology for Midwestern Utility Fuel Switch Project

Over the last few years, Clyde Bergemann’s US Boiler Efficiency Product Division special-ists have been supporting a major utility with their fuel flexibility project. The Midwestern Power Station has two units, each was de-signed with the net generating capacity of 615 MW, making a combined generat-ing capacity of 1,230 MW. Early 2016, the plant initiated a fuel switch project where the fuel burned in both boilers was changed from purely Illinois basin bituminous coal to a mixed of Illinois basin and Powder River Basin (PRB) coals. Although PRB coal has the advantage of lower SO 2 emission and lowest coal price in the US market, it is well known that it causes severe slagging in the furnace and heavy fouling in the convection section.

SMART Clean™ along with SMART Can-

non™ system were trusted to control the furnace slag-ging and the deposit accu-

mulation in the heat exchanger

tube areas.

SMART Clean™ is a boiler clean-ing optimization system that is designed to realize plant’s perfor-mance and operational objectives regardless of the changes in fac-tors influencing the slagging and fouling conditions in the boiler. The system accomplishes the plant tar-gets by using real time intelligent feedback.

The SMART Cannon is an ad-vanced, extremely effective clean-ing device for furnaces. Its con-struction with two linear drives and a spherical cannon guide provides a horizontal and vertical blowing arc of 90°. Based on in-house developed control technology, the water jet creates a meander-shaped pattern cleaning the sides and oppo-site wall from a distance of up to 25 meters. The SMART Cannon’s cleaning radius and flexibility lend it unbeatable efficiency in ar-eas like these, where water is the preferred medium for cleaning.

At similar MW load, SMART Clean™ re-duced the Furnace Exit Gas Temperature (FEGT) by 73° F (40 °C), and Economizer Exit Gas Temperature (EEGT) by about 10° F

(5.6 °C). The unit can generate additional 16 MW when SMART Clean™ is utilized while maintaining EEGT. This additional 16 MW is valued around $2.7 million per year. Due to this strong result, Clyde Bergemann Power Group was awarded with the similar order for the second unit.

Danny Tandra, CBAT [email protected]

A Submerged Scraper Conveyor (SSC) is used to receive bottom ash from coal-fired boilers. The SSC has a water tub section that sits under the boiler throat. Hot bottom ash falls into the water bath section where it is quenched and collected. A dual strand chain and a series of scraper flight bars are used to drag the collected bottom ash from the SSC tub section, up a dry inclined section where it dewaters by gravity, before discharging into a three sided storage bunker.

As part of Santee Cooper’s Coal Combus-tion Residuals (CCR) compliance, CBET was

contracted to supply equipment for their Cross and Winyah Power Stations. Santee Cooper is South Carolina’s leading power company. At Cross Station, CBET supplied (3) Submerged Scraper Conveyors to handle bottom ash on Units 1, 3 & 4. The CBET scope of supply also includes (2) Remote Me-chanical Dewatering (RMD) Conveyors han-dling pyrites at Cross and (2) RMD conveyors handling bottom ash for the four Units at Winyah. RMD technology is similar to SSC but in a remote position. An RMD Conveyor is made by modifying a Submerged Scraper Conveyor to accept the bottom ash slurry


Clyde Bergemann Environmental Technologies (CBET) Passes Factory Acceptance Test for Submerged Scraper Conveyor

On February 7th, the Clyde Bergemann En-vironmental Technologies (CBET) arm of Clyde Bergemann Power Group Americas successfully passed the Factory Acceptance Test (FAT) for the first of three SSC systems being supplied for their current Santee Cooper contract.

This SSC is also the first US installation us-ing a new modular approach for the fabri-cation and assembly process. Typically an SSC is split horizontally along the path of the conveyor. This usually results in support columns, tub, plate work and stiffeners be-

ing shipped loose, in many pieces, for field assembly and welding. The new modular ap-proach splits the conveyor, tub, and legs in large vertical sections. This greatly reduces the field assembly time by shop fabricating the SSC modules into the large sections.

Innovative designs and quality workmanship will position CBET as a leader in CCR compli-ance solutions.


Ash mixers are used to offload fly ash from storage silos into open top dump trucks. To assure fly ash does not escape into the at-mosphere, the ash mixer conditions the ash with water to make a dust free mixture.

The Clyde Bergemann Environmental Tech-nologies arm of Clyde Bergemann Power Group Americas has recently completed the start-up and commissioning on two new fly ash mixers for their current contract with Santee Cooper, South Carolina’s leading power company.

There are two fly ash silos at Santee Coo-per’s Cross Power Station, Unit 1 and Unit 2. The Unit 1 fly ash silo had a pugmill mixer originally supplied by Allen-Sherman-Hoff in 1992. The Unit 2 fly ash silo had a drum mixer originally supplied by United Conveyor Corporation in 1981.

As part of a large plant retrofit contract, CBET scope included the design and supply replacement for the existing mixers with new ash pugmill mixers. CBET pugmill mixers are rated for 150 TPH unloading rate. They use a rotary valve to meter fly ash from the silo into the mixing tub. The mixing tub has twin shafted shafts with paddles that mix the fly ash while a series of nozzles spray water. Be-cause the ash will be hauled away for dispos-al, excess water would increase the weight and increase the cost of disposal, so it is im-portant to minimize the use of water. The result is the discharge of a moist dust free fly ash. Clyde Bergemann holds a US Patent on this technology.

This arrangement provides an efficiently and reliable method for fly ash unloading that will serve the plant for many years to come.

Clyde Bergemann Environmental Technologies (CBET) Replaces Competitors Fly Ash Mixers

that normally would be discharged into an ash pond. It uses large overflow troughs to separate the ash from the water. The dis-charge of the RMD provides a moist ash that can be handled in a dust free disposal.


Shanghai Clyde Bergemann Machinery Co., Ltd.

The new Shanghai Clyde Bergemann site – a view from the outside …

… and inside the production.

Production of a DRYCONTM bottom ash handling system

Shanghai Clyde Bergemann

Machinery Co., Ltd.

21F, Wentong Building, No.739,

Kunming Road, YangpuDist.,

200082 Shanghai, China

Phone: +86 21 65396385

Mail: [email protected]

Managing Director: Yueqi Xin

Production Range: Boiler Efficiency

Material Handling

Air Pollution

Control

Energy Recovery

Employees 2017: 215

Office space: 1.860 m2

Production space: 25.450 m2

Shanghai Clyde Bergemann Machinery Co., Ltd. (SCB) was established as a joint venture between Clyde Bergemann and the Shanghai Power Station Auxiliary Accessory Factory in 1996.

Since its establishment, the company was focused on product design and manufactur-ing of sootblowers. With the greatest vari-ety of products and the largest production capacity within the Clyde Bergemann Power Group, SCB today is the domestic market

leader. As well as supplying to its home market, SCB has also occasionally

exported products to South Korea, Europe, Middle East and Southeast Asia – where market conditions and customer require-ments permit this to happen.

Having achieved annual production quan-tities of over 10,000 sootblowers, SCB is by far the market leader within the Clyde Bergemann Power Group (CBPG). One re-cord it holds without question is the pro-duction of the longest sootblower. In 2010, SCB manufactured for its customer Bei Jiang Power Plant in Hubei Province a long retract-able sootblower with a travel length of over 17 m, deployed for the cleaning of the con-vection part of the boiler.

In regards to gypsum dewatering for Flue Gas Desulphurization (FGD) processes in coal fired power plants, SCB also delivers vacuum belt filters. The core business has been enhanced by the introduction of hori-zontal vacuum belt filter (VBF) technology since 2003. Vacuum belt filters (also known as horizontal belt filters) provide high extrac-tion efficiency, low cake moisture, increased production and reduced operational expen-diture whilst providing optimal filtration when compared with other techniques. In 2006, SCB installed the world’s largest vac-uum belt filter in China, which has been in operation since then. The key dimensions being: filtrate area of 90 m2, belt width of 3.2 m and vacuum box length of 30 m.

When it comes to Air Pollution Con-trol solutions, SCB offers Wet Electrostatic Precipitators (WESPs), mainly for the power and steel industry. WESPs are used for simul-taneous removal of acid gases and fine particulate matter as polishing device af-ter FGD scrubber. A WESP also offers the additional benefit of some heavy metal re-moval. SCB offers different types of WESP such as plate type WESP, tubular WESP and tubular WESP with swirl de-dust device to fulfill different requirements in the Chinese market.

Since 2014, SCB has included heat-dis-placement systems to its product range. Heat displacement systems – also called tube-type gas-gas heaters – are replace-ment products for rotary gas-gas heaters in power plants. Generally, the challenge for these heat exchangers is that a large section of the heat transfer surfaces oper-ates below the acid dew point temperature and therefore needs to be built from cor-rosion-resistant materials. Some custom-ary products in the market use corrosion-resistant alloy steels, an expensive and heavier alternative. Clyde Bergemann de-veloped a new heat displacement system, using specialized plastic-lined steel tubes, thereby meeting the specific conditions of these environments. This novel alternative is not only a key part of a low emission solution to fight the current environmental pollution issue in China but also offers cost advantages for the plant operators.

Last but not least, SCB offers both H finned tube and spiral finned tube heating surfaces for economizers and flue gas coolers – re-covering heat from waste gas – with more than 80 currently in commercial service in China and Europe. SCB has, in total, five production lines of finned tubes.

Within the Clyde Bergemann group of companies, SCB remains one of the fastest growing, with continued focus on Research and Development of products/technologies within its fields of activity with an ultimate objective to continually enhance its market share and competitive position.

Additionally, the Shanghai production facility serves other group companies as a manufacturing plant for Clyde Bergemann products, like DRYCONTM systems, e. g.


RPT Shanghai Environmental Equipment Co., Ltd. 21F, Wentong Building, No.739Kunming Road, Yangpu Dist.200082 Shanghai, ChinaPhone: +86 21 65396385

Xiaoliang Liu, CB RPT [email protected]

Tube Anode Module for Wet-ESPThe Tubular Anode Module for Wet-ESP has also been developed in Shanghai and utilizes a plastic material that is electrically conduc-tive. Compared to the commonly used FRP anode, this module has a better all round electrical conductivity and of course is more environmentally friendly.

Both the Heat Exchanger and the Tubular Anode modules are sub components of larger systems and used typically in Gas-gas heaters and Wet ESPs.

Clyde Bergemann RPT primarily delivers these parts and components to Shanghai Clyde Bergemann (SCB), who act as system suppliers of Gas-Gas Heater and Wet-ESPs to the market place. Clyde Bergemann Shanghai has successfully collaborated with RPT since 2012 and looks forward to con-tinuing this relationship as part of the larger Clyde Bergemann family.

A New Addition to Our Group of Companies: RPT Shanghai Environmental Equipment Co., Ltd (Clyde Bergemann RPT)

Clyde Bergemann acquired RPT Shanghai Environmental Equipment Co., Ltd in December 2016. RPT started business in China in 2005 with a focus on clean emission of flue gas in the energy sector and industrial areas. The core competence lies in special plastic “know-how” based solutions for environmental protection and energy saving.

The product portfolio includes mist elimi-nators (ME), heat exchanger modules with plastic coated tubes and tubular anode modules for Wet Electrostatic Precipitators (Wet ESP).

Mist Eliminators Mist Eliminators (ME) are designed to re-move contaminants from process air emis-sions. There are five types: flat ME, roof ME, ME for horizontal gas flow, tubular ME and cyclone ME. The tubular and cyclone ME were developed in Shanghai and are pat-ented. RPT offers complete ME systems, including conception, design, production, installation and services.

Heat Exchanger Modules with Plastic Coated TubesHeat Exchanger Modules with plastic coated tubes are developed in-house in Shanghai in cooperation with a German material sup-plier. This is a typical application of so called high performance engineering plastic. The material is thermo conductive, corrosion resistant and has high temperature capabil-ity compared to other engineering plastics. With our unique specialized production know-how, the material is applied on to the metal tube surfaces. RPT is the only compa-ny in the market that can deliver this kind of tube for heat exchangers.

Generally, the challenge for heat exchangers is that a large section of the heat transfer surface operates below the acid dew point temperature and therefore needs to be built from corrosion-resistant materials. Some customary products in the market use corro-sion-resistant alloy steels, an expensive and heavier alternative.

Clyde Bergemann presents DRYCON Compact at “Power Plant Components Workshop“ in Germany

amount of ash is reduced by 90 %, making the process predestined for deploying DRYCON Compact.

In the same year, the Russian power plant engineering and construction company Podolskmash ordered three DRYCON Com-pacts for each of the new-build 65 MW bitu-minous coal-fired boilers in Primorsky. From 2018 on, Primorsky power plant is scheduled to supply parts of Russia with power. In times where the market is characterized by the need to apply economically and ener-getically efficient as well as environmentally friendly systems, the use of dry bottom ash handling systems is inevitable – not only for larger power plants. By extending its prod-uct portfolio by DRYCON Compact, Clyde Bergemann covers the entire bandwidth and is able to offer its clients maximum advantage with regards to dry bottom ash handling for operators of industrial boilers, biomass-fired plants and local electricity generators.

The 10th annual Power Plant Components Workshop, organized by the German Association for Construction of Steam Boiler, Vessels and Piping (FDBR), focused on the theme “Power Plants and the Future of the Industry. About 100 participants, including power plant operators, manufacturers and service providers, attended the event on October 30, 2016 in Gelsenkirchen, Germany. The various speeches dealt with topics such as energy transition, a resulting decline in profitability – especially for German power plants – and solution approaches to handle the changing market conditions.

DRYCON Compact – an Industry-Oriented Expansion of the Product Range for Dry Bottom Ash Handling SystemsClyde Bergemann GmbH, represented by B. Eng. MSc Andre Engelmann, presented “DRYCON Compact“, an industry-oriented expansion of the product range for dry bot-tom ash handling systems and an option to adjust to the changing market.

The development of DRYCON Compact, a streamlined version of the proven, patented pan belt conveyor for bottom ash handling, started already in 2011. The advantages lie in an environmentally friendly operation – DRYCONTM operates without using any wa-ter – and an increased energy efficiency and cost effectiveness.

By returning heat energy to the boiler, DRYCONTM not only reduces coal usage and CO2 emissions but also delivers a by-product – dry bottom ash – that is saleable to other industrial markets

Characteristics Like DRYCONTM The introduction of DRYCON Compact of-fers operators of industrial boilers, generat-ing significantly less boiler ash, a profitable bottom ash handling system.

Compared to the large version, alterations primarily lie in a reduced headroom, a small-er chain size and a smaller wheel diameter. This results, on the one hand, in a lower investment cost. Additionally the system offers customers with limited installation space an option to make use of the advan-tages DRYCONTM offers.

In Use Across EuropeOne customer that already makes use of all those benefits is Schoellershammer pa-per mill in Dueren, Germany. Since 2015, DRYCON Compact has successfully removed all bottom ash from the industrial boiler that provides process steam to the mill. By eliminating the substantial costs for water disposal, caused by the initial wet removal system, and a reduction of the maintenance costs, DRYCON Compact amortized itself al-ready in the first year.

In 2016, when retrofitting three 140 MW coal-fired units to biomass, the operator of the British power plant Lynemouth decided to implement DRYCON Compact. By switch-ing the fuel from coal to biomass, the

Andre Engelmann, CBW [email protected]

16 NEWS 1 | 2017

Caren Borges… has been appointed to the position as CFO and VP of the Clyde Bergemann Power Group with effect from March 2017. Caren has been with Clyde Bergemann since 2002 most re-cently as Director Treasury & Controlling. In the last 14 years Caren has gained a broad experi-ence from various Group functions and is very well prepared to take this wider responsibility.

Dr. Danny Tandra… has been appointed as the Group R&D Steering Group Leader with effect from March 2017. In addition to his responsibili-ties as Vice President of Clyde Bergemann Atlanta, Danny will work together with our Group R&D Teams on individual projects and support the groupwide coordination and involvement on technical develop-ments.

Xiaoliang Liu … has been appointed as Managing Direc-tor of Clyde Bergemann RPT effective from March 2017. Xiaoliang joined Shanghai Clyde Bergemann in 2005 and has gained a wide experience in a number of operational roles with focus on production and supply prior to this appointment.

Events Diary

Personnel

Esta-Carina Cieslik, CBPG [email protected]

DATE NAME OF EVENT COUNTRY PLACE

May

21 – 25 IEEE-IAS/PCA Cement Conference

Canada Alberta

24 – 26 International Chemical Recovery Conference

USA Halifax, Nova Scotia

June

27 – 29 POWER-GEN Europe Germany Cologne

July

17 – 20 APC-Wastewater/ PCUG Conference

USA Charlotte, NC

The latest Young Talents launch event took place in Fort Lauder-dale, Florida (USA). A group of 20 talented young employees of the Clyde Bergemann Power Group (CBPG) underwent three full days of training and development, facilitated by APEX, a team of dedicated coaches. The diversified program – entitled “Navigating Change” – included several workshops, group teamwork sessions as well as a number of presentations. The workshops provided a per-fect forum for team collaboration and discussed many of the issues our Young Talents are faced with in their daily duties. Some of the interesting topics covered during these workshops included how the group collectively looses if individual teams are not cooperating. An-other workshop discussed “resilience” and how teams could adjust to change, disruption, or difficulties and showed how to positively move on after a negative experience.

Additionally, the Young Talents were given presentations by CBPG executives including; Franz Bartels (former CEO & President, CBPG), Dominick Garton (President of CBPG Americas), Jim Connor (Vice President of Sales & Marketing of CBPG Americas) and Daniel Bar-tels (Head of Projects & Engineering of CBG). All attended the event in Florida and provided valuable insights into the workings of our group. Franz Bartels shared the “CBPG Strategy and Execution”, giving an overview about the group’s current status as well as an outlook on future perspectives. Dominick Garton, a former Young Talent, captivated the new comers with his success story, presented in a lively and personal way.

The Young Talents Launch event was a great opportunity for ev-eryone not only to meet but also to interact with colleagues from around the world and to begin a process of developing long and useful inter group col-laborations. The event was not

all presentations, talks and strategy – the team also enjoyed a sight-seeing boat cruise, an evening event where the Young Talents were asked to perform on stage as well as a “scavenger hunt” made more challenging during some heavy rainfall. All attendees thoroughly enjoyed the event and experienced the challenge of “Navigating Change” through Discussions, Presentations, some leisure time and hopefully prepare them for their next journey in their developing careers.

“Navigating Change“: New Young Talent Program Kick-Off

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