Hardox: Coal Power

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Process of Coal Power Plants

Hardox is useful in crushing : •coal•limestone•ash

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A Success Story at Kangal Power Plant, TURKEY

•Their maintenance time before using HARDOX 400 is about 60 days.(Including controls of the liner plates + changing all of them)•They were stopping during maintenance.• After using HARDOX their maintenance last 25 to 40 days. (Includingcontrols of the liner plates + changing some of them)• Their income for 1 day is app.. USD 1,000,000.

A state-run Power Plant at East Side of Turkey, with 457 MWatt Capacity

Coal powerstation = mechanical processing of raw materials and

by-products

• Raw materials:

• - Coal (ca 7800 ton coal/year for 1 MW of the elektric power)

• - Limestone for flue gas desulfurization. Coal contains ca 1% -5% sulfur. (Ca 390 ton limestone/year for 1MW)

• By-products:

• - Slag. Coal contains 10% - 35% ash. After burning the coal the ash is distributed to slag and fly-ash. Ca 1/3 goes to slag, 2/3 goes to fly-ash. (Ca 500 tons slag/year for 1 MW)

• - Fly-ash (ca 1000 tons/year for 1 MW)

• - Gypsum (hydrogen calcium sulphate) - ca 670 tons/year for 1 MW

All above mentioned data are aproximately valid for brown coal powerstation and theoretical 100% production during an year..

• For black coal powerstations are the values ca half.

400 MW BROWN COAL POWERSTATION

ANNUAL CONSUPTION / PRODUCTION

(roughly):

• 2.000.000 tons coal

• 112.500 tons limestone

• 94.000 tons slag

• 188.000 tons fly-ash

• 169.000 tons gypsum

Hardness reduction due to tempering

250

300

350

400

450

500

550

600

650

100 150 200 250 300 350 400 450

Su

rface H

ard

ness (H

BW

)

Tempering temperature (C)

Surface Hardness vs. Tempering temperature

HARDOX 600

HARDOX 500

Above 200°C to 250°C HARDOX starts losing hardness!

The Quarry - loaders

Part Steel grade

Cutting edge HARDOX 500

Bucket Shell HARDOX 450

Side sheets HARDOX 450

Side cutters HARDOX 500

Main wear plates HARDOX 500

Outer wear plate HARDOX 450

Floor reinforcement HARDOX 450

Strip Mining of Coal

Bucket wheel ReclaimersMine Soft Coal in Large Open Cuts

Hardox 400-500

Dead bed liner concept

• Low weight

• Favorable flow reduces wear

• Dead bed liner at selected areas

• Advanced to produce

• Easy to handle and quick to bolt on

Crusher Feeder & Chute

Feeder and Hopper to the primary crusher.

Liner plates in HARDOX 400-600

Wear plates in vibrating feeder

Wear plates in vibrator: Hardox 400 10 mm

Grating to lignite conveyor made by Hardox 450

Crusher at a limestone quarry and cement plant

• Segments for the grate basket and the perpendicular wear bars are made of HARDOX 500. The wear bars are 75 mm.

suspension

Stone

rubber Breakage is common in both segments and wear bars, both usually made out of 12 %Mn-steels. With the HARDOX 500, breakage is minimized and wear life increased.

Gryzzly bars in the secondary crusher

Wear plates in hammer millWear plates

HammersBeaterarm

Coal processing – the crushers

• Hammer crusher. The hammers are

usually from 12%Mn cast steel. Thickness

50 mm – 120 mm. It is supposed that

HARDOX 500 will have aproximately the

same lifetime as 12%Mn. HARDOX 550

will be better.

• Ventilator mill. It works at higher

temperatures (200 – 400 °C). Erosion

instead of abrasion. For the impact desks

is used everything (from S355 to high Cr

cast iron). HARDOX 500, 15 mm were

successful as liner plates.

• Ball mill. Coal is crushed by balls which

are run up by special wear resistant cast

lining. Just entry part is potential aplication

for HARDOX. (HX500, 12 mm)

Hardox 450-500

Hardness vs Temperature and timeFrom previous information that we have we know that the crushers in East Europe

is working at the temperature is between 180 and 200 degrees Celsius, temporary the temperature can reach 300 degrees.

The hardness after 2000 hours can be calculated according to Holloman Jaffe in which the temperature and time gives the annealing dose. The result is usually quite conservative and the temperature has a much bigger impact then the time. The estimation, according to Holloman Jaffe curve and 2000 hour working time, is.

HARDOX 400 325 to 350 HBHARDOX 500 375 to 390 HB

Hardox 550-600Hardox 450

Ventilator mill- impact desksPresent life time of impact desks is to 2200h in a Turkish plantThe improvement to 2500 is considered as a sucessPictures showing worn out 13% Mn steel ready for replacement

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A Test at Elbistan A-Power Plant, TURKEY

IMPACT LINER PLATES

Current Version Test Version

Erdemir 3995 (Mild Steel)90 & 110 mm thicknessMaksimum 4000 h life time

Lamella Solution (HX500 + HX400)Same thicknessSingle plate design (HX500) is planned for serial production

Test is is ongoing, has started in Jan 2010

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Hammers made by Hardox 500-600 for longer service life

Lamella hammer

Segments of wheel to smash lignite made by Hardox 600

• Segments of wheel to smash lignite before the coal will be transported to the fire.

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Breaking wings in a lignite coal crusher

Description:For crushing the funded lignite before being transported on a conveyor.

Technical data:

HARDOX 550th The rotational speed in the crusher is

about 230U/min. Originally from St 37 and some hard

facing.

Dimensions and quantity:Thickness 30 mm. The crusher has 2 x 6 pairs of wings. Dimensions: 700 mm x 450 mm for each wing.

Operating Condition:Wing with armored St 37 950 h were in use before they had to be replaced. The HARDOX 550 wings must be replaced after 1100 hours in use.

Kontakt person:Detlef Semar, Senftenberg, Deutschland

Bild hier einfügen

HARDOX 550

Hammers by hardox 600

New hammer sultions with hardox

Makes it easier to replace and

tailor make the hammers in the míll.

Ball mill

Wear protection at inlet and outlet chutes

HARDOX 500

HARDOX 550

Hopper• Bottom part made in

HARDOX 400 or HARDOX 450

Lignite cyclone

Lignite is separated under high water pressure in a cyclone. Hardox 450 is used in the cylinder and cone

Lignite cleaning cyclone

It is used to wash coal and the main abrasive is iron powder.

The service life was max 6 months with 10 mm S235. The target is to reach 1 year with Hardox 400.

They will try 6 mm Hardox 450 in the chutes as well.

New Hardox cyclone Old worn out made by S235

Material flow - burning

Coal bunker

Ventilator mill

Coal crusher

Slag crusher Air

ventilator

Chimney fan

Slag conveyer

chain

Fly-ash separator

Wear plates in cleaning knivesThe oven doors evolves a coating of graphite material while processing.This graphite is machined off by the pressing box vessel.

Hardox 500 15 mm

Coal processing

• Grain size of the input coal is ca 30 mm

– 100 mm. All coal has to be crushed to

final granulity 0 – 2 mm.

• The crushing is normally provided in 2

stages (2 different types of crushers). First

stage is usually hammer crusher. Second

stage is normally ventilator mill or ball mill.

• Coal is not just coal! Coal contains ca

30% of another minerals (quartz, pyrit, illit,

ortoklas, plagioklas, chlorit ....). These

minerals are responsible for wear.

Material flow - desulfurization

Limestone stock

Conveyer

Limeston bin

Limestone crusher

Mixer

Pump

Inlet of flue gas

Chimney ventilator

Pump

Outlet of gypsum

chimney

Water inlet

By-products processing

• Slag has to be crushed to enable

useing it for another processing. Before

crushing is slag cooled down by water, so

the temperature is normally under 100°C.

• Slag contains SiO2 (quartz), Al2O3,

CaCO3, Fe2O3. Majority is quartz.

• For the crushing are used roller

crushers (see pictures). They are also

called teeth crushers. For the teeth rolls

can be used HARDOX 500, 550 or 600.

Thickness ca 20 mm.

• Because of high content of quartz

HX600 should be used. But we have also

good experiences with HX500.

By-products processing

• By-products from desulfurization

(gypsum) have to be also processed.

Substantial part of the process is in wet

condition, but also here could be HARDOX

used. We have positive experiences with

blades of compouder (HARDOX 500, 8

mm).

• Fly-ash is fine enough – no crushing.

Newerless it has to be transported, mixed

(with slag, gypsum ....).

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The use of Our ProductSynergies Strip Plate

ELECTROSTATIC FILTERS

Domex 355 W

Raw meal conveyors

• Bucket elevator• HARDOX 400, 450

Raw meal conveyors

Other possible applications for HARDOX:

- Sprockets in HARDOX 500

- Reinforced chain parts in HARDOX 400 and 450

- Wear protection on elevator housing

Sprocket wheels

conveyor

Plates

Mild steel

HARDOX 450

chute

• Often made in hard faced material

• To compete with this we have try HARDOX 550 or maybe even HARDOX 600

HARDOX 550

HARDOX 600

Conveyor scrapers

• Chain of scrapers

• Sliding wear

Scrapers

HARDOX 400

HARDOX 450

Screw conveyors

Flanges made in

HARDOX 400

HARDOX 450

Flanges made in

HARDOX 400 or 450

Could also have wear protection plates on the centre axle

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Damatech d.o.o.

Cesta Franceta Prešerna 63SI-4270 JeseniceSlowenien

T +386 5 923 55 00F +386 5 923 55 01E sales@damatech.comW www.damatech.com

Damatech GmbH

Wolfernstraße 20bA-4400 SteyrAustria

T +43 7202 70041F +43 7202 70042E office@damatech.comW www.damatech.com

Damatech – certified Hardox Wearparts Partner