Hardox: Coal Power 1

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1 1 Hardox: Coal Power

2 Process of Coal Power Plants Hardox is useful in crushing : coal limestone ash 2

3 A Success Story at Kangal Power Plant, TURKEY A state-run Power Plant at East Side of Turkey, with 457 MWatt Capacity 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. (Including controls of the liner plates + changing some of them) Their income for 1 day is app.. USD 1,000,000. 3

4 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.

5 400 MW BROWN COAL POWERSTATION ANNUAL CONSUPTION / PRODUCTION (roughly): tons coal tons limestone tons slag tons fly-ash tons gypsum

6

7 Surface Hardness (HBW) Hardness reduction due to tempering Surface Hardness vs. Tempering temperature Above 200 C to 250 C HARDOX starts losing hardness! HARDOX 600 HARDOX Tempering temperature (C)

8 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

9 Strip Mining of Coal Bucket wheel Reclaimers Mine Soft Coal in Large Open Cuts Hardox

10 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

11 Crusher Feeder & Chute Feeder and Hopper to the primary crusher. Liner plates in HARDOX

12 Wear plates in vibrator: Hardox mm Wear plates in vibrating feeder

13 Grating to lignite conveyor made by Hardox 450

14 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.

15 Gryzzly bars in the secondary crusher 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. suspension

16 Wear plates in hammer mill Wear plates Beaterarm Hammers

17 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 ( 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)

18 Hardox Hardox Hardox 450 Hardness vs Temperature and time From 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 to 350 HB HARDOX to 390 HB

19 Ventilator mill- impact desks Present life time of impact desks is to 2200h in a Turkish plant The improvement to 2500 is considered as a sucess Pictures showing worn out 13% Mn steel ready for replacement

20 A Test at Elbistan A-Power Plant, TURKEY Current Version IMPACT LINER PLATES Test Version Erdemir 3995 (Mild Steel) 90 & 110 mm thickness Maksimum 4000 h life time Test is is ongoing, has started in Jan 2010 Lamella Solution (HX500 + HX400) Same thickness Single plate design (HX500) is planned for serial production 20

21 Hammers made by Hardox for longer service life Lamella hammer 21

22 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. 22

23 Breaking wings in a lignite coal crusher HARDOX 550 Bild hier einfügen 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 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

24 Hammers by hardox 600 New hammer sultions with hardox Makes it easier to replace and tailor make the hammers in the míll.

25 Ball mill Wear protection at inlet and outlet chutes HARDOX 500 HARDOX 550

26 Hopper Bottom part made in HARDOX 400 or HARDOX 450

27

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

29 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

30 Material flow - burning Coal bunker Coal crusher Fly-ash separator Ventilator mill Chimney fan Slag crusher Slag conveyer chain Air ventilator

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

32 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.

33 Material flow - desulfurization chimney Limestone stock Chimney ventilator Conveyer Limeston bin Limestone crusher Water inlet Inlet of flue gas Mixer Outlet of gypsum Pump Pump

34 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.

35 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...).

36 The use of Our Product Synergies Strip Plate ELECTROSTATIC FILTERS Domex 355 W 36

37 Raw meal conveyors Bucket elevator HARDOX 400, 450

38 Raw meal conveyors Other possible applications for HARDOX: - Sprockets in HARDOX Reinforced chain parts in HARDOX 400 and Wear protection on elevator housing Sprocket wheels

39 conveyor Plates Mild steel HARDOX 450

40 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

41 Conveyor scrapers Chain of scrapers Sliding wear Scrapers HARDOX 400 HARDOX 450

42 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

43 Damatech certified Hardox Wearparts Partner Damatech d.o.o. Cesta Franceta Prešerna 63 SI-4270 Jesenice Slowenien T F E sales@damatech.com W Damatech GmbH Wolfernstraße 20b A-4400 Steyr Austria T F E office@damatech.com W 43

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