Case studies show how our products perform in different industries and different material clogging problems.
This time, it is about the discharge problem of bulk solid materials with poor fluidity such as slaked lime, trona, soda ash and sodium bicarbonate.
A major utility company's coal-fired power plant in the American Midwest needed to maximize power output while meeting federal emissions standards. The 2600 MW plant operated a set of the largest coal-fired power plants in the United States.
To meet federal emissions standards, the plant installed a Dry Sorbent Injection (DSI) system designed to mitigate flue gas emissions of hydrogen chloride (HCI) and sulfur dioxide (SO2) Did.
[problem] At this rate, you will have to pay the fine!
DSI technology relies on poorly flowing bulk solid materials such as slaked lime, trona, soda ash and sodium bicarbonate. At this power plant, the process of feeding powdered material to the DSI system consisted of a mixer approximately 1.5 m in diameter connected to three legs of a parallel screw conveyor.
Materials were dropped from three stories high via an array of rotary valves, screw conveyors, hoppers, and finally fed to the DSI system by a dilute phase pneumatic conveyor. There are a total of two of these DSI systems (one for each 1300 MW generator), and to keep the system running properly, the torsion, rotation, and distance required for the powder to travel reliably can be overcome. Considering the continuum, the chances of having flow problems have more than doubled. If the emissions from the plant did not meet compliance standards, the company faced severe penalties and had to pay millions of dollars in fines.
[solution] The only solution that can provide on-demand flow of various DSI materials!
The power company contacted Control Concepts, Inc., the manufacturer of the air sweep. The AirSweep system was the default anti-clogging solution among many DSI system manufacturers and the leading manufacturers of DSI materials used in these systems.
DSI system manufacturers know that air sweep systems can provide on-demand flow of a variety of DSI materials such as slaked lime, trona, soda ash, calcium carbonate, and sodium bicarbonate. Each air sweep nozzle delivers a powerful pulse of compressed air or inert gas that slashes between material and internal contact surfaces such as vessels, chutes, ducts, etc. to break down friction and quickly restore flow Let Control Concept's primary distributor in the Midwest worked closely with utility and power plant representatives to design an effective system.
The air sweep system consisted of a vessel-mounted VA-51 nozzle and a model VA-06 nozzle mounted at numerous possible flow chokepoints in ducts, screws, and bends. All nozzles installed were of 316 stainless steel specification to resist corrosion. A local controller is provided to connect to the plant's DSL system and operate the system to start and stop as required for DSI material.
[results]
The plant has been in continuous operation since fall 2015 with the assistance of the DSI system and the Air Sweep Material Activation System, with no compliance issues.