Technical comparison between Steel belt conveyor and Chain (steel plate) conveyor

Item 1.Technical background Steel belt conveyor Research and development by Guodian Futong: Chain (steel plate) conveyor Chain (steel plate) conveyor: Firstly invented by Japan's Kawasaki Heavy Industries Ltd.

In 1997, Sanhe Power plant introduced steel belt dry bottom ash handling After the application in small units, potential dangers exist. As a result, it is systems for 2350MW units as an experimental project. But the high cost of this immature technology with no industrial applications. imported system and spare parts as well as clinker problem in Changchun Thermal Power Plant strongly impeded the promotion of this new technology. In 2000, China National Power Company listed The Research on the Steel Belt Dry Bottom Ash Handling System and its Key Components for Coal Fired Boilers as the key technology project of the State Power Corporation with the project No. KJ00-02-15, which is aimed to fill up the gap of domestic dry bottom ash handling system, to imporve the technology, substitute traditional wet ash handling system. Project team conducted research and test on the key technology. Developed dry bottom ash handling technology with independent intellectual property rights and has been awarded national patent. In May, 2002, steel belt conveyor dry bottom ash handling system passed the technical identification by National Power Company. Steel belt conveyors has been in operation in more than 200 units worldwide since 1986 with sable and safe system. It is the most advanced and mature technology at present. Futong steel belt conveyor dry bottom ash handling system has been awarded 15 patents, including 4 international patents from Australia and India. And its new technology was applied for the latest international patents in Russia, Australia, America, Vietnam and India through PCT in 2010.

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2.

Difference

on of

key Key component of steel the belt conveyor structure and connection of high temperature super steel resistance belt are Key component of Chain (steel plate) conveyor chain structure and connection are sown in the figure: Connection between the chain plate and chain is connected by many connecting pins (shown as the figure below). Adjacent chain plate speads and composes conveying path.

components conveyor

shown in the figure: The super belt is formed of heat resistance, resistance

wearing

stainless steel mesh, and overlapped carrying pan of steel belt. Each

overlapped carrying pan looks like inclined ladder and fixed together by stainless steel bolt and lock bar.

Features: A: Due to the flexible component steel belt mesh, the relatively tightness between
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Connecting pin

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carrying pan can be effectively guaranteed by reasonable pressing force (Note: the process can ensure pressure by nail electric welding) and overlapping arrangement of carrying pan, so as to prevent leakage of fine ash onto the lower section. Some fine ash accumulated on the lower part because of cooling air, it can be effectively conveyed to discharge outlet by fine ash cleaning chain under the super steel belt. A: Connection between the chain plate and the chain is hard-wired. Fine slag is easy to leak through the gap between adjacent chain plates. Although installed the below fine ash clean plate, it is difficult for the clean plates to scrape bottom ash from the tail of the conveyor to the upper ash channel, so as to cause a large accumulation of fine ash and serious wear and tear of the tail curved plate and cleaning plate.

B: When super belt conveys bottom ash, bottom ash can be flatly spread on the steel belt, whose effective width is 1.2m. The heat exchange surface area between the cooling air and bottom ash is large so the cooling effect is googd. The maximum capacity of the steel belt conveyor can reach 100t/h with strong capability to adapt the load changes of boilers. C: Impact bars for large clinker can effectively avoid direct impact of the large clinker onto the super steel belt. And because of the overlapping arrangement of the carrying pan up on the steel belt, as well as the large number of carrying idlers across the width of steel belt under the belt, the direct impact from the bottom ash to the mesh is effectively avoided, so as to prolong the service life of the steel belt. D: Due to the line contact between adjacent carrying pans, the carrying pan can rotate by the axis of that through cylinder, so as to reduce additional resistance. In addition, friction between the super steel belt mesh and cylinder can transmit driving force. It is the surface contact between the steel belt mesh and cylinder. As a result, the
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Tail of conveyor and Curved cleaning plate A: The Chain (steel plate) conveyor is composed of several channels. The height of the scrapper is only 200mm and the volume of each trough is the same. As a result, the capacity of this system is limited and the capability to adapt load change is poor.

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adhesion is strong while the wear is small.

Ash trough A: When the steel plate (chain) conveyor is in operation, bottom ash accumulates in each ash trough. This conveyor is like bucket chain conveyor, with poor cooling effect. B: This steel plate (chain) conveyor is the modified product of Super steel belt traditional scrapper chain conveyor. Using chain drive, it can be

E: The special structure of steel belt can have free expansion to any direction in hot avoid chain deformation in long term hot operation condition. condition, and free draw back in cold condition, without potential dangers such as The impact of large clinker, as well as the changes of center chain break. It will not reduce efficiency of the boiler or cause boiler shutdown. Drive and return Sprockets And it can adapt to any working condition of boilers. distance of the chain caused by uneven accumulation of the total expansion of both sides, may cause chain jump and jam, and other accidents. In the high rate of bottom ash condition (ash rate 5t/h), the drive chain may suddenly break, causing serious boiler shutdown accident.

Super steel belt conveyor F: The steel belt of the conveyor is supported by many carrying idlers across the width of the steel belt. In the condition of high bottom ash rate, the load is distributed evenly across the width and length of the conveyor, so the super steel belt is not easily deformed.
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Chain break after plastic deformation

Sudden break of chain

Carrying idler of super steel belt

E: Chain plates are supported by small carrying idlers on both sides. In the condition of high

G: Guaranteed service life of steel belt is longer than 55000 hours. Based on domestic bottom ash rate, they are easily deformed. and international project applications, the average service life of the super steel belt is more than 10 years.

Carrying idlers at both side of chain plate

Figture of carrying idlers at both side

F: For steel plate (chain) conveyor, there are only two 600MW units operation projects. From October 2008, chain plates block accidents happened six times and the chain plates have been changed. Other two 300MW steel plate (chain) conveyors has changed the whole set of chain plate since 2008. It is hard to ensure safe and stable operation. 3. Design of clinker The clinker crusher is integral cast structure: The shutting door is inserted structure:

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crusher

A: The clinker crusher is composed of impact bars, pre-crushing bottom door, shell, A: This structure did pass practical application verification. driving hydraulic cylinder, monitor system, hydraulic power pack and piping. The key hydraulic components, such as oil pump and adjusting valves, are imported ones.

Hydraulic pre-crushing bottom doors (clinker crusher) B: The body of clinker crusher is made of high temperature resistance, abrasion and wear resistance material, can be used as shutting door and crusher. It designed to be free maintenance structure with 30-year service life. Inserted shutting gate

C: The crushing teeth of clinker crusher use hydraulic drive. It can flexible open and close as the shutting door. And it can effectively pre-cool and pre-crusher clinkers. Clinkers, large than 200mm, fall onto the impact bars firstly to be pre-cooled. Then they can be crushed by tooth-like horizontal moved extrusion heads, then conveyed by ash conveyor. The impact bars can withstand the impact of 2-ton clinker falling
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within 40m without deformation and damage. D: The open and close of clinker crusher is horizontal movement. Vertical force is born by the immobile impact bars. The shutting door is not forced and will never open automatically even if the cylinder does not work properly. E: The falling and crushing process can be monitored by camera system. When the extrusion heads closed, they are used to open and close ash hopper.

Shutting gate installation site A: Does not own independent intellectual property right.

Video camera detection online F: Clinker crusher is evaluated by projects applications (more than 9 years operation) to be safe and reliable.

G: Clinker crusher is Futongs patented technology and owns independent intellectual property rights, with national patent No. ZL01200943.1 and Australian patent No. 2006100112.
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4.

Features

of

the Section structure of steel belt conveyor:

Section structure of steel plate (chain) conveyor:

structure of ash conveyor

The fundamental problem of steel plate (chain) conveyor is sourced from its 1.upper cover of conveyor 2. Ash guidance plate 3. Super steel belt 4. Guidance idlers to prevent line deflection of carrying layer of steel belt 5. Carrying idlers of steel belt 6. Assistant air inlet on the lateral side of conveyor (check type) 7. Guidance idlers to prevent line deflection of return layer of steel belt 8. Carrying idlers of return layer 9. Cleaning chain supporting wheel 10. Fine ash clean scrapper Features: A: There are two layers of the conveyor, the upper on be super steel belt and the
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side-double-chain drive mode, which shortages cannot overcome by itself. A: The steel plate (chain) conveyor is one layer arrangement, which means the chain and chain plate (ash trough) combined. It does not have misalignment adjusting device. The misalignment caused by large clinker impact or uneven heat expansion cannot be adjusted.

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lower one be fine ash cleaning chain.

Section structure of steel plate (chain) conveyor B: In the operation of steel plate conveyor, the temperature of chain plate will reach more Section structure of steel belt conveyor B: Ash guidance plate is above the steel belt to lead the ash onto the whole width of steel belt. It can improve the cooling effect. And the guide plate is sealed under the shell and isolated from dust which can ensure clean environment, also forms cooling wind flow channel. C. Bearing blocks are designed at the outside of shell. Carrying idlers, return idlers and other rotation parts are dust proof sealed on the lateral plate of shell. Bearings work in low temperature, dust-free environment to ensure reliable operation. D. All bearing blocks, carrying idlers and return idlers can be overhauled and replaced outside the shell. than 300 . The horizontal expansion amount will more than 5mm (usually, the expansion coefficient for steel 1mm/m. 100 ). The space between chains will increase. When the head wheel engages, vertical chain link will rub drive wheels ring trough, which cause extra wear of the chain. C: Because of the falling down of the bottom ash, the materials accumulated on the chain plate are not even, which may cause heat unevenness of two sides chains and cause difference heat expansion. Meanwhile, when head wheel engages, two sides horizontal chain links are asynchronous, which may cause incline of the chain plate relative to the drive shaft and cause extra wear of the chain. D: Double-chain drive depends on stress of two chains. If uneven wear happens, or other factors cause one of them strength reduction or damage, the security of the system is reduced greatly. E: Due to principle of double chain drive is meshing transmission mode, it has its own problems. The uneven wear and different speeds may affect safety operation and service
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life. In the high temperature and high dust condition, it will not ensure 55000 hours service life. For the steel belt conveyor, using the basic principle of belt drive, the above problems do not exist. The key component of dry bottom ash handling system is ash conveyor, which safety and stable operation can ensure normal operation of the boiler.

Appearance of steel belt conveyor

Appearance of steel plate (chain) conveyor 5.Performance parameters The guaranteed service life of steel belt is longer than requirement in bidding Steel plate conveyor cannot reach the requirement of 50000h service life. Even if the document, which requires that service life of mesh is longer than 50000h. All data are manufacturer promises, the data is short of supports by theory and practical application. based on theoretical calculation and project application.

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6. Cooling technology of At present, steel belt conveyer is the most advanced cooling technology for bottom The bottom ash cooling technology exists insurmountable faults, and China domestic power bottom ash ash in the field of air cooling bottom ash handling system. Market share is larger than groups rarely use it. 99%. A: For domestic coal-fired units which have large bottom ash rate, Guodian Futong has developed two new technologies and filed patents respectively. They are reviewed by State Patent Office in January 2006 and registered international patents. The patent number 200610011273.1 and 200610011274.6 respectively. These two patented technology is to solve the cooling problem in large clinker condition. The technology has been applied in dry bottom ash handing system of # 1, # 2 units in Huaneng Shangan power plant. B: The patent technology can effectively deal with large bottom ash rate (change of the coal quality) in 1000MW units and can support safety and stable operation. 7.Manufacture technology In the tender, Guodian Futong has described its material selection, surface treatment, No quality inspection in detail. And there are more than 30 units manufacture references. Ash conveyor is the key component and Guodian Futong controls its quality by the following measures. A: Material selection: shell of conveyor heavy-duty H section steel for the skeleton. Carrying idlers are made from thick-walled seamless steel pipe. Conveying mesh is manufactured by imported ultra-low carbon stainless steel. And key components, such as cylinder and its shaft, are conducted non-destructive ultrasound test. B: Control of components: components and self manufactured components are strictly checked and timely complete the "FT-QR8-25 components inspection record card. And establish more than 100 inspection record card for key components. Each component has a complete set of quality record after manufacture. C: Part Assembly: Qualified components are assembled next. Assemble is conducted in strict accordance with FT-QRT-24b production process card and the
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TZ2005-01A technical requirements of steel belt conveyor factory assembly, testing, commissioning and packaging. D: Operation and commissioning: after assemble the shell, steel belt and cleaning chain should be installed based on practical length and angle of the project and conduct 48 hours test, and then fill out the form TZ2005-01A steel belt conveyor factory acceptance form. For oversized steel belt conveyor (extra length, width or large capacity), it is required to do load test. E: Delivery: Pass the test and qualified, fill out FT-QR8-26B steel belt conveyor factory acceptance, and signed FT-QR7-28d product certification. Then do the equipment disintegration, packaging and delivery.

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8. Practical application

Until November 2010, reference of Guodian Futongs dry bottom ash handling system There are only 4 operation reference, 2 x300MW units (A plant) and 2x 600MW units (B include 22 1000MW units, 88 600MW-660MW units, 63 300MW-350MW units and 36 plant) and bottom ash rate is less than 2 t/h. 200MW and below units. The longest reference is 9 years and 8 months. It is a All ash troughs have been replaced in B plant within 2 years from 2008. technology mature system which can meet the requirement of safety and reliability. There were six times of blockage of chain plate in A plant and replaced steel ash trough from And its feature of energy-saving and environmental benefit is remarkable. The number of reference projects of Guodian Futongs bottom ash handling system has reached 209 sets until now. October, 2008.

Connection pin out of ash trough

Damage of ash trough and much bottom ash accumulated at back side 9. Standardization A: Entrusted by national standards committee, Guodian Futong has completed the No compilation work of industry standard of air cooling steel belt conveyor (Dry bottom ash handling system). B: Entrusted by national standards committee, Guodian Futong is doing the compilation work of industry standard of technical requirements of clinker crusher.

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