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About Mitsubishi Hitachi Power Systems, Ltd.

Mitsubishi Hitachi Power Systems, Ltd. (MHPS) based in Yokokama /Japan, is a global energy

plant constructor player and has a total of 58 subsidiaries (9 in Japan, 49 in other countries).

The company was established as a joint venture in February 2014. It unites the thermal power

plant divisions of Mitsubishi Heavy Industries, Ltd. and Hitachi, Ltd. MHPS employs some

23,000 staff (consolidated) and its aim is to be No. 1 in thermal power plant construction.

Content Internationally on the Go 2

Service as a Key Business 4

Maintaining Performance 6

Trendsetting Technologies 8

Fitting Solutions for Any Application 9

Lignite Coal Dust Burner 10

Firing Systems 11

Grate Firing – Roller Grate 12

Stoker Firing – Moving Grate 14

Pulverizers 16

Assembly Planning 20

Conversion – Modernisation – Maintenance 21

Commissioning 22

Shield for Accelerated Boiler Service (SABS®) 24

Boiler Service 28

Quality Management & QC Monitoring 30

References 32

BUSINESS ACTIVITIES / PRODUCTS OF MITSUBISHI HITACHI POWER SYSTEMS, LTD.

Power Generating Plant Peripheral Equipment

Steam Turbines

Environmental Plants SCR (DeNOX) Systems / Flue Gas desulfurization

Gas TurbinesGas Turbine Combined Cycle (GTCC) Power Plants

Integrated Coal Gasifi-cation Combined Cycle (IGCC) Power Plants

Boiler & Turbine Generation Plants

Geothermal Power Plants

Boilers

Generators

2

Internationally on the Go

About Mitsubishi Hitachi Power Systems Europe GmbH

Mitsubishi Hitachi Power Systems Europe GmbH (MHPSE) is a 100 % subsidiary of Mitsubishi

Hitachi Power Systems, Ltd. (MHPS). The energy plant constructor headquartered in Duisburg

both designs and builds thermal power plants (coal, gas). With its references MHPSE ranks

amongst the market and technology leaders. The company also supplies key components

such as utility steam generators, environmental engineering equipment, turbines and coal

grinding systems.

Along with supplying key components, MHPSE also concerns itself with pro-active service.

Green technologies – in energy storage and biomass, for instance – are further examples of

the energy plant constructor’s innovation and reliability.

MEERANER DAMPF KESSELBAU GMBH

Manufacturing of premium components for utility steam generators

(e. g. pressure parts) for power plants

DONGES STEEL TEC GMBH

One of Germany’s leading steel and bridge constructors;

manufacturing of steel structures for power plants

BABCOCK FERTIGUNGSZENTRUM GMBH

Production of first-class components for power plants

(e. g. coal mill), mainly for MHPSE

MITSUBISHI HITACHI POWER SYSTEMS EUROPE GMBH

Subsidiaries and Related Companies

Powerful Services 3

Everything from a single source

In supplying spare parts, revamping components, raising efficiency and extending the plant

life cycle, Mitsubishi Hitachi Power Systems Europe provides extensive service solutions for

power plants and components. The company has obtained comprehensive references

thanks to a 100 year+ track record in designing, constructing and commissioning energy

plants. This applies both to the new construction business and also to repairing external

and in-house facilities as well as servicing/optimizing components (e.g. grinding systems,

turbines, grates).

The expertise gained covers all types and sizes of power plants and firing systems

for all conventional fuels:

■■ Water tube boilers (natural circulation)

■■ Heat recovery boilers (process)

■■ Heat recovery boilers

(downstream of gas turbine)

■■ Waste-to-energy systems

■■ Fluidized bed systems

■■ Special boilers (chemical industry)

■■ Benson® steam generators

The Service business includes construction, commissioning, quality management, documen-

tation and a 24-hour emergency service. MHPSE specialists provide solutions from a single

source and thus ensure that orders are handled reliably and efficiently.

4

Service as a Key Business

Beater wheel of an NV mill

Service for mills

Whether it is lignite or hard coal, whether they are our own products or from other

manu facturers: Mitsubishi Hitachi Power Systems Europe has comprehensive expertise in

the optimisation of crushing and grinding plants. Our experienced service specialists

determine reliable and operationally safe solutions to significantly improve the performance of

coal mills. Spare parts, repairs and a comprehensive on-site service complete the portfolio.

Our services at a glance:

Optimisation

■■ Adaptation to changed

coal properties

■■ Increase of throughput and

grinding fineness

■■ Milling of non-standard fuels

■■ Classifier / fuel laden vapour

separator optimisation

■■ Process engineering consulting

■■ Mill instrumentation and control

systems

Upon request, our specialists will perform comprehensive mill measurements and will

utilise specifically developed, highly precise CFD calculations (Computational Fluid Dynamics).

Spare parts / repairs

■■ Installation of complex components

■■ Overhauling of components, repair

■■ Complete solutions / overall packages

(from removal to commissioning)

On-site service

■■ Providing staff for performing

conversions

■■ Long Term Service Agreements,

LTSA

Powerful Services 5

Service for turbines

Maintaining performance and availability: That is the premise for the service for turbines.

Due to many decades of experience in the construction and commissioning of steam /gas

turbines within the Group, our experts can perform a comprehensive fault analysis in case

of mechanical, electric and instrumentation and control system problems. A 24 / 7 hotline

and instant service for gas turbines are a matter of course. Our services in the area of

turbine service also include:

On-site service

■■ Combustion chamber inspection

(gas turbines)

■■ Hot gas routes inspection

(gas turbines)

■■ Main inspection (gas turbines)

■■ Training of the customers’ staff

■■ Service for generators

■■ Elimination of mechanical, electrical

and instrumentation and control

system problems

Engineering

■■ Support for modification, modernisation

and conversion

■■ Planned / unplanned maintenance

■■ Long Term Service Agreements, LTSA

1 Removal of the second generator stage

2 + 3 Removal and cleaning of the turbine housing during

inspection of the hot gas routes

1 2

3

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Maintaining Performance

Construction / Commissioning

Whether new plant construction, revamping or servicing individual components is involved,

the Service division of Mitsubishi Hitachi Power Systems Europe provides both technical staff

and equipment for construction and commissioning of power plant installations and their

components.

This is undertaken whatever the location and country with regard to:

■■ New steam generator construction

■■ Inspection, repairs and

maintenance work

■■ Boiler implementation

■■ Field site inspection

■■ Plant optimization

■■ Measuring technology

■■ Power plant chemistry

■■ Personnel instructional training

■■ 24hr hotline service

Spare parts

Mitsubishi Hitachi Power Systems Europe can resort to both manufacturing facilities

within the Group and from associated companies. That makes MHPSE an ideal partner for

optimising work and obtaining spare parts.

Our spare parts service includes the following components:

■■ Feeders

■■ Grinding systems

■■ Firing systems

■■ Ash extractors

■■ Gas and steam turbines

■■ Boiler pressure parts

■■ Stoker firing

Whether it is new plant construction, modernisation or maintenance of individual components – we provide the specialist staff and equipment

Powerful Services 7

Optimal furnaces for every kind of fuel

For over 50 years Mitsubishi Hitachi Power Systems Europe GmbH has been successful in

constructing and manufacturing burners, as well as developing combustion concepts for

wordwide plant engineering.

Whether in power plants strictly for power generation or in industrial power plants for steam

and power generation, the furnace systems of Mitsubishi Hitachi Power Systems Europe

are applied in almost all areas of energy conversion and are always optimally adapted to the

prevailing requirements.

Fuels have different chemical components, combustion properties, calorific values and

flame velocities. This demands a careful selection of the type of combustion, the burner

arrangement in the furnace, as well as the burner construction.

To not only achieve the legislative limits for air pollutants imposed for the protection of the

environment but rather stay below them, we are constantly further developing our furnace

systems in cooperation with the UMSICHT Fraunhofer Institute and the Chair of Environ mental

Process Engineering and Plant Design at the Duisburg-Essen University (LUAT – Lehrstuhl

für Umweltverfahrens- und An lagentechnik). As a result, our plants have already been trend-

setting for many years in the field of primary corrective measures for pollutant reduction.

According to customers requirements, we carry out thermodynamic calculations, create

concepts based on these models for the modernisation, rehabilitation, repair, conversion,

as well as fuel adaptation, including all the related E-C&I components.

From planning, basic and detailed engineering to the delivery and construction as well as

commissioning and acceptance, we implement the concepts up to final hand-over of the

plant, and guarantee an interface-free optimal integration into the energy production system.

Firing systems

■■ Burner and firing systems for fossil fuels

■■ Burner and firing systems for process gases

■■ Thermal disposal of residues

■■ Claus Plants for sulphur recovery

■■ Firing systems for GT exhaust gases

Steam atomisation for liquid fuels

8

Trendsetting Technologies

Our types of burners and their different applications

Independent of the different combustion characteristics of the fuels being used, we have the

suitable burner types and combustion systems. This diversity of combination options ensures

the optimal solution for any field of application.

Fuels Type of furnace Burner design

■■ Natural gas■■ Light fuel oil (LFO)■■ Heavy fuel oil (HFO)■■ Hard coal■■ Lignite■■ Coke-oven gas

■■ Front firing■■ Boxer firing■■ Tangential firing■■ Bottom firing■■ Top firing

■■ Swirl burner■■ Stage burner■■ Jet burner

■■ CO exhaust gas■■ Blast furnace gas■■ Sour natural gas■■ Tail gas■■ Contaminated air ■■ Contaminated steam

■■ Combustion chamber■■ Front firing■■ Tangential firing■■ Bottom firing

■■ Swirl burner■■ Multi-nozzle burner■■ Claus burner

■■ Waste water■■ Salt residues■■ Residual coke / petroleum coke■■ Slugdes

■■ Preceding combustion chamber■■ Front firing■■ Top firing

■■ Special burner■■ Cyclone

■■ Residual gases NOX , HCN, NH3 burdend

■■ Reactors with 2 or 3 air stages / fuel staging

■■ Central burner■■ Stage burner■■ Multi-nozzle burner

Low NOX pulverised coal burner

Powerful Services 9

Fitting Solutions for Any Application

Harmonised range of products

In medium-sized power plants, pre-fabricated pulverised lignite dust is increasingly used as

fuel to avoid costly milling machinery.

Our round swirl burners with their primary NOX -reducing measures have also been success-

fully in use for this fuel for years. Likewise, the formation of nitrogen oxides (NOX ) is reduced

by the staged air supply, and low emission values are achieved with the combustion of

pre-fabricated pulverised lignite dust.

Pulverised coal furnace for hard coal and lignite

The round swirl burners, used and proven in power plants for years, have been further

developed and improved by staged air in the burner, resulting in Low-NOX furnaces,

and are therefore also known as “Low NOX” pulverised coal burners.

The possibility to adjust the various airflows, permits an adaptation to a broad range of fuels.

Here, too, similar to gas-oil combustion, the generation of nitrogen oxides (NOX) is reduced

by the sub-stoichiometric combustion in the core of the flame. The simultaneous avoidance

of temperature peaks during combustion decreases the rate of formation of thermal

nitrogen oxides.

Another NOX-reducing measure is the staged combustion over the entire combustion cham-

ber. The combustion air is hereby provided in stages both to every burner level as well as

across the whole combustion chamber. Downstream of the overfire air injection, the sub-

sequent residing time of the solid fuel particles in the respective combustion areas determines

the burnout and the degree of NOX reduction.

Another possibility of NOX reduction is the injection of a reduction fuel between the last

highest burner level and the upper air. One such typical reduction fuel consists of a mixture

of recirculated flue gas and natural gas.

For hard coal and lignite furnaces, our scope of delivery comprises of all components of the

combustion system including all necessary auxiliary equipment, such as:

■■ Pre-fabricated dust silo

■■ Inertisation plants

■■ Weighing equipment

■■ Pneumatic conveying equipment

■■ Burners

■■ Burner control units

■■ Measurement and control components

■■ Coal mills

■■ Pulverized fuel lines

■■ External flue gas recirculation

■■ Coal feeders

■■ Ash removal plants

10

Lignite Coal Dust Burner

OIL / GAS FURNACES

MHPSE uses special burner systems for low NOX combus-

tion of fuels with a high calorific value, such as oil and gas.

OUR COMBUSTION FOR BLAST FURNACE GAS AND COKING GAS

Blast furnace gas comes from the blast furnace process

and is characterized by low calorific values. An additional

difficulty is the usually very low pressure of the gases,

requiring the lowest possible pressure drop across the

burner. Particular attention must therefore be paid to the

burner design for achieving a proper fuel / air mixture.

LOW BTU GAS FURNACES

Gases with low heating values, such as low-calorific

gases from process technologies, require special gas

burner designs.

FURNACE SYSTEMS FOR GT EXHAUST GASES

In combination power plants whose steam generator

plants are equipped with gas and steam turbines, the

energy conversion processes permit an increase of net

efficiencies of more than 50 %.

PLANTS FOR NOX REDUCTION

In our plants the already existing NOX is reduced again

and reduction rates of up to 95 % can be attained.

Powerful Services 11

Firing Systems

Roller grates – the robust, low maintenance grate concept

Whether in power plants purely for power generation, or in industrial power plants for steam

or power generation: The firing systems of Mitsubishi Hitachi Power Systems Europe GmbH

are applied in almost all fields of energy conversion and are always optimally adapted to the

specified requirements.

Environmentally-friendly combustion requires special concepts and measures for household

and municipal waste, RDF, treatment of residues as well as biomas. The use of the thermal

energy generated from grate firing offers an appropriate and economic alternative to landfilling.

Different grate systems are selected depending on the calorific values. Medium and high

calorific waste requires grate systems with grate bar cooling systems to limit the grate bar

temperature, such as our patented air- and /or water-cooled moving grates.

For low or medium calorific residues, however, quite often the robust roller grate systems with

the more economical cast iron surfacing are frequently used.

Whatever the composition or calorific value of your waste may be, with our numerous grate

system currently in use that have proven themselves for many year, we definitely have a

suitable combustion grate for your case.

Our service portfolio:

■■ Air- and water-cooled combustion grates

■■ Feeding devices & ash extraction systems

■■ Systems for primary / secondary air and recirculation flue gas

■■ Ignition and auxiliary firing system

■■ Firing optimisation

■■ Fluid dynamics simulations (CFD studies)

■■ Combustion control systems

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Grate Firing – Roller Grate

Technical parameters of the roller grate

Fields of application

■■ LCV from 5,000 to 14,000 kJ / kg

■■ Max. throughput up to 40,000 kg / h

Advantages

■■ Robust and low-maintenance grate system

■■ Intensive turning and mixing of the waste

■■ Fast drying and ignition of the fuel

■■ Use of low-alloyed grate bars (cast iron)

■■ Long service time of the grate bars

(thermal load only on the upper side of the roller grate,

the lower part is cooled by the air flow)

Structural data

Roller diameter 1,500 mm

Grate widths 2,000 – 8,000 mm

Number of air zones / grate sifting hoppers up to 4,250 mm of width = 6 up to 4,500 mm of width = 12

Grate inclinations 20°, 25° or 30°

Grate length (based on roller size) 6 rollers = 14,810 mm 7 rollers = 17,390 mm

Design data

Rotation speed of a roller 0.6 rph to 12 rph (rounds per hour)

Range of LCV 5,000 kJ / kg – 14,000 kJ / kg

Thermal grate load 0.5 MW / m² – 0.75 MW / m²

Mechanical grate load 200 – 280 kg / m²

Waste throughput 8 t / h – 37.5 t / h at reference calorific value of 9,300 kJ / kg

Firing rate 21 MW – 100 MW at reference calorific value of 9,300 kJ / kg

Primary air pre-heating up to 200 °C possible


Your fuel – our know-how

Our grate technologies, which have proven successful in operation for many years,

deliver the solution for thermal disposal even at the highest calorific values.

The mechanical and thermal grate surface load, as well as the layout data of the respective

firing diagram are the decisive variables for the layout of the grate bar. Furthermore, the

ignition and burn-out behaviour of the fuel, as well as the waste size and burn-out quality

determine the grate lengths and fuel layer height.

Fuel Method

Household waste, municipal waste, industrial waste, biomass

Air-cooled moving grate

Household waste, municipal waste, bio refuse, RDF, industrial waste

Air / water-cooled moving grate

Household waste, municipal waste, RDF, industrial waste

Water-cooled moving grate

Projects / Products of Mitsubishi Hitachi Power Systems Europe (selection)

Project Technology Total capacity

EVI-Europark Emlichheim Germany 2 Lines 365,000 t / a

Spreerecycling Spremberg Germany 1 Lines 240,000 t / a

Moscow MSZ 3 Russia 2 Lines 360,000 t / a

MVA Spittelau Vienna Austria 2 Lines 250,000 t / a

swb Bremen Medium calorific power plant (MKK) Germany

1 Line 230,000 t / a

swb Bremen Germany 4 Lines 500,000 t / a

Our know-how is protected by various German and international

patents and registered designs.

14

Stoker Firing – Moving Grate

Our own grate technology makes the difference

Built as a module, each grate carriage has two primary combustion air zones. A grate track

with a length of 9,200 – 10,800 mm, used for example for thermal disposal of domestic waste,

consists of three grate carriages, whereby the number of grate tracks will be determined by

the waste throughput.

The grate carriages of the moving grate supported on ball bearings are activated by push

rods connected to a hydraulically operated shaft. Since the ball bearings of the grate carriage

do not require any lubrication, the operation at higher combustion air temperatures is possible

without any problem.

Air-cooled

The patented air cooled grate bars are dimensioned for a longer lifetime. This is possible by

using a second wear front plate, located behind the frontside. The outer frontside guarantees

the function of the grate bar and therefore also the extension of the lifetime, even at higher

thermal wear. The grate bar can be constructed so that it is possible to use it for “one side”

or “two side-reverse” bar.

Area of application:

■■ Unrestricted use for mid and low LCV

LCV = < 12,000 kJ / kg

Economic and operational benefits:

■■ Long lifetime resulting from the use of our grate technology with wear front wall

Water-cooled

Manufactured from cast iron with a width of 240 mm, the grate bars are cooled with casted

in water tubes. Their seal effectiveness is also guaranteed at higher temperatures.

Area of application:

■■ Unrestricted use for the LCV range from 6,000 to 20,000 kJ / kg

and with restrictions even to 30,000 kJ / kg

Economical aspects:

■■ 32,000 h operation guarantee

■■ 8,000 h (operation) dry running operation

with service life extension

■■ Availability > 8,000 h per year

■■ Increased operational safety

■■ Reduction of maintanance costs

■■ Extension of the inspection intervals

■■ Reduced number of spare parts to keep in stock Water-cooled grate bar

Feed principle

Air-cooled grate bar


High grade and reliable

Mitsubishi Hitachi Power Systems Europe plans and designs high-grade grinding systems for

thermal power plants. The plant constructor has extensive know-how and detailed references

in coal mills and related components.

The in-house manufacturing facility at subsidiary Babcock Fertigungszentrum GmbH, Ober-

hausen ensures that MHPSE supplied components are high grade in quality and dependable

in their functioning.

The company supplies the following components for the construction of new power plants

fired either with bituminous coal or lignite:

■■ Raw coal bunker design

■■ Internal coal feeding equipment

■■ Grinding systems for lignite

■■ Grinding systems for bituminous coal

■■ Grinding systems for biomass

■■ Hopper ash extraction systems

■■ Ash dewatering and recooling systems

■■ ESP and / or fly ash disposal systems

■■ Ash transport and loading equipment for

loading on ships, trucks and rail wagons

In addition our experienced technicians and engineers determine customized solutions for

performance increases, load change speeds and grinding fineness.

MPS® Mill

16

Pulverizers

Grinding systems for bituminous coal

In the mills, the raw coal is simultaneously pulverized, dried and evenly distributed to the coal

burners. Hot air or flue gases transfer the pulverized fuel to the burner and reduce the

moisture in the coal.

MPS® Bowl & Roller Mill

The MPS® bowl & roller mill from Mitsubishi Hitachi Power Systems Europe grinds and dries

hard coals and difficult-to-grind lignite with a low moisture content to pulverized fuel and

distributes them evenly directly to the burners.

Various-sized mills for throughputs ranging from 10 t/h to 200 t/h can be supplied. Constant

refinements and impro vements have led to excellent crushing results with high fineness

grades from raw coal found throughout the world. The positive operating properties and low

energy requirements have contribu ted in no small measure to the success of these mills.

RKD Tube Ball Mill

The Mitsubishi Hitachi Power Systems Europe RKD tube ball mill grinds and dries difficult-

to-pulverize hard coals (particularly low-volatile coals such as lean coal and anthracite).

This mill type can deal with approx. 150 t /h of coal. Depending on size and space, the

tube ball mill can be designed with drum or neck bearing and be of the single or double

pass type.

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A Rotary classifier

B Oversize return

C Neck bearing

D Drive gear rim

E Grinding ball filling

F Feed spiral conveyor

G Classifier riser

RKD Mill MPS® MillA Rotary classifier

B Classifier drive

C Grinding rollers

D Hydro-pneumatic system

E Grinding table

F Gear

G Motor


Grinding systems for lignite

Pulverizing lignite is particularly challenging in view of its high moisture content and the

considerable throughputs involved. Here again Mitsubishi Hitachi Power Systems Europe

has the right products in this segment.

DGS® Integral Fan Distributor and Beater Mill

MHPSE supplies DGS® mills of various sizes up to a 180 t/h throughput for drying and

pulverizing raw lignite and brown coals with a high moisture content.

DGS® technology involves the raw coal and flue gases being initially put through the

pre-crushing beater section of the beater wheel. This ensures excellent air and coal dust

distribution into the beater wheel. Crushing in the DGS® mill is usually so intensive that

adequate grinding fineness can be obtained in one working operation – without the need

of an additional classifier. This both raises the pressure balance and cuts back on energy

requirements.

NV Wet Coal Fan Mill

The NV mills ranging from 10 t/h to 140 t/h throu ghputs are for crushing high moisture

content lignites for direct injection into the furnace. Together with the flue gases, the raw lignite

is brought for crushing purposes into the beater wheel. It acts as a fan impeller fitted

with beater plates. Baffle-type classifiers ensure that the required fuel fineness for combustion

is fulfilled.

The high-tech NV mill more than meets the ongoing demands worldwide of operational

availability and low costs.

The DGS® mill has stood the test of time particularly with difficult-to-work lignites –

something that explains its considerable lifetime and unrivalled properties.

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A Gate valve housing

B Grinding chamber door

C Grinding chamber

D Beater wheel

E Baffle-type classifier

F Double bearing

G Motor

NV Mill

A Flue gas gate valve

B Inlet housing

C Beater shaft

D Beater wheel

E Coupling

F Motor

G Bearing

DGS® Mill

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Pulverizers

Mill Feeders

Designed as coal bunker dischargers, the mill feeders supply the pulverizers with raw coal –

evenly dosed and in keeping with boiler load requirements. Even under very demanding

requirements, the Mitsubishi Hitachi Power Systems Europe designed mill feeders operate

both reliably and safely.

Experienced MHPSE staff establish the optimum feeder in keeping with the requested fuel

quantity, design directives (including DIN EN 12952-9, NFPA 85 F) and customer require-

ments (for instance, volumetric and gravimetric metering). Other selection factors are the

various bulk material properties, such as coal flow and erosion behavior. The belt speed is

determined by the quantity conveyed. Purge air is supplied to the housing to stop condensate

forming and, in turn, to stop corrosion.

Belt conveyor

The corrugated edge belt conveyor ensures high outputs, uniform bunker discharge and

continuous mill charging – even under low conveying rates. This design permits volumetric /

gravimetric metering and quantities conveyed of up to 120 t/h. Conveyed material falling to

the bottom of the feeder is transferred to the coal downcomer by the simultaneously

running scraper chain.

Drag-chain conveyor

Drag-chain conveyors are meant for limited conveyed quantities of up to approx. 40 t/h –

this can, in special cases, be raised to 70 t/h. The fuel is discharged opposite to the direction

of conveying. The drag-chain conveyor principle allows both a compact design with minimum

spacing between bunker discharge and conveyor dumping as well as a possible large

spacing between material charging and dumping.

In hard coal boiler units, belt conveyors are used to discharge the raw coal from the bunker. In lignite plants, drag-chain conveyors together with belt conveyors are used to discharge the raw coal from the bunker.

Raw coal

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A Bed depth limiter

B Belt drive station

C Belt tensioning station

D Corrugated edge belt

E Scraper chain

F Lower belt supporting roller

G Bunker shut off gate

H Conveyor-type weigher (optional)

Belt conveyor

A Bed depth limiter

B Belt drive station

C Tensioning station

D Forged fork link chain

E Bunker shut off gate

Drag-chain conveyor


Decades of Experience

As an internationally leading company in the field of industrial and power plant service,

Mitsubishi Hitachi Power Systems Europe GmbH also offers extensive service apart from

comprehensive engineering. This service covers the areas of assembly, commissioning

and quality management.

The basis for this service is our decades-long experience in large power plant, boiler and

furnace construction, starting with the disassembly and reassembly concepts all the way to

the contractually compliant hand-over to the customer. Already in the planning stage we put

special value on predictive and detailed processing. We can execute extensive and

challenging projects on schedule and goal-directed. Potential problems are thus recognised

early on and taken into consideration. Our experienced commissioning team accompanies

the completion of the work to the end of assembly and at an early stage makes itself

acquainted with the local conditions of the overall plant. After having finished the erection

works, commissioning begins incl. functional checks, boiler cleaning, load tests and test run,

training of the operating staff and transfer to the customer. In parallel, a quality management

that accompanies both the project and the order ensures an implementation in compliance

with the applicable regulations.

Our installation team – your partner

Installation planning focuses on all areas of industrial and power plants including their ancillary

equipment, regardless of where the plant is located. The relevant specialised departments of

our parent company support every construction site for the entire duration of construction.

This direct involvement ensures maximum flexibility at all times and in every situation, allowing

for joint handling and implementation of solutions even for unusual or unexpected situations.

Assembly planning

■■ Conversion – modernisation – new construction

■■ Maintenance & inspections

■■ Boiler relocation

■■ Site supervision

■■ 24-hour service

NEW PLANT CONSTRUCTION

And when constructing new plants, we also supply experienced construction super-

visors through to site management in addition to our specialists. The specialised

knowledge and leadership skills of our experts guarantee quality and success! That is

why we attach great importance to the qualifications and continuous education of our

employees.

Construction is carried out on the basis of detailed engineering documents, which are

prepared by our experienced staff and then undergo continuous internal and external

quality assurance and checking for compliance with project scheduling. Moreover,

our 24-hour on-call service takes care of short-term deployment of personnel even

outside regular working hours in order to respond to damage events, assess and repair

damages through to restoring plant availability.

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Assembly Planning

We bring your plant up to date!

Revamping and modernisation

New environmental regulations, changed operating parameters or constant demand to

increase efficiency have, amongst other reasons, made it necessary to modernise or even

replace existing plants.

Mitsubishi Hitachi Power Systems Europe GmbH sees itself as a partner that is committed to

finding the optimal and most efficient solution for our customers. In this regard, we place

particular emphasis on ensuring a smooth continued operation of the remaining plant sections

during the revamping works. To be able to assure this, we conduct thorough plant walk-

through inspections and determine together with the customer the respective interfaces.

Planning is based on the information gathered and our findings and focuses on optimum work

processes and co-ordinated deployment of personnel and equipment with the ultimate goal

of keeping any possible downtimes to the minimum. After all, time is money!

With our experienced installation team, we revamp and modernise both plants built by us and

by third parties in Germany as well as in other countries. And the size or type of boiler does not

even matter to us thanks to our decades of experience in plant construction and engineering.

Maintenance / reconditioning

A boiler unit is only efficient, if it operates smoothly without any disturbances. And that does

not happen automatically! Problems arise without regular and proper maintenance and

upkeep. Failure to ensure the aforementioned requirements might result in long-term

problems and damages that could necessitate a complete replacement instead of repairs.

That also applies to individual components and sections through to the whole plant. Usually,

however, the most cost-effective solution is to recondition. This alternative is also based on

an in-depth overhaul of the current situation. In this case, we try to assess the condition of

individual components and the entire plant and then determine the scope of work required.

Lists of spare parts that are in stock are prepared, and missing parts are ordered. To ensure

a smooth overhaul, we provide highly qualified personnel who have many years of experience

and corresponding equipment.

For our customers we also carry out the realization of existing plants and their ancillary installations at new sites:

■■ Project planning

■■ Dismantling and re-assembly

■■ Quality control

■■ Restarts


Conversion – Modernisation – Maintenance

PLANT OPTIMISATION – TAPPING POTENTIALS

Customer requirements regarding the performance of their plants change continuously.

It does not matter if operating necessities, official regulations or changed service

conditions make a plant optimisation necessary, we develop specific tailored solutions

for you and optimise your plant to suit your needs.

Process-related analysis of current situation and weaknesses

That includes measures for boosting operating efficiency and for improving incineration

as well as for decreasing emissions. We carry out a targeted analysis of the current

situation and weak points in order to identify the potential that is still available in the plant.

Preparation of inspections performed by the authorities and authorised inspectors

An integral part of the tasks we perform for our customers includes implementing

optimisation potential and targeted preparation of plants for inspections by the authorities

or authorised inspectors.

Preparation of operating instructions

It goes without saying this that entails comprehensive documentation of our work and

preparation of operating instructions.

POWER PLANT CHEMISTRY – THE RIGHT CONDITIONING

We will gladly answer your questions about power plant chemistry and make plant-specific

suggestions for a wide array of aspects like water-chemical method of operation and

chemical conditioning.

We have experience in preventing boiler units from entering shutdown, will prepare the

optimum concept and implement it for you. After extended standstills, revamping

activities or construction of new facilities, we also take care of the requisite cleaning

tasks for water and steam piping systems and the boiler’s pressure parts by means of

boiling out, blowing out or acid cleaning.

We offer complete test management for fuels like biomass. From systematic sampling,

storage, reserve samples and analysis through to interpretation of analytical results by

way of comparison.

Commissioning and start-up

Our commissioning and start-up service unit is your competent partner for performing

all processes with regard to the commissioning of power plant systems and their components.

Our service unit is also at your disposal during operation, after revamping, shutdowns or

inspections with the following services:

Power plant chemistry

■■ Water treatment

■■ Standstill conservation of plants

■■ Boiler cleaning both water / steam-side and flue-gas-side

■■ Fuel analytics

22

Commissioning

CLIENT SUPPORT – INSPECTION, REPAIR & MAINTENANCE

Industrial and power plants and especially waste-to-energy plants with stokers and

air pollution control systems, e.g. electric filters, are subjected to thermal, chemical

and mechanical stresses in a wide variety of forms during operation. The results include

material deterioration, corrosion and erosion in the area of boiler walls, heating surfaces

and the associated components and units.

Inspections

As part of regular inspections, boiler units are taken off-line and assessed after specified

runtimes are reached. The scope of the inspection is established in close consultation

with the customer. We support our customers both in the assessment of the boiler

units and in the performance of inspections and utilise our specialists to minimise plant

downtime, even in multiple shifts, if necessary.

Repairs and maintenance

And when it comes to repairs – be it during planned or unplanned shutdowns – we offer

fast assistance without any bureaucracy by providing both our specialists and the

requisite equipment.

Regular maintenance is crucial for preventing any damage-related, unplanned shut-

downs and to ensure the operability, safety and availability of a plant. By supplementing

your plant personnel with our maintenance specialists, you ensure a high level of

modernisation and availability, maximum effectiveness and thus long-term good operating

efficiency of your plant.


More quickly back on the grid

The Shield for Accelerated Boiler Service (SABS®) is a newly developed protection system

which enables a protected workspace to be formed in the most diverse of areas inside a

power plant.

The SABS® consists of a flexible, stretchable special canvas. It covers the entire cross-section

of a selected area and protects the workspace underneath from any falling objects. The

SABS® also includes all components needed for transport, installation and operation.

The components of SABS® are patented.

Especially in the operation of fossil-fired steam generators, deposits develop at the bank

tubes and steam generator walls. They are made up of precipitating slag and ash particulates

and accumulate over time, coating the steam generator tubes. This has a detrimental effect

on the heat transfer, leading to a considerable reduction in boiler efficiency. That is why steam

generators need to be regularly cleaned, inspected for wear and possibly repaired. This

involves shutting down the steam generator to allow the required repairs to be carried out

in the furnace and in the convective area. The risk with this work is that those working in the

furnace could be hit and injured by falling lumps of slag and ash. Thus, workspace is not safe

and needs to be protected by means of special safety installations.

The protective devices used to date, such as safety nets and scaffolds, only afford limited

protection and, in the case of scaffolding, need a considerable time to install. The SABS® has

clear-cut benefits in comparison with conventional forms of safety equipment. In contrast to

conventional safety nets, SABS® tightly seals off the edges and offers reliable protection from

falling objects. The workspace underneath it is secure - and in comparison to safety scaffolds,

installing SABS® yields considerably less time and work force investments, which reduces

outage periods as well as inspection costs.

By using the Shield for Accelerated Boiler Service (SABS®) devised by Mitsubishi Hitachi

Power Systems Europe GmbH, a completely protected workspace can be formed within

a very short time. This both significantly cuts the outage periods and costs of a steam

generator and, at the same time, markedly raises personnel safety.

Thanks to its high degree of flexibility and its modular setup, the application of the

SABS® system is not limited to the furnace of fossil-fired coal power stations. It can also be

deployed wherever working spaces surrounded by perimeter walls are to be protected from

falling objects.

SABS® is a registered Trademark of Mitsubishi Hitachi Power Systems

Europe GmbH

24

Shield for Accelerated Boiler Service (SABS®)

The components of the SABS® system

The SABS® consists of the following modular functional units: SABS® canvas, supporting

structure, lifting and traversing equipment. These functional units are described in more

detail in the following sections.

SABS® canvas

The SABS® canvas is lifted into the steam generator as possible just underneath the super-

heater screen (figure bottom).

Together with the canvas compensator 1.2 , the canvas 1.1 ends flush with the walls of the

area to be protected. By means of guy wires and edge ropes guided through the net openings

of the boiler, the canvas is connected to the supporting structure and interlocked with it.

1.21.1

SABS® canvas in the utility steam generator

Positioning and tightening of the SABS® canvas at the Boxberg power plant, unit Q


Performance characteristics of SABS®

The SABS® was developed in collaboration with Vattenfall Europe Generation (VEG) and

the original specifications – in terms of drop energy, solidity, load bearing capacity and heat

resistance – have been matched with the experiences of VEG. In the course of developing

the SABS®, these specifications have been met – and eventually surpassed as well –

in all instances.

Flexible area of application

The SABS® system is a new, flexible safety concept for carrying out installation and inspection

work on steam generators.

By using the Shield for Accelerated Boiler Service (SABS®) developed by Mitsubishi Hitachi

Power Systems Europe, a completely protected workspace can be formed within a very short

time. This allows for a considerable reduction of outage periods and costs as well as a

significant increase in personnel safety.

The system’s modular setup is the basis for flexible and efficient use of the SABS®. Thanks

to its high degree of flexibility and its modular setup, the application of the SABS® system is

not limited to the furnace of fossil-fired coal power stations. It can also be deployed wherever

working spaces surrounded by perimeter walls are to be protected from falling objects.

Achieved SABS® performance characteristics Requirements

Drop energy 2,500 J

Resistance to piercing and abrasion

750 kg load bearing capacity

Heat resistance

Drop energy of over 5,000 J obtained (340% increase of seam resistance)

Canvas coating for achieving piercing and abrasion resistance

Load bearing capacity in excess of 3,000 kg

Heat resistance up to ~ 400 °C

Results

26

Shield for Accelerated Boiler Service (SABS®)

The service concept

The average reaction span before the arrival of the service crew on-site is 12 hours.

The deployment phase refers to the time during which the customer carries out inspection

work on the steam generator. During this time, inspection rounds are regularly carried out

on the canvas. If necessary, it is cleared of any excess weight from material that has

dropped down.

It takes approximately 6 hours to disassemble the SABS® once the inspection work is

over. Time is saved not only by shorter periods for assembly and disassembly, but also by

inspection work being carried out at the same time both above and below the SABS®.

To ensure the safety of the canvas for deployments that follow, the SABS® canvas is tested

and repaired after each and every use referring to: cleaning and inspection. This process is

fully documented and hence provides complete transparency for all those involved.

The SABS® system is ready for the next deployment provision) following repair and storage

of the canvas and equipment.

With the SABS® service, Mitsubishi Hitachi Power Systems Europe provides customers with

a solution matching their wishes and optimally suited to individual requirements. Matters such

as area coverage and service availability – even with multiple, non-scheduled outages –

are included in the portfolio.

The latest state of technology

The soiling of the bank heat recovery sections or incrustations on the membrane walls seem

to play a dominant role in the generation of risk from potentially falling masses, which to date

is relevant, in particular, at lignite-fired power plants. But this current trend to increasingly use

imported coal, the quality of which is increasingly getting worse, is leading in part also in hard

coal power plants to these incrustations typical of lignite and to a situation of changing

fundamental prerequisites for safety. Therefore, the use of safety equipment in the combus-

tion chamber of hard coal fired power plants is gaining in importance.

The further development of SABS® focuses primarily on the energy sector, such as the use

within the flue gas recirculation pit, the empty pass and the absorber of the power plant

systems. Another area of application are waste-to-energy plants which also display a high

degree of soiling.

The added value generated by the use of SABS® is multi-layered and can therefore not be

clearly assessed monetarily. The increased safety, in particular, due to the use of SABS®

represents a new state of technology which has to be valued considerably higher in com-

parison to the time and cost savings.

✓ Dependable safety

✓Short assembly- and disassembly spans

✓Reduction of scaffolding costs

✓Parallel operation possible both above and below the shield

✓Tried-and-tested traversing concept can be retained

✓Complete shielding service from one single source

Summary of the added value of SABS®


Boiler service & rehabilitation

Mitsubishi Hitachi Power Systems Europe GmbH (MHPSE) is a leading global provider of

services for energy and power generation plants.

We provide a complete array of services for modernization of power plants and combustion

plants, which differ in design and size for all conventional fuels. These include:

■■ Boiler technology

■■ Combustion technology

■■ Flue gas cleaning

■■ Coal grinding systems service

■■ Assembly and construction

■■ Commissioning

■■ Spare parts

Our extensive expertise in boiler technology has enabled us to provide customer-oriented

service and rehabilitation for steam generators and its components, e. g. mill, burner and firing

systems, coal feeders, conveyors etc. We have an experienced team offering comprehensive

solutions for fossil-fired power plants including its parts as well as steam generators.

Our Competence

■■ Technical consulting and studies

■■ Concept, basic and detail engineering

■■ Design revision, e. g. thermal /

process calculation

■■ Failure diagnosis / Troubleshooting

■■ Increase in power, efficiency and

availability

■■ Life time extending measures

■■ Optimisation and replacement of parts

■■ Conversion i. e. fuels, components

■■ Rehabilitation and modernization

■■ Retrofit, modification and upgrading

■■ Overhaul

■■ Shut down planning

■■ Inspection, revision, repair

■■ Maintenance

(scheduled and unscheduled)

■■ Supervision

■■ Procurement, manufacturing,

construction and commissioning

■■ Spare and wear parts

(OEM and non-OEM)

28

Boiler Service

Industrial boiler & stoker firing systems

Mitsubishi Hitachi Power Systems Europe GmbH (MHPSE) is not only a leading provider of

service for the core of every power plant – the steam generator, but also supplies key

components for industrial power plants:

■■ Natural circulation boilers

■■ Firing systems

■■ Burners

■■ Stoker firing systems

■■ Components for firing systems

■■ Spare parts

Our customer-orented solutions are based on MHPSE’s comprehensive engineering

know-how. In addition to our engineering, we are able to supply and deliver systems, perform

assembly and commissioning worldwide.

Natural Circulation Boilers:

■■ Direct fired boilers / Superheaters

■■ Heat recovery boiler downstream gas turbine

■■ Boilers for chemical processes, e. g. steel industry

■■ Boilers for waste disposal plants

■■ Boiler downstream fluidized bed firing systems

■■ Special boilers, converter boilers

Firing Systems / Burners for:

■■ Natural gas / Light and heavy fuel oil

■■ Blast furnace gas / Lean gas / CO gas

■■ Waste water and waste gas

■■ Thermal residue disposal

■■ GT gas in combination with natural gas (CCPP process)

■■ Sulphur extraction (Claus Plants)

Stoker Firing Systems:

■■ Boiler for waste-to-energy plant

■■ After burning grate

■■ Roller grate

■■ Moving grate

■■ Grate bars

■■ Ash / Slag extractor

■■ Ignition / Support firing


Support of performance processes by our QC

An essential component of our company’s philosphy is to ensure our products’ adherence to

national and international quality criteria and compliance with the required standards and

regulations.

To this end, our energy system service is subject to a demanding and systematic quality

management according to DIN EN ISO 9001:2008 and SCC:2011.

We possess highly modern testing and measurement equipment and are thus always able to

carry out precise material testing during the manufacture, assembly and commissioning of

steam generator plants, on schedule at all times.

Furthermore, we perform

■■ Video endoscopic pipe interior inspections for all usual diameter ranges

■■ Welding seam inspections by means of ultrasound, radiographic imaging,

dye penetration and magnetic particle testing procedure

■■ Service life as well as load testing

■■ Steam generator plant inspections

At regular intervalls we demonstrate the successful operation of our quality management as well as our

approvals and expert knowledge by audits.

■■ DIN EN ISO 9001:2008

■■ Safety Certificate for Contractors

(SCC**): 2011

■■ DGRL 97 / 23 EG-Modul H1

■■ DIN EN 1090-1, EXC 3

■■ AD-HP 0, TRD 201

■■ AD-2000 / HP-0

■■ WHG § 19 L

■■ DIN EN ISO 15614-1

■■ DIN EN 287-1

■■ DIN EN ISO 3834-2

■■ DIN EN ISO 14731

■■ DIN EN 473 (VT, PT, MT, UT, RT)

■■ ASME Stamp “S”

■■ National Board Stamp “NB” / “R”

Our range of services:

■■ Quality management & QC monitoring

■■ Manufacturing, assembly, site inspections

■■ Welding and inspection planning

■■ Damage analyses

■■ Mechanical-technological and non-destructive testing examinations

■■ Inspection documentations

30

Quality Management & QC Monitoring

Quality – our most important product

With the Integrated Management System (IMS) we have implemented for years, we ensure that all

products designed, manufactured, delivered, assembled and commissioned at Mitsubishi Hitachi

Power Systems Europe GmbH satisfy the prescribed requirements of our customers and the

supervisory authorities to their complete satisfaction.

Therefore, our valid process tests, for instance, with all the usual materials and material

combinations employed in plant engineering, are the basis of our welding technology.

Our qualified personnel examines throughout the compliance with the quality requirements

according to DIN EN ISO 3834-2. Apart from the quality quality monitoring, we also carry out

special service life and breaking load tests, total boiler examinations and damage analyses.

Testing procedures

Here, we employ mechanical-technological as well as non-destructive testing procedures

such as:

Crack detection

■■ Magnetic powder testing

■■ Dye penetration test

Microstructural examination

■■ Metallographics

■■ Replica

■■ Incident-light microscopy

(macro-microscopy)

Wall-thickness measurement

■■ Radiographic imaging and

ultrasound testing

Welding seam testing

■■ Examination by means of x-ray

and ultrasound

Mix-up testing

■■ Spectral analysis

Visual composition investigation

■■ Endoscopy

We accompany the execution of the work from the beginning of production through

the construction monitoring and the creation of the QC documentation all the way up to the

hand-over to the customer and guarantee thereby a high quality throughout.

Crack detection Microstructural examination Wall-thickness measurement


Projects / products of Mitsubishi Hitachi Power Systems Europe (selection)

Project Technology Capacity Work carried outDrax Power Ltd. Drax Power Station Selby, UK

Electrical power genera-tion plant, Unit 4, 5, 6

660 MWel, 2,400 MWth, 165 bar, 570 °C

Engineering, manufacturing, delivery, construction and commissioning of 60 low NOX coal burners each unit including plant optimisation

Drax Power Ltd. Drax Power Station Selby, UK

Electrical power genera-tion plant, Unit 1, 2, 3

660 MWel, 2,400 MWth, 165 bar, 570 °C

Engineering, manufacturing, delivery and commissioning of 48 low NOX Biomass burners each unit

Wien Energie, MVA Spittelau, Vienna, Austria

Waste-to- energy plant Line 1, 2

14 MWel, 45 MWth, 55 t/h, 40 bar, 400 °C

Engineering, manufacturing, delivery, construction and commissioning of 2 complete boilers for a waste-to-energy plant including stoker grate firing, flue gas cleaning, steel structure and auxiliaries

Co-generation plant Würzburg Germany

Combined- cycle power plant

45 MWel, 115 MWth, 72 bar, 515 °C

Dismantling the existing coal boiler and installing a new combined-cycle power plant incl. heat recovery boiler, ducts, steelwork, pipework, chimneys, fittings, gas turbine, integration of the existing steam turbine, C&I technology, civil works including foundations and pile driving.

MSZ 3 Moscow Russia

Waste-to- energy plant

10 MWel, 46 MWth, 115 t / h, 37 bar, 360 °C

Engineering, design, supply, construction and commis-sioning of the air-cooled moving grate firings in accordance with 17. BImSchV, including ignition and auxiliary firing system, ash removal, slag removal, combustion air systems and E-C&I technology and detailed engineering for the combustion control system.

Medium calorific power plant, MKK-Bremen Germany

Refuse derived fuel power plant

27.5 MWel, 100 MWth, 127 t / h, 39 bar, 400 °C

Engineering, design and supply of: combustion grate, ash removal, slag removal; construction and commissioning of: boiler pressure parts, combustion grate, air and flue gas ducts, steelwork, feed water tank, pumps, valves, pipe-work, live steam piping, refractory, insulation and E-C&I technology and the detailed engineering for the combus-tion control system.

Engineering, design and production of about 1,000 m² cladded vaporiser walls for the 1st pass with Alloy 625 and a minimum layer thickness of >2 mm. In addition, the required cladding work with an area of about 80 m² was carried out on site.

Nikola Tesla, Obrenovac Serbia

Electrical power generation plant

305 MWel, 900 MWth, 920 t / h, 183 bar, 543 °C

Improving the efficiency of and generally overhauling the lignite-fired power station unit including pressure parts, oil and coal firing system, E-C&I technology, turbine, generator, air and flue gas ducts, feed water treatment, forced draught fans, induced draught fans, soot blower, rotary air pre-heater, ash removal, electrical precipitator, pumps, valves, live steam piping, refractory, insulation and auxiliary equipment.

Energy power plant Bernburg Germany

Refuse derived fuel power plant, Lines 1– 3

each 26 MWel, 67 MWth, 80 t / h, 41 bar, 410 °C

Engineering, supply, construction and commissioning of 3 combustion grates for lines 1– 3, including slat conveyor ash removal, combustion air systems including E-C&I technology and detailed engineering for the combustion control system.

32

References

Projects / products of Mitsubishi Hitachi Power Systems Europe (selection)

Project Technology Capacity Work carried outN. V. Elektriciteits-Produktiemaat-schappij Zuid- Nederland (EPZ) Maasbracht Netherlands


646 MWel, 1,694 MWth, 1,960 t / h, 196 bar, 540 °C

Conversion of unit A & B to low NOx firing and eliminating boiler vibrations. Apart from supplying pressure part components, low NOx gas burners, natural gas valve stations, fresh air and flue gas ducts, pipework, valves and resonators, construction and commissioning were also carried out.

Agroenergética de Algodonales, El Tejar Spain

Biomass power plant

5 MWel, 25 t / h, 72 bar, 450 °C

Based on a detailed inspection of the existing flue gas cleaning system, the necessary modernisation and repair work was planned and carried out including supervision of the construction and the obtaining of all spare parts.

Versorgungs- und Verkehrsgesellschaft Saarbrücken GmbH Germany

Combined cycle power plant

33 MWel 44 t / h 55 bar 450 °C

Design, delivery, installation, commissioning and trial run of a heat recovery boiler with auxiliaries

VW Kraftwerk GmbH Kassel, Germany


45 MWel 110 MWth 126 t / h 96 bar 515 °C

Engineering, fabrication, delivery, installation and commis-sioning of a heat recovery boiler including steel structure, feed water system, air and exhaust gas ducts, chimney, FD fan and forced-draught ducts, pumps, valves, dampers, piping, E-C&I, refractory, insulation

SWB Energie und Wasserversorgung Bonn / Rhein-Sieg GmbH Germany


25 MWel 113 MWth 100 t / h 145 bar 540 °C

Engineering, fabrication, delivery, installation and commis-sioning of a heat recovery boiler including steel structure, feed water system, air and exhaust gas ducts, chimney, FD fan and forced-draught ducts, pumps, valves, dampers, piping, E-C&I, refractory, insulation

voestalpine Stahl GmbH Linz, Austria

Steam generator with blast furnace gas firing

120 MWth 135 t / h 70 bar 525 °C

Engineering, delivery, dismantling, installation and commissioning of a steam generator with blast furnace gas and natural gas firing, combustion air and GT ducts, flue gas and recirculation ducts, E-C&I, piping and valves, insulating

Sabiya Power Plant Kuwait


300 MWel 975 t / h 146 bar 540 °C

Dismantling of damaged pressure parts, installation of boiler pressure parts, superheater, membrane walls, steam-water pipes and header, burner system, steel structure and platforms, insulation and brick linings, expansion joints, hangers, auxiliaries

Kostolac B2 Serbia

Lignite coal fired boiler

330 MW 8 N270.45 Retrofit / replacement of classifier, coal change, capacity increase, improved classifier outlet fineness

Mega IV Greece


650 MW 8 DGS® 180 Retrofit / replacement of classifier, coal change, capacity increase, improved classifier outlet fineness

Nicola Tesla A5 Serbia


330 MW 6 DGS® 100 Retrofit / replacement of burners and mills, revolution grinding desk / beater wheel, coal change, capacity in-crease, improved classifier outlet fineness, low NOX firing

Mehrum Germany

Bituminous coal fired boiler

650 MW 3 MPS® 190 Retrofit / replacement of classifier, coal change, capacity increase, improved classifier outlet fineness

Amer Netherlands

Biomass fired boiler

600 MW 6 MPS® 235 Retrofit / replacement of mill, biomass grinding


Mills and components activities of MHPSE (selection)

Project Technology Capacity Design

Kusile Unit 1 – 6 South Africa


6 x 800 MW 117 t/h

Belt conveyor, according to NFPA 3.5 bar 6 x 5 MPS® mill, size 265 incl. gear box Submerged scraper conveyor

Medupi Unit 6 – 1 South Afric a


6 x 794 MW 114 t/h

Belt conveyor, according to NFPA 3.5 bar 6 x 5 MPS® mill, size 265 incl. gear box Submerged scraper conveyor

Maasvlakte Netherlands


1,100 MW 84 t/h

Belt conveyor, according to TRD 1.0 bar 5 MPS® mill, size 255 incl. gear box Submerged scraper conveyor

Duke Cliffside USA


900 MW 72 t/h

6 MPS® mill, size 235 incl. gear box

Datteln 4 Germany


1,100 MW 84 t/h

Belt conveyor, according to TRD 1.0 bar 5 MPS® mill, size 255 incl. gear box Submerged scraper conveyor

Moorburg Unit A + B Germany


2 x 820 MW 76 t/h

Belt conveyor, according to TRD 1.0 bar 2 x 4 MPS® mill, size 245 incl. gear box Submerged scraper conveyor

Rotterdam Netherlands


800 MW 65 t/h

Belt conveyor, according to TRD 1.0 bar 4 MPS® mill, size 225 incl. gear box

Wilhelmshaven Germany


800 MW 65 t/h


Walsum 10 Germany


750 MW 68 t/h


Genesee Power Generation Station Phase 3 Canada


495 MW 58.9 t/h


Shentou II Power Plant Phase 2 China


2 x 500 MW 60.5 t/h

2 x 6 MPS® mill, size 225 incl. gear box

Kogan Creek Australia


750 MW 80 t/h

Belt conveyor, according to NFPA 3.5 bar 6 MPS® mill, size 255 incl. gear box

Mid American Energy Company USA


830 MW 80 t/h


Shanxi Wangqu Thermal Power Plant China


2 x 600 MW 51.6 t/h

2 x 6 MPS® mill, size 200 incl. gear box

Paroseni Co-Generation Power Plant Romania


180 MW 39.5 t/h

Belt conveyor, according to NFPA 3.5 bar 4 MPS® mill, size 212 incl. gear box

Iskenderun Sugözü Power Plant Turkey


2 x 605 MW 77.8 t/h

Belt conveyor, according to TRD 1.0 bar 2 x 4 MPS® mill, size 255 incl. gear box

Boxberg R Germany


660 MW 113 t/h

8 NV mill, size 110 Submerged scraper conveyor

Boxberg Q Germany


900 MW 140 t/h

8 NV mill, size 130 Submerged scraper conveyor

Lippendorf III Germany


933 MW 116 t/h

8 NV mill, size 110

Megalopolis IV Greece


850 MW 956.4 t/h (steam)

6 DGS® mill, size 180 Submerged scraper conveyor

Elbistan B Turkey


4 x 360 MW 4 x 1,037 t/h (steam)

4 x 6 DGS® mill, size 180

Schkopau Germany


2 x 450 MW 2 x 1,365 t/h (steam)

2 x 8 DGS® mill, size 65

Dezhou Unit 2 + 1 China

Special fuels fired boiler

70 t/h 2 x 6 RKD mill, size 420 x 650 Submerged scraper conveyor

Lausward Unit D + B Germany


46 t/h 2 RKD mill, size 340 x 500

Lausward Unit A1 Germany


28 t/h 1 RKD mill, size 340 x 500

Herne 4 Germany


500 MW 85 t/h

3 RKD mill, size 500 x 700

Herne 3 Germany


300 MW 55 t/h

2 RKD mill, size 440 x 650

34

References

Service / retrofit activities for grinding and firing systems (selection)

Project Technology Capacity Work carried out

Kostolac B2 Serbia


330 MW 8 N270.45 Retrofit / replace of classifier, coal change, capacity increase, improved classifier outlet fineness

Mega IV Greece


650 MW 8 DGS® 180 Retrofit / replace of classifier, coal change, capacity increase, improved classifier outlet fineness

Nicola Tesla A5 Serbia


330 MW 6 DGS® 100 Retrofit / replace of burners and mills, revolution grinding desk / beater wheel, coal change, capacity increase, improved classifier outlet fineness, low NOX firing

Weisweiler F / E Germany


2 x 300 MW / 2 x 300 MW

2 x 6 DGS® 60 / 2 x 6 DGS® 60 Retrofit / replace of mills, coal change, capacity increase

Mehrum Germany


650 MW 3 MPS® 190 Retrofit / replace of classifier, coal change, capacity increase, improved classifier outlet fineness

Nicola Tesla A4 /A3 Serbia


330 MW / 330 MW

6 DGS® 100 / 4 DGS® 100 Retrofit / replace of mills, revolution grinding desk / beater wheel, coal change, capacity increase, improved classifier outlet fineness

Weisweiler D / G + H Germany


300 MW / 600 MW

8 N80.75 / 8 DGS® 130 Retrofit / replace of mills, coal change, capacity increase

Mega IV Greece


650 MW Bottom ash Retrofit / replace of bottom ash handling, higher unit availability

Buschhaus Germany


650 MW 6 DGS® 90 Retrofit / replace of classifier, coal change, capacity increase

Wilhelmshaven Germany


720 MW 4 MPS® 225 Nozzle ring, higher unit availability

Kiel Germany


320 MW 4 MPS® 180 Retrofit / replace of classifier, coal change, capacity increase

Heyden Germany


900 MW 4 MPS® 255 adjustable grinding force, revolution grinding desk / beater wheel, retrofit / replace of P.F. pipes, coal change, capacity increase

Amer Netherlands

Biomass fired boiler

600 MW 6 MPS® 235 Retrofit / replace of mill, biomass grinding

Veltheim Germany


330 MW MPS® 150 Retrofit / replace of classifier and mill, coal change, capacity increase, reducing of unburnt carbon, improved classifier outlet fineness

Reuter Germany


320 MW MPS® 170 Retrofit / replace of burners, classifier, p.f. pipes and sealing air system, low NOX firing, reducing of unburnt carbon, improved classifier outlet fineness

Milliken USA


150 MW MPS® 150 Retrofit / replace of mill air fans, classifier, mill, P.F. pipes and sealing air system, coal change, capacity increase, low NOX firing, improved classifier outlet fineness


MITSUBISHI HITACHI POWER SYSTEMS

EUROPE GMBH

Schifferstraße 80, 47059 Duisburg, Germany

Phone +49 203 8038-0, Fax +49 203 8038-1809

[email protected], www.eu.mhps.com

Service Emergency Number +49 172 2608481

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