solid fuel firing systems
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Solid Fuel Firing Systemsand Components
Mitsubishi Hitachi Power Systems Europe
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From Coal to Electricity
Generation of electricity in a typical coal power plant
A Before being injected into the furnace, the raw coal is crushed down to a fi ne pulverized form in the coal mills.
2 Flue gases up to 1,450 °C arise from pulverized fuel combustion in the steam generator furnace. The liberated heat is used to generate high-pressure and high-temperature steam.
3 The steam is directed to a turbine; it fl ows onto the blade wheels and turns the turbine shaft. An attached generator then generates the electrical power.
4 With the help of catalysts, the nitrogen oxides in the fl ue gas react in the DeNOx system to produce nitrogen and water vapor.
5 Ash particles adhere to electrically-charged surfaces in the electrostatic precipitator; they are rapped and removed from the fl ue gas.
6 In the fl ue gas desulphurization system (FGD) lime slurry or suspended pulverized limestone bind the sulphur dioxide coming from the fl ue gas. The fi nal product arising is gypsum.
Contents
Mitsubishi Hitachi Power Systems Europe 2
Selection Criteria 5
Furnace 6
Mill Feeders 8
Pulverizers 10
Pulverized Fuel Burners 14
Burn-Out Grate 20
Ash Removal Systems 21
Replacement Parts Service 23
Coal Firing Systems 3
Stronger together
The merger of the “thermal power plant” fields of Mitsubishi Heavy Industries, Ltd., (MHI)
and Hitachi, Ltd., has brought about Mitsubishi Hitachi Power Systems, Ltd., (MHPS) – one of
the world’s largest companies in thermal power generation systems.
An important mainstay of this corporate group is Mitsubishi Hitachi Power Systems Europe
GmbH (MHPSE), the successor to Hitachi Power Europe GmbH. The energy plant con
structor (based in Duisburg) looks back over a +100year track record in planning and
constructing fossilfired power plants. MHPSE constructs turnkey plants, supplies key
components (e. g. utility steam generators, environmental engineering equipment, turbines,
burners, grinding systems) and handles service and rehabilitation.
Stakeholders in Mitsubishi Hitachi Power Systems Europe GmbH
MHPSE
MHPS
MHI Hitachi, Ltd.
65% 35%
100%
Mitsubishi Hitachi Power Systems Europe GmbH
Babcock Fertigungszentrum GmbH
Production of first-class components for power plants (e. g. coal mill), mainly for MHPSE
Mitsubishi Hitachi Power Systems Africa (Pty) Ltd.Subsidiary of MHPSE in South Africa
Meeraner Dampfkesselbau GmbHManufacturing of premium components for utility steam generators (e. g. pressure parts) for power plants
Donges Steel Tec GmbHOne of Germany’s leading steel and bridge constructors; manufacturing of steel structures for power plants
MH Power Systems Europe Service GmbHService, rehabilitation and components in the industrial plant field
SUBSIDIARIES AND RELATED COMPANIES
Firing Systems and Components
Ensuring Economic Efficiency, Conserving Resources
As one of the global cutting-edge companies in power plant design and construction,
Mitsubishi Hitachi Power Systems Europe provides highly advanced firing systems which can
be used in their entirety or as single components for practically all fossil fuel qualities.
MHPSE develops solutions, which are just as flexible as our customers’ requirements, for
energy suppliers and industry alike. This can be seen most clearly from the large number of
different types of references (see table) available. A high degree of operational efficiency and
conservation of resources / environment is looked upon as an obligation and challenge by
MHPSE in designing and manufacturing new utility steam generators. This also applies to the
modernization and enhancement of existing power plants and their components, such as
pulverizers and burners.
It goes without saying that MHPSE as a certificated DIN ISO 9001 company always orientates
itself to the best possible quality.
Project Country Kunde MW Fuel Order obtained
Niederaußem Germany RWE Energie AG 1 x 1,012 Lignite 1995
Boxberg Q Germany VEAG 1 x 907 Lignite 1995
Elbistan B Turkey TEAS 4 x 360 Lignite 1998
Dezhou 5 / 6 China CNTIC 2 x 660 Anthrazit 1998
Hamborn Germany RWE Energie AG 1 x 260 Blast Furnace Gas 1999
Iskenderun Turkey Siemens / STEAG 2 x 660 Hard Coal 2000
Neurath F & G Germany RWE Rheinbraun AG 2 x 1,100 Lignite 2003
Baosteel China Baoshan Iron & Steel Co. Ltd 1 x 350Blast Furnace Gas, Coke Oven Gas, Heavy Fuel Oil
2005
Boxberg R Germany Vattenfall Europe 1 x 670 Lignite 2005
Walsum 10 Germany Evonik 1 x 790 Hard Coal 2006
Moorburg A / B Germany Vattenfall Europe 2 x 820 Hard Coal 2006
Datteln Germany E.ON Kraftwerke 1 x 1,100 Hard Coal 2006
Gent Belgium Electrabel 1 x 300 Blast Furnace Gas 2006
Medupi South Africa Eskom 6 x 790 Hard Coal 2007
Maasvlakte Netherlands E.ON Kraftwerke 1 x 1,100 Hard Coal 2008
Wilhelmshaven Germany Electrabel 1 x 750 Hard Coal 2008
Kusile Südafrika Eskom 6 x 790 Hard Coal 2008
Rotterdam South Africa Electrabel 1 x 790 Hard Coal 2008
Maja India NTPC 2 x 660 Hard Coal 2012
Solapur India NTPC 2 x 660 Hard Coal 2012
Raghunathpur India NTPC 2 x 660 Hard Coal 2012
Kozienice Poland Enea 1 x 1,000 Hard Coal 2012
Selection of steam generator orders since 1995
Coal Firing Systems 5
What Counts is the Choice
The planning and design of firing systems is primarily dependent on the fuel used and
must be individually tailored – something requiring above-average achievements on the part
of our designers.
Whilst there is no secret about uptodate firing systems, one still needs considerable
knowhow and a long track record in plant concepts and specific sequences. Playing a prime
role here are the fuel properties themselves, such as calorific value, moisture and ash content,
volatiles and coal grindability.
Advanced firing systems with a staged combustion sequence lower emissions and require
substantial design and material selection outlay on the basis of the standards and legislation
in force. This applies equally to the selection and construction of the firing components.
Hard coal
Slag-tap firing system Cyclone firing system
Tangential firing system
U/double U firing system
Double front firing system
Front firing system
Opposed firing system
Corner firing system
Direct firing system with vapor separation
Direct firing system
Direct firing system with vapor recycling
Double front firing system
Opposed firing system
Dry bottom ash firing system
Normal volatile coal
Low volatile coal
Dry bottom ash firing systemLignite
Direct firing system
Indirect firing systemDry bottom ash firing systemBiomass
Furnace
Pulverized Hard Coal Firing System
Fossil-fired power plants are currently enjoying a boom across the world. And hard coals,
in particular, can be widely used for energy transformation purposes.
The decision to design a firing system with dry bottom ash removal or as a slagtap furnace
largely depends on the fuel properties themselves. Volatile matter, ash content and chemical
ash composition have always been of decisive significance.
The decisionmaking process was simplified with the launching of innovative DS® burners
followed by tremendous combustion stability. Modern steam generators are usually designed
today solely as dry ash discharging boiler plants at low cost and high efficiencies. This applies
to practically the entire range of fuels irrespective of their effects from high volatile bituminous
coal to anthracite.
For many years now, the linear arrangement as front, doublefront or opposed firing equip
ment complete with vertically offset burner levels has proved to be the most suitable system
for pulverized hard coal firing systems.
The clear arrangement of mill and burner level ensures that the highly complex systems are
clearly designed and arranged. This, in turn, creates a high degree of accessibility and ease
of maintenance.
The principal features are:
■■ Uniform liberation of heat
■■ Low nitrogen oxide emissions coupled with practically a total fuel transformation
■■ Oxygen-rich flue gas atmosphere right next to the boiler tube walls
CAD model of the Datteln 4 utility steam generator
■■ 1 x 1,100 MWel / 1 x 2,939 t/h
■■ Benson® Steam generator
■■ Hard coal
■■ Steam parameters: Superheated steam: 600 °C / 305 bar; Reheater: 620 °C / 78 bar
■■ Entering into service: 2011
■■ Scope of delivery: Utility steam generator including all the related components, engineering, installation and commissioning
Coal Firing Systems 7
Pulverized Lignite Firing System
Combustion systems for lignite operated steam generators can be designed as direct
systems for the use of raw lignite or as combined systems using raw and pre-dried lignite
in the same furnace.
Even with the usage of very high ash lignites, the new MHPSE lignite swirl burners (RS® burn
ers) do not need any vapor separation.
The excellent igniting stability of the RS® burners allows the burners to be arranged in a
different way at the combustion chamber – for instance in the form of an allwall firing system.
Such a system combines the benefits of linear firing equipment with those of a tangential
firing system. The firing steps alone enable the 200 mg/m3 NOx standard to be undercut in
RS® burners. As a result, there is no need for complex, multiple airstaging concepts for
adherence to the NOx standards.
The stable ignition of RS® burners produces a marked improvement in the percentage load
operations of lignite firing systems. Even with problematical fuels, the excess stoichiometric
operation of these burners has a positive effect on fouling and slagging and it optimally
protects the evaporator tube walls from corrosive flue gas products.
The future will see boiler plants mainly being planned for the use of dry pulverized lignite with
interim storage.
CAD model of the Boxberg R utility steam generator
■■ 1 x 670 MWel / 1 x 1,710 t/h
■■ Benson® Steam generator
■■ Lignite
■■ Steam parameters: Superheated steam: 600 °C / 315 bar; Reheater: 610 °C / 72 bar
■■ Entering into service: 2010 / 2011
■■ Scope of delivery: Utility steam generator including all the related components, engineering, installation and placing into service
Mill Feeders
Reliability even under Demanding Requirements
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 129529, 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
Coal Firing Systems 9
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.
Belt conveyor
The belt conveyor with corrugated edge belt ensures high outputs, uniform bunker discharge
and continuous mill charging – even under low conveying rates. This design permits volumet
ric / 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
Dragchain 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 dragchain 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.
A Bed depth limiter
B Belt drive station
C Tensioning station
D Forged fork link chain
E Bunker shut off gate
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
Conveyor-type weigher (optional)
Raw coal
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Raw coal
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Pulverizers
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Excellent Results
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 mois-
ture in the coal.
MPS® Bowl & Roller Mill
The MPS® bowl & roller mill from Mitsubishi Hitachi Power Systems Europe grinds and dries
hard coals and difficulttogrind lignite with a low moisture content to pulverized fuel and
distributes them evenly directly to the burners.
Varioussized 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.
MPS® Mill
A Rotary classifier
B Classifier drive
C Grinding rollers
D Hydro-pneumatic system
E Grinding table
F Gear
G Motor
Coal Firing Systems 11
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Long Service Life
RKD Tube Ball Mill
The Mitsubishi Hitachi Power Systems Europe RKD tube ball mill grinds and dries difficultto
pulverize hard coals (particularly lowvolatile 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.
RKD Mill
A Rotary classifier
B Oversize return
C Neck bearing
D Drive gear rim
E Grinding ball filling
F Feed spiral conveyor
G Classifier riser
Low Energy Requirements
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 pulver
izing 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 distribu
tion 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. The DGS® mill has stood the test of time par
ticularly with difficulttowork lignites – something that explains
its considerable lifetime and unrivalled properties.
DGS® Mill
A Flue gas gate valve
B Inlet housing
C Beater shaft
D Beater wheel
E Coupling
F Motor
G Bearing
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Pulverizers
Coal Firing Systems 13
Easy Maintenance
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. Baffletype classifiers ensure that the
required fuel fineness for combustion is fulfilled.
The hightech NV mill more than meets the ongoing demands
worldwide of operational availability and low costs.
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
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Pulverized Fuel Burners
Optimum Combustion
How do you lower NOx emissions and at the same time control as many different fuels as
possible? Questions like these are today determining the concept of pulverized fuel firing
systems and burners.
DS® burners were introduced early in the 1990s and continuously developed over the years.
The burner’s principle is focused on fuel treatment to prepare the particles for the pyrolysis
and ignition process that follows. The characteristic features of this burner type are expressed
by the definition of initiation and course of ignition.
Ignition = Pyrolysis + Oxidation
This type of burner with a concentric design and swirled flow streams in all sections, has its
field of application mostly in direct firing systems using all kinds of pulverized fuels.
The DS® burner concept utilizes operating experience from more than 1,100 applications.
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1,400
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0 0
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859 879959
1,0311,095 1,119 1,135
1,1651,303
1,4871,607
1,667 1,697
17546
787144
■ Total number ■ Year of commissioning
Fuel Nozzle
Secondary Air Tertiary AirPulverized FuelAdjustable Swirlers
Core Air
Igniter
DS® Burners
Coal Firing Systems 15
DS® burners with an operating range of 1: 3,5 are available for direct operated combustion
systems in a range of thermal capacities from 20 to 100 MW.
Basically developed for bituminous coal, these burners are applicable now for all carbon
containing solid fuels like anthracite, subbituminous coal, lignite and biomass of different
structures. The DS® burner is suitable for applications with individual air control as well as for
the use in common windboxes.
DS® burner design for a windbox arrangement
Fuels Burner Classes (MW thermal capacity)
20 40 60 80 100
Lignite* x x x
Subbituminous coal x x x x
Bituminous coal x x x x x
Anthracite x x x
Biomass (cofiring with coal) x x x x
Biomass (standalone) x x
* Pulverizer operation on air basis
Pulverized Fuel Burners
DST Burner
The DST burner has been developed on the basis of the DS® burner concept for use in
indirect fi ring systems.
This burner type is the right one for predried pulverized fuels like anthracite, bituminous and
subbituminous coal, lignite, peat, biomass of various types as well as further carboncon
taining pulverized fuels separately or in any combination. Dust loading can range from 0.5 up
to 15 kg fuel / kg medium.
DST burners can be used for atmospheric operation or in pressurized systems with air and / or
oxyfuel atmosphere.
Air, inert gas and fl ue gas with or without oxygen enrichment can be used as the transport
medium for the fuel.
DST burners can be operated with a turndown rate up to 1:17. As a result a boiler can be
operated from lowest startup load up to full load conditions with an unlimited load response
rate. Due to an extremely high PF / PA ratio the NOx emission rate is rapidly reduced.
DST burners are available for thermal capacities from 20 to 60 MW for all kinds of predried
pulverized fuels used in indirect fi ring systems.
Fuel Nozzle
Secondary Gas Tertiary GasPulverized Fuel
SwirlerCore Gas
Oil Lance
Fuels(pre-dried & pulverized)
Burner Classes (MW thermal capacity)
20 40 60
Lignite x x x
Subbituminous coal x x x
Bituminous coal x x x
Anthracite x x x
Biomass (standalone) x x x
Coal Firing Systems 17
Energy storage and plant flexibility are the main challenges of power generation in the future.
With the DST burner control range of 1:17 coal firing systems will be best prepared to meet
the resulting operating demands.
DS® burner direct (left)
DST burner indirect (right)
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Burner control range (as tested)
Direct firing system, DS® burner
Indirect firing system, DST burner
Indirect firing system, DST burner
minimum load range
Comparison of both burner systems
Burner capacity [MW]
Coal
/ PA
Ratio
[kg/
kg]
DST Burner
Flexibility is what is demanded of power generation now and in the future. With development
of the DST burner, flexible concepts using indirect firing systems are now becoming the focus
of interest.
This system offers lots of advantages like:
■■ Turn down of investment and operating costs
■■ Independency of mill and boiler operation
■■ Wide load range with all burners in service
■■ Quick response in case of high load change demand
■■ Boiler operation without supplementary fuel (oil / gas) – even for startup
■■ Exact definition of burner air ratios that enable boiler excess air below 10 %
The combined firing system using the advantages of the direct and indirect systems is the
consequential answer to the fascinating questions surrounding coal fired power plants in
facing the challenges of the future.
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Combined firing system
100 %
75 %
50 %
25 %
0 %Flexible Load Range
Pulverized Fuel Burners
Coal Firing Systems 19
RS® BurnersOrders since 1994
RS® Burner
The extensive findings acquired from developing DS® burner technology (flame stability, igni
tion as well as air staging in the burner proximate zone) are also available for lignite firing
technology purposes.
What has been developed is the lignite RS® burner. In contrast to the conventional jet burner,
the RS® burner permits control of the fuel / air mixture and flame propagation in the burner
proximate zone.
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40
30
20
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60
40
20
01994 1996 1998 2000 2002 2004 2006 2008 2010
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010 6
16
0
16
0
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0000 0
24
48
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100 100 100 100 100 100 100
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2012
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0 0
124
70 160
■ Total number ■ Year of commissioning
Secondary Air
Coal Dust Cooling Air
Pulverized Fuel
Secondary Air Deflecting Cone
Radiant Shielding Pipe
BurnOut Grate
A Boiler furnace hopper
B Refractory jacket of retarded combustion reactor
C Water seal gasket
D Firmly fi xed grate supporting bars
E Grate carriage
F Grate surface
G Hydraulic system for grate carriage and deashing fl ap
Ash hopper
Cooling and combustion air
J Deashing fl ap
K Ash discharge chute
Shutoff gate valve in ash discharge chute
Deasher
Monitoring system
High Effi ciencies
In lignite coal or peat-fi red plants with a high proportion of xylitol or fi bers in the fuel,
the proportion of unburnt residue in the boiler hopper ash can be extremely high and this
impairs fi ring effi ciency.
The optimum designed burnout grate ensures that the ash burnout in the boiler hopper is
improved to over 80 % – thus substantially raising the overall effi ciency of the boiler plant.
In addition, afterburning results in additional heat input into the boiler hopper, which would
otherwise be relatively cold. This leads to an even distribution of temperature in the furnace.
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Burn-out grate diagram
Coal Firing Systems 21
Ash Removal
Submerged scraper conveyor functions:
■■ Air sealing to the boiler hopper
■■ Ash cooling
■■ Ash conveying
■■ Inlet for furnace inspection
1 Bottom ash
2 Transfer chute with immersion piece
3 Expansion joint
4 Submerged scraper conveyor
5 Drive station frequency controlled
6 Tensioning station
7 Idler stations
8 Discharge chute
9 Cooling water inlet
J Overflow
K Travelling rails
Submerged scraper conveyor
Stable in the Extreme and Long Lasting
Ash removal systems have been part of MHPSE’s range of production and supplies for many
years now. This applies to bottom ash removal as well as to the transfer of ash accumulating
in the course of air heater and electrostatic precipitator ash removal.
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Submerged scraper conveyor for hard coal-fired systems
Submerged scraper conveyor for lignite-fired systems
➞➞Conveying direction
Other Ash Removal Systems
MHPSE provides a broad range of ash handling systems. These systems apply to ash handling
for furnace bottom ash removal and also to the ash removal from all downstream ash
accumulation points.
Our systems offer a lot of benefits: they are stable in the extreme, wear parts are long lasting
and both the energy requirements and operating / upkeep costs are low. MHPSE provides
the entire range for utility steam generators with pulverized hard coal and lignite firing: from
design, manufacturing and erection up to commissioning the complete ash disposal systems
including loading systems for transport by truck, rail and ship.
Ash Removal Components
■■ Ash silos and dewatering bunker
■■ Singlestrand chain conveyors
■■ Apron conveyor
■■ Screw conveyors
■■ Single and double roller crushers
■■ Hammer crushers
■■ Rotary feeders
■■ Single and double pendulum flap
■■ Shut off gates
■■ Ejectors
■■ Buckettype conveyors
■■ Sluice ways
Our Other Ash Removal Systems
■■ Dry mechanical ash removal systems
■■ Hydraulic ash removal systems
■■ Pneumatic ash removal systems
■■ Mill reject systems
■■ Recooling systems for submerged
conveyor overflow water
Coal Firing Systems 23
Replacement Parts Service
As a designer and manufacturer of original components, MHPSE is the ideal partner to contact
when modernization or replacement parts are needed.
Our extensive expertise derived from designing and delivering utility steam generators
with the associated components over many years enables our MHPSE experts to provide
professional solutions matched to customer requirements in the matter of plant design and
operations. Optimized plants ensure that performance and availability are raised and that
effi cient operations are attained as far as possible. As a competent and fl exible partner,
MHPSE’ expertise is available in the fi elds of process engineering, plant optimization, measur
ing technology, plantinternal inspection, component installation and commissioning. At the
same time, MHPSE supports customers in the design and confi guration of their future
plants – from the technical point of view (planning, design, optimizing) and in the matter of
operating economy analyses.
Rapid Service from a Competent PartnerManufacturing from a single sourceAs stakeholder in Babcock Fertigungszentrum GmbH in Oberhausen, we are in the closest possible contact with our partners and, as such, are fl exible and quick in handling your enquiries and can provide you with dependable solutions. More on this under:
www.bfz-ob.de
Service Hotline: +49 2065 4221960
Service Fax: +49 2065 4221997
Email: spareparts@service.eu.mhps.com
Feedersconveyor Coal Mills Burners Ash submerged
scraper conveyor
Belts Wear partsPulverized fuel line elbows
Chains
Chains Linings Pulverized fuel lines Scraper bars
Drives Nozzle rings Impact plates Wear plates
Bearings Shaft seals Housings Drives
Gate valves Feeding screw conveyors
Adjusting mechanisms
Conveyortype weighers
Beater sections Bearings
Expansion joints Gear units
Drives
MITSUBISHI HITACHI POWER SYSTEMS
EUROPE GMBH
Schifferstraße 80, 47059 Duisburg, Germany
Phone +49 203 8038-0, Fax +49 203 8038-1809
infobox@eu.mhps.com, www.eu.mhps.com
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