coal pipeline transportation

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Coal Pipeline TransportationSerial No.:CPTO2013.07.03

I N D U S T R I A L C H A N N E L


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WDRI was founded in 1954 and is now ranking as a national Class-A survey and design institute with profound history. Over the past 60 years, WDRI has undertaken over 100 projects of master plans of mine area, completed over 500 mine shafts and accomplished over 50 coal preparation plants all over China. Among them, 29 mines and coal preparation plants boast a production capacity of 5 Mt/a or above, 14 of which standing out with a production capacity of 10 Mt/a or above.

FavorSea Industrial Channel Limited is appointed as marketing agent of WDRI.

FavorSea are privileged to be partnered with some of the most highly regarded manufacturing enterprises and prestigious research & design institutes in China's mining and mineral processing sector. In our co-branding role as export channel partner, we bring world-class “Designed & Made with Pride in China” products, world-class technology and advanced industry solutions to the global mining community.

1. About Us The First Commercial CTP in the WorldConstruction Year: 1957George Coal P r e p a r a t i o n Plant – East Lake Power PlantDistance: 173 KmVolume: 1.4 MtCost: $3.7/t for r a i l w a y transportation $2.2/t for p i p e l i n e transportation (58.82% of railway)The pipeline had been in operation for 6 years with an aggregate transportation volume of 6.3 Mt.Unsuccessful High-Concentration CTP in Russia In 1986, a high-concentration coal slurry pipeline from Belovo to Novosibirsk was constructed under joint effort of former Soviet Union and Italy with a designed capacity of 5 Mt/a. The pipeline totaled a length of 260km with a diameter of 530 mm. a power plant in Novosibirsk with a scale of 2×220 kw. In spite of a total investment of 300 million US dollars, due to occurrence of blockage during trial operation, the pipeline failed to be put into operation hence.Up to now, there have been only 3 coal transportation pipelines in the world, two of which are general coal slurry pipelines for long-distance and high-volume transportation, ending up with sound economic benefits, while the one in Russia failed.

Average Concentration (normal and medium concentration) CWSFeatures: Weight Concentration: 50% or soGrading Composition: 0-2mm, average particle size: 0.3mm or soSlurry Viscosity: 30—80 CPThe coal slurry was transported in turbulence flow inside the pipe.Flow rate: 1.5-2 m/s

Objective of Technical R & D:To solve the problems in long-distance and large-volume coal pipeline transportation

2. CPT Technology Development Overview The research of coal pipeline transportation technology was initiated by American experts in late 19th century

(1881), and the experiment turned out a success. At the beginning of the 20th century, London Power Plant succeeded in its trial operation with a coal t r a n s p o r t a t i o n pipeline of short distance extending all the way to the

power plant across the river of Thames,

and the pipeline transportation technology was into the practical hence.

East Lake Power Plant

Cleveland

Canton

Akron Pump Station No.3

Pump Station No.2

Ohio

Pump Station No. 1



Academic Research & Development WDRI Owns More Than 30 Supporting Professional Departments Related to Pipeline Transportation Projects The test center of coal slurry, pulping, the pump output system, pipelines, roads, railways, bridges, tunnels, signals, anti-corrosion; HVAC, water supply, drainage, sewage treatment and comprehensive utilization of water and soil conservation, environmental impact assessment, environmental control, power supply, control automation, machinery, mechanisms, civil engineering, construction, coal preparation, mining, surface coal mining, mine safety, measuring, surveying, geotechnical engineering, ground handling, project cost, computer software, equipment maintenance, project management, production safety.

Completed Pipeline R&D ProjectsSince 1981, WDRI has accomplished the planning and feasibility study of normal concentration CPT project for over 20 pipelines, including Meizhou-Shantou, Zhungeer-Qinhuangdao, Jincheng-Nantong, Jincheng-Wuhan, Huangling-Wuhan, Jincheng-Jining, Panjiang-Zhanjiang, Enhong-Fuyuan, Mengxian-Tianjin, Mengxian-Weifang-Qingdao, Shenmu-Weinan, etc.

Presently, our institute is working for the EPC general contracting of Shemu-Weinan CPT Project under Shanxi Coal Industry Company Limited.

Advantages of CPT over Other Means of Transportation

High Concentration Coal Water Mixture (CWM) Features: Weight concentration: 70% or soSize Composition: 0-0.3mm, average size 0.071mm or so (200 mesh)Slurry Viscosity: 800—1100 CPThe coal slurry was transported in a laminar flow form inside the pipe.

Objective of the technical research and development:To develop coal water mixture as a new fuel to replace oil

China’s CPT TechnologyIn early 1980s, China began the research and development of coal transportation pipeline, which was successively listed as key scientific and technological projects by former Ministry of Planning and State Science Commission, and included into national strategic development plan.The coal pipeline transportation technology is in line with national policy on industrial development, and conducive to environmental protection, energy saving. In recent years, it has been listed into National Guidance Catalog for Industrial Restructuring and Catalog for the Guidance of Foreign-Invested Industries by State Development and Reform Commission and Ministry of Commerce as encouragement project, thus vigorously advancing the development of coal transportation pipeline project in China.

WDRI’s Contribution to the R & D of CPT Technology In early 1980s, our institute began the research, development and promotion of CPT-based technology. After three decades, WDRI has made itself the only specialized institution fully committed to coal transportation pipeline project and the only design and research institute boasting various professional personnel in CPT. We have the test center of CPT with fullest function, largest scale and best software and hardware conditions, which enabled WDRI to have undertaken the overwhelming majority of domestic CPT projects. ◆The Institute sent the study tours of technicians to investigate almost all other slurry transportation pipelines in China, such as iron ore concentrate and bauxite mine pipeline transportation projects. The technicians also investigated the domestic long-distance petroleum and natural gas transportation pipeline projects.◆The Institute also sent technicians to Brazil and Australia for investigating the other long-distance slurry pipeline transportation projects. ◆Based on the long-distance CTP technologies learned from American Black Mesa Pipeline Co., Ltd. and long-distance petroleum, natural gas and other slurry transportation pipeline technologies both from home and

transportation pipeline technologies both from home and abroad, the Institute has developed and mastered long-distance CPT technologies which are safer, more reliable and more advanced. At present, the Institute has more than one hundred proprietary technologies on long-distance coal transportation pipeline.◆Having experts who have 30 years of experience on researching long-distance coal transportation pipeline, engineers and technicians, the Institute also has introduced a number of experts and technicians from fields of other long-distance slurry transportation pipeline, design and research such as petroleum and natural gas transportation pipeline and project management and operation.

strong adaptability

Characteristicsof the CPT

to the terrainLow land

occupancy

Low investment and freight fee

Environment -friendly and transportation clean

Less process, higher efficiency

Shorter cycle, faster recoveryMore reliable

resource and use



Economical Efficiency Analysis of CPTAs a means of commercial transportation, sound economical efficiency is needed in addition to safety and reliability so as to be competitive in the market. According to documented analytical research: Generally, pipeline transportation cost is 1/2～1/3 of railway transportation, and 1/5～1/10 of highway transportation.

Cost Comparison Between CPT and Railway Design code formulated by WDRI

Item

5

13

46

11

12

70

26

15

Labor Force

Power

Maintenance

Depreciation

Pipeline Transportation (%)

Railway Transportation (%)

Chinese Coal Pipeline Transportation Planning Completed by WDRI



Academic Research, Technical Exchange and Field VisitOver 40 monographs have been published in national key journals or periodicals, and some of them have been included into China Dictionary of Practical Science Achievement, World Collection of Outstanding Patent and Technology (China Volume), and Proceedings of National Academic Exchange on Slurry Pipe Technology; We have formulated “Long-distance Coal Transportation Pipeline Design Discipline”We have participated in International Academic Symposium on Slurry Pipe for five times.We have dispatched in total 7 delegations to the site of Black Mesa Pipeline for observation, study and technical exchange.

Black Mesa pipeline In United States Construction Year: August, 1969 — November, 1970Kayenta Open Pit — Mohave Power PlantDistance:440 Km Volume: 5.0Mt/aCost: $16/t for railway transportation $9.55/t for pipeline transportation (59.69% of railway cost)The pipeline had been in operation for 35 years with a total transportation volume of 150.0 Mt.

Slurry Preparation Plant

Rod Mill Workshop

The Internal Structure of Rod Mill

Raw Coal Bins In Slurry Preparation Plant

3.Introduction to Black Mesa Pipeline



Pump Station No.2

Large-Scale Tanks with Mechanical Agitator In Slurry Preparation Plant

Pump Station No.3

Pump Station No.4

Construction Site of Black Mesa Pipeline

Major Pump Equipment

Geographic Landscape of Black Mesa Pipeline



Terminal Power Plant in Mohave

Terminal Power Plant in Mohave 4.Technical cooperation between WDRI & Black MesaWDRI has signed a long-term strategic cooperation agreement with American Black Mesa Pipeline Technologies Services Co.Ltd, the only company in the world with practical experience in large coal pipeline transportation construction and 35 years experience in the operation. The feasibility study report of Yu-Wei-Qing coal pipeline transportation has been accomplished under our joint efforts, and we have full access to the entire technical data of construction, management and operation of Black Mesa Pipeline.

This photo records the delegation headed by Lu Yaohua, the former general director of Infrastructure Department of Coal Ministry visiting Mohave power plant in 1994.

Large-Scale Tank with Agitator In Mohave Power Plant

Coal Transportation Pipeline Planned by the United States



Coal Pipeline Transportation LaboratoryCPT Laboratory was designed in August 2009, and completed by the end of that year. It covers an area of 680 square meters.

The laboratory consists of 7 systems, namely: coal pulverizing system, basic test system, coal slurry preparation system, flush water system, sample test loop system, centralized control system and waste slurry discharge system.

The laboratory staff team consists of 11 members, 5 with senior title, 1 with doctor’s degree, 5 with master’s degree, and is equipped with the most fully functional, the largest scale and the best hardware and software, making it the best CPT laboratory in China.

Basic Test System

The basic test (otherwise named small sample test) of coal pipeline transportation serves as an importance method for the research of coal slurry character. Basic test aims to detect the physical and chemical property of coal and coal slurry in a static state, figuring out the rheology of slurry so as to select proper rheological model and optimize the selection of coal slurry particle grading, coal slurry concentration, coal slurry viscosity, flow velocity in pipeline transportation, slip angle of coal slurry, repose angle of coal slurry, and PH value of coal slurry, which could provide accurate hydraulic parameters for pipeloop test and pipeline design.

Coal Slurry Preparation System

Based on the recommended particle size grading and concentration from basic test, overflow rod mill could produce coal slurry eligible for the test loop sample.

5.CPT Laboratory and Test Center of WDRI

Shared Documents



Coal Pipeline Transportation Research ● Since the coal to be transported varies in type and quality, so does its physical and chemical properties, which may result in fluid state difference, and consequently lead to variation in the character and features of hydraulic parameters for the coal transportation pipeline, impacting directly to the safety and smoothness of slurry pipeline transportation. Therefore, it is necessary to conduct tests for specific coal type and coal property before the design of transportation pipeline in order to optimize the design parameters. ●Scientific and prudent mathematical analysis should be conducted for the coal slurry flow character and hydraulic property stemming from experiments, and only in this way we can obtain optimum parameter for pipeline transportation so as to ensure its safe and economical operation. ●The Pipeline Coal Transportation Research Center of our institute is now under construction in order to promote the development and construction of pipeline coal transportation in China, provide scientific basis and technical support for the design, construction, safe and economical operation of coal pipeline transportation projects, and enhance our strength and core competitiveness in coal pipeline transportation technology.

Coal Pipeline Transportation Research Center● The center mainly researches on the test of coal slurry and molded coal, focusing on normal concentration coal slurry, coarse particle coal slurry, and high concentration coal slurry.● The test system consists of basic test, slurry preparation test, pumping test, dewatering test, coal slime wastewater treatment test and molded coal test.● The structure of the research center: Coal sample and dump sample storing and transporting department, basic test department, industrial test department, centralized control and data processing department, R&D department of utilization and transfer of CPT technology, technical training department.

● The center consist of all coal pipeline transportation technology system , which are: Slurry Preparation System, Pump System, Pipeline System, Communications System, Control System and so on.Coking coal pipeline transportation 1 Coarse particle would be adopted for coking coal slurry pipeline transportation. In the process of coal for coking, there are certain requirements for the particle size of the coke production. General, the upper limit of the particle size will be piped in 6-10mm. As long as select the appropriate particle gradation, the coal slurry can be made with good flow pattern. Therefore, the pipeline transportation of the coarse particles coke coal is feasible technically.2 According to our study results that: 6-10mm coarse coking coal transport by Pipeline fully meet the requirements of coking process.3 After mechanical dewatering of coal slurry that reaches the terminal transport by pipe, generally do not need to dry to granulation. For coking coal, based on the experiments what we have done proved no any impacts on its coking characteristics after piped transportation dehydration, drying experiments. So, the experiments show that it is also feasible to granulate molding directly for transportation without a drying treatment. 4 However, in view of varies in physical and chemical characteristics, we recommend that the coking experimental and briquette processing experiments after dried should be focused on Mozambique coal samples, so that it would be more practicality. Coking coal pipeline transportation According to the purpose of Mozambique project, here are some descriptions for the characteristics of coking coal

1. Coarse particle would be adopted for Coking Coal slurry pipeline transportation2. According to our study results that: 6-10mm coarse coking coal

transport by pipeline would fully meet the requirements;3. Do not need to

s p e c i a l drying for

briquette molding4. The experiments will be necessary and crucial

Sample Test Loop System

Test loop system is mainly used for:Measuring hydraulic parameters for the pipeline transportation;



6.Shen-wei CPT Project Overview

Pipeline Capacity: 10.00Mt/aStarting: Hongliulin Coal Mine , Shenmu County, Shanxi ProvinceTerminal: Pucheng, Weihua, ShanhuaSpan: The pipeline totals a length of 729km with 206 in plains and mild hills and the rest 523 in mountains and rolling hills.

There are a total of 6 pump stations in whole line, pump station No.1 to No.5 are mainline pump stations with pipe diameters of φ610mm and φ559mm. The φ610 pipe lasts 525km while the φ559 pipe extends 67km, and the capacity is 10Mt clean coal per year. Pump station No.6, the transfer pump station, is situated in Pucheng terminal 1, it distribute the coal slurry to Shanxi Coal Chemical Industry Group (terminal 2) and Weinan Coal Chemical Group (terminal 3), distributing volume of 1.2Mt/a to the terminal 2 and 1.8Mt/a to the terminal 3. Pipeline distance from terminal 1 to terminal 2 is 66km, while that of from terminal 1 to terminal 3 is approximately 73km.

Current progress of the “Shen-Wei”project

“SHEN-WEI” Projects across the three regions of Yulin, Yan‘an and Weinan. Allworks in Yan’an and Weinan have been started, works inYulin region will be started in the near future; The pipeline laying has been completed amount of 18000m, the tunnel construction has been completed amount of 1335m. The permanent site construction work will be started to carried out in the near future, the large equipment bidding has been completed so far.

The System Diagram of Shen-Wei Project

Site Construction

《The China National Design Specifications of Coal for Coking Process 》（GB50432--2007）



Site welding

After Manual Primer Paint Welding

Tunnel Construction Tunnel construction

Completion of Welding

coal pipeline transportation

Documents

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george coal p r e p