Solid Fuel Firing Systemsand Components
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Hitachi Power Europe
From Coal to Electricity
Generation of electricity in a typical coal power plant
� Before being injected into the furnace, the raw coal is crushed down to a fine pulverized form in the coal mills.
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.
The steam is directed to a turbine; it flows onto the blade wheels and turns the turbine shaft. An attached generator then generates the electrical power.
� With the help of catalysts, the nitrogen oxides in the flue gas react in the DeNOx system to produce nitrogen and water vapor.
� Ash particles adhere to electrically-charged surfaces in the electrostatic precipitator; they are rapped and removed from the flue gas.
In the flue gas desulphurization system (FGD) lime slurry or suspended pulverized limestone bind the sulphur dioxide coming from the flue gas. The final product arising is gypsum.
Contents
Hitachi Power Europe 2
Selection Criteria 5
Furnace 6
Coal Mill Feeders 8
Pulverizers 10
Pulverized Fuel Burners 14
Burn-Out Grate 16
Ash Removal 17
Replacement Parts Service 19
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Coal Firing Systems 3
Technology Leader with Excellent References
Whether as a plant constructor or as a supplier of key components, Hitachi Power Europe
GmbH (HPE) is one of the technology and market leaders in fossil-fired power plants.
The company – a subsidiary of Hitachi, Ltd. – has its head offices in Duisburg. HPE designs
and builds not only power plants but also supplies all the key components such as utility
steam generators, environmental engineering, turbines and pulverizers. In so doing, HPE can
turn back to a track record going back over many years, an extensive list of references and
to the outstanding know-how of its workforce. Within the Hitachi Group, HPE is responsible
for the markets in Europe, Africa, Russia (incl. Belarus) and India.
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� Hitachi Power Europe GmbH, Duisburg
� Babcock Fertigungszentrum GmbH, Oberhausen
BGR Boilers Private Ltd., Chennai
� Donges SteelTec GmbH, Darmstadt
� Meeraner Dampfkesselbau GmbH, Meerane
Hitachi Power Africa (Pty) Ltd., Johannesburg
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Firing Systems and Components
Ensuring Economic Efficiency, Conserving Resources
As one of the global cutting-edge companies in power plant design and construction,
Hitachi Power Europe provides highly advanced firing systems which can be used in their
entirety or as single components for practically all fossil fuel qualities.
Project Country Customer MW Fuel Order obtainedNiederaußem 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 Anthracite 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
Neurath F&G Germany RWE Rheinbraun AG 2 x 1,100 Lignite 2003
Baosteel China Baoshan Iron & Steel Co. Ltd 1 x 350 Blast 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 South Africa Eskom 6 x 790 Hard Coal 2008
Rotterdam Netherlands Electrabel 1 x 790 Hard Coal 2008
Selection of steam generator orders since 1995
HPE 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 HPE 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 HPE as a certificated DIN ISO 9001 company always orientates
itself to the best possible quality.
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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 up-to-date firing systems, one still needs considerable
know-how 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 with vapor recycling
Double front firing system
Direct firing system
Dry bottom firing system
Normal volatile coal
Low volatile coal
Dry bottom firing systemLignite
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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 slag-tap furnace
largely depends on the fuel properties themselves. Volatile matter, ash content and chemical
ash composition have always been of decisive significance.
The decision-making 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, double-front or opposed firing equipment
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
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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 HPE lignite swirl burners (RS burners)
do not need any vapor separation.
The excellent igniting stability of the RS burners allows the burners to be arranged in a differ-
ent way at the combustion chamber – for instance in the form of an all-wall 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 air-staging 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
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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 Hitachi Power Europe designed mill feeders
operate both reliably and safely.
Experienced HPE staff establish the optimum feeder in keeping with the requested fuel quan-
tity, design directives (including DIN EN 12952-9, NFPA 85 F) and customer requirements
(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
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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 volu-
metric / 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.
� Bed depth limiter
� Belt drive station
� Tensioning station
� Forged fork link chain
� Bunker shut off gate
� Bed depth limiter
� Belt drive station
� Belt tensioning station
� Corrugated edge belt
� Scraper chain
� Lower belt supporting roller
� Bunker shut off gate
� Conveyor-type weigher (optional)
Raw coal
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Pulverizers
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
moisture in the coal.
MPS® Bowl & Roller Mill
The MPS® bowl & roller mill from Hitachi Power 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 proper-
ties and low energy requirements have contribu ted in no small measure
to the success of these mills.
MPS® Mill
� Rotary classifier
� Classifier drive
� Grinding rollers
� Hydro-pneumatic system
� Grinding table
� Gear
� Motor
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Coal Firing Systems 11
Long Service Life
RKD Tube Ball Mill
The Hitachi Power 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.
RKD Mill
� Rotary classifier
� Oversize return
� Neck bearing
� Drive gear rim
� Grinding ball filling
� Feed spiral conveyor
� Classifier riser
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Pulverizers
Low Energy Requirements
Pulverizing lignite is particularly challenging in view of its high moisture content and the
considerable throughputs involved. Here again Hitachi Power Europe has the right products
in this segment.
DGS Integral Fan Distributor and Beater Mill
HPE 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-crush-
ing 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 opera-
tion – 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 particularly with
difficult-to-work lignites – something that explains its consid-
erable lifetime and unrivalled properties.
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DGS Mill
� Flue gas gate valve
� Inlet housing
� Beater shaft
� Beater wheel
� Coupling
� Motor
� Bearing
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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 con-
tent 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.
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� Gate valve housing
� Grinding chamber door
� Grinding chamber
� Beater wheel
� Baffle-type classifier
� Double bearing
� Motor
NV Mill
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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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Pulverized Fuel Burners
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250
200
150
100
50
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200
400
600
800
1,000
1,200
1,400
1,600
1,800
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787144
� Total number � Year of commissioning
Fuel Nozzle
Secondary Air Tertiary AirPulverized FuelAdjustableSwirlers
Core Air
Igniter
DS® Burners
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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, sub-bituminous 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.
Coal Firing Systems 15
Fuels Burner Classes (MW thermal capacity)20 40 60 80 100
Lignite* x x x
Sub-bituminous coal x x x x
Bituminous coal x x x x x
Anthracite x x x
Biomass (co-firing with coal) x x x x
Biomass (standalone) x x
* Pulverizer operation on air basis
DS® burner design for a windbox arrangement
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Pulverized Fuel Burners
DS®T Burner
The DS®T burner has been developed on the basis of the DS® burner concept for use in
indirect firing systems.
This burner type is the right one for pre-dried pulverized fuels like anthracite, bituminous and
sub-bituminous coal, lignite, peat, biomass of various types as well as further carbon-con-
taining pulverized fuels separately or in any combination. Dust loading can range from 0.5 up
to 15 kg fuel / kg medium.
DS®T burners can be used for atmospheric operation or in pressurized systems with air and/or
oxyfuel atmosphere.
Air, inert gas and flue gas with or without oxygen enrichment can be used as the transport
medium for the fuel.
DS®T burners can be operated with a turndown rate up to 1:17. As a result a boiler can be
operated from lowest start-up 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.
DS®T burners are available for thermal capacities from 20 to 60 MW for all kinds of pre-dried
pulverized fuels used in indirect firing systems.
Fuels Burner Classes (MW thermal capacity)(pre-dried & pulverized) 20 40 60
Lignite x x x
Sub-bituminous coal x x x
Bituminous coal x x x
Anthracite x x x
Biomass (standalone) x x x
Fuel Nozzle
Secondary Gas Tertiary GasPulverized Fuel
SwirlerCore Gas
Oil Lance
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Energy storage and plant flexibility are the main challenges of power generation in the future.
With the DS®T burner control range of 1:17 coal firing systems will be best prepared to meet
the resulting operating demands.
Coal Firing Systems 17
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5
3
2
1
00 5 10 15 20 25 30 35 40 45
Expected burner control
Burner control range (as tested)
Direct firing system, DS® burner
Indirect firing system, DS®T burner
Indirect firing system, DS®T burner
minimum load range
DS® burner indirect (left)
DS® burner direct (right)
Comparison of both burner systems
Burner capacity [MW]
Coal
/PA
Ratio
[kg/
kg]
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Pulverized Fuel Burners
DS®T Burner
Flexibility is what is demanded of power generation now and in the future. With development
of the DS®T 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 start-up
� 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.
M M M M
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Combined firing system
100%
75%
50%
25%
0%Flexible Load Range
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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 tech-
nology 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.
60
50
40
30
20
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140
120
100
80
60
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124
� Total number � Year of commissioning
Secondary Air
Coal Dust Cooling Air
Pulverized Fuel
Secondary Air Deflecting Cone
Radiant Shielding Pipe
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Burn-Out Grate
� Boiler furnace hopper
� Refractory jacket of retarded combustion reactor
� Water seal gasket
� Firmly fixed grate supporting bars
� Grate carriage
� Grate surface
� Hydraulic system for grate carriage and deashing flap
� Ash hopper
� Cooling and combustion air
� Deashing flap
� Ash discharge chute
� Shutoff gate valve in ash discharge chute
� Deasher
� Monitoring system
High Efficiencies
In lignite coal or peat-fired plants with a high proportion of xylitol or fibers in the fuel,
the proportion of unburnt residue in the boiler hopper ash can be extremely high and this
impairs firing efficiency.
The optimum designed burn-out grate ensures that the ash burnout in the boiler hopper is
improved to over 80 % – thus substantially raising the overall efficiency 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.
Burn-out grate diagram Ash�
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Ash Removal
Coal Firing Systems 21
Submerged scraper conveyor for hard coal-fired systems
Submerged scraper conveyor functions:
� Air sealing to the boiler hopper
� Ash cooling
� Ash conveying
� Inlet for furnace inspection
$ Bottom ash
Transfer chute with immersion piece
Expansion joint
� Submerged scraper conveyor
� Drive station frequency controlled
Tensioning station
% Idler stations
& Discharge chute
' Cooling water inlet
� Overflow
� Travelling rails
Submerged scraper conveyor for lignite-fired systems
��Conveying direction
Submerged scraper conveyor
Stable in the Extreme and Long Lasting
Ash removal systems have been part of HPE’s range of production and supplies for many
years now. This applies to bottom ash removal as well as to the transfer of ash accumu-
lating in the course of air heater and electrostatic precipitator ash removal.
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Ash Removal
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Other Ash Removal Systems
HPE 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. HPE 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 includ-
ing loading systems for transport by truck, rail and ship.
Ash Removal Components
� Ash silos and dewatering bunker
� Single-strand chain conveyors
� Apron conveyor
� Screw conveyors
� Single and double roller crushers
� Hammer crushers
� Rotary feeders
� Single and double pendulum flap
� Shut off gates
� Ejectors
� Bucket-type conveyors
� Sluice ways
Our Other Ash Removal Systems
� Dry mechanical ash removal systems
� Hydraulic ash removal systems
� Pneumatic ash removal systems
� Mill reject systems
� Re-cooling systems for submerged
conveyor overflow water
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Replacement Parts Service
Coal Firing Systems 23
As a designer and manufacturer of original components, HPE 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 HPE 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 efficient opera-
tions are attained as far as possible. As a competent and flexible partner, HPE’ expertise is
available in the fields of process engineering, plant optimization, measuring technology, plant-
internal inspection, component installation and commissioning. At the same time, HPE sup-
ports customers in the design and configuration of their future plants – from the technical
point of view (planning, design, optimizing) and in the matter of operating economy analyses.
Service Hotline: +49.203.8038-2550
Service Fax: +49.203.8038-612550
Email: [email protected]
Rapid Service from a Competent PartnerManufacturing from a single sourceAs stakeholder in Babcock Ferti-gungszentrum GmbH in Oberhau -sen, we are in the closest possiblecontact with our partners and, assuch, are flexible and quick in handling your enquiries and canprovide you with dependable so-lutions. More on this under:
www.bfz-ob.de
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
Conveyor-type weighers
Beater sections Bearings
Expansion joints Gear units
Drives
Replacement Parts Service
GB_Prsp_Kohlefeuerung_9-9_AK.qxp:Prsp_Kohlefeuerung 09.09.2011 14:52 Uhr Seite 23
Hitachi Power Europe GmbH
Schifferstraße 80
47059 Duisburg, Germany
Phone +49.203.8038-0
Fax +49.203.8038-1809
www.hitachi-power.com
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