2. Sorbent Handling Plant by NHI-Design & Equipment Specifications
Ibtisam Mahyyuddin
Management Associate (Machinery CPP)

3. Objective
“To provide complete overview of Sorbent (limestone) Handling Plant and description of its main equipment supplied by NHI.”

4. Contents Sorbent Handling Plant (SHP) Battery Limits
Mechanical Conveying Section
Sorbent Unloading & Storage Building
Crushing House
Limestone Storage Silo (450T)
Pneumatic Conveying Section
Compressor House
Dense Phase Pumps
Pneumatic Conveying Piping
Summary

5. Sorbent Handling Plant
Designed to convey Sorbent (limestone) of required size to the CFB boiler limestone bins in Coal Power Plant
Limestone as desulphurization agent
Sorbent Handling Plant
Mechanical Conveying Section
Pneumatic Conveying Section

6. Mechanical Conveying Section Pneumatic Conveying Section
Battery Limits
Start Point: Limestone Unloading Station
End Point: Outlet Flange of limestone storage silo (450T)
Mechanical Conveying Section
Start Point: Outlet Flange of limestone storage silo (450T) `
End Point: Inlet Flange of boiler limestone bins
Pneumatic Conveying Section

7. Mechanical Conveying Section
Sorbent Unloading & Storage Building
Belt
Conveyor
Limestone Storage Silo 450t
Crushing House
Column Mill
Air Classifier
Double Cyclone Separator
Mill Feeding Silo

8. Mechanical Conveying Section
Sorbent Unloading & Storage Building
Purpose
To receive limestone from trucks & keep it as storage
Specifications
Type: Shed & three sides covered (Only South Side Open)
Capacity: 1000MT
Pile Dimensions: 30x11x3 m (LxWxH)
Main Equipment
Unloading hopper
Rod gate
Belt Conveyor

9. Belt Conveyor & Selection
Options For Raw Limestone Conveying From Unloading Hoppers
Belt Conveyor & Bucket Elevator
Chain Conveyor
Belt Conveyor
FPCL Selection Parameters
Reliable Operation
Easy Maintenance
Safe Working

10. Belt Conveyor Specifications
Title
Description
Horizontal Length (Pulley center to center)
148.5 m
Width
650 mm
Rated Capacity
100 t/h
Troughing Angle
30°
Belt Speed
1.25 m/s
Belt conveyor Inclination
10°
Belt Construction Type
EP belt (fire resistant)
No. Of Plies 3
Belt cover material grade
DIN class F
Total Thickness of Belt
14.1 mm

11. Mechanical Conveying Section
Limestone Crushing House
FPCL Requirements
Facility: Covered Building
Milling Type: Single Stage Milling
No. of Mills: 2
Capacity of each Mill: 50 t/h
Inlet Granulometry: 20 ~ 30 mm (nominal size) 5% above 30 mm up to max. 35mm
Outlet Granulometry: <1mm Grinded Powder (Particle Size Distribution as per graph 1.1)

12. Graph 1.1

13. Mechanical Conveying Section
Limestone Crushing House
Main Equipment
Mill Feeding Silo
Weighing Belt Feeder
Column Mill
Air Classifier & Separator
Belt Feeder (Enclosed)
Bucket Elevator
Chain Conveyor
Bag Filter
Mill Feeding Silo
Weighing Belt Feeder
Column Mill
Air Classifier
Belt Feeder (Enclosed) +
Bucket Elevator
Cyclone Separator

14. Mill Feeding Silo Purpose Specifications Title Description
Receiving limestone from unloading hoppers
Maintaining continuous supply to column mill
Store raw limestone for emergency
Specifications
Title
Description
Capacity
100 ton
Shape
Cylindrical
Material of Construction
Steel
Liner
Hardox 400
Diameter
5 m

15. Weighing Belt Feeder Purpose Specifications Title Description
Two weighing belt feeders to feed limestone to column mills from mill feeding silo (100t) and air classifier (recycled oversize).
To weigh limestone received from mill feeding silo (100t) only.
Specifications
Title
Description
Horizontal Length
(Pulley center to center)
7.5 m
Width
1000 mm
Capacity
150 t/h
Location
Before column mills

16. Column Mill & Selection
Options For Milling of Raw Limestone
Option 1
70 mm
< 1 mm
Option 2
35-30 mm < 1 mm
Crusher
Column Mill
30 mm
Column Mill

17. Column Mill Purpose Specification Title Description
Carrying out milling of limestone
Specification
Inlet
Chute
Main Shaft
Title
Description
Type
Conical Grinding Mill
No. of column mills
2 (1 Operational + 1 Standby)
Capacity
45-50 t/h
Input Material Size Range
≤35mm
Output Material Size Range
<1mm
Rollers
Outlet Chute

18. Air Classifier & Cyclone Separator
Purpose
Separation of particles for following motives:
Re-cycling of oversized material
Conveying desired material to 450t Silo
Specifications
Double Cyclone Separator
Title
Description
Type
PL Waterfall-type Powder Separator
Desired Material Output Size
<1 mm
Capacity
50 t/h
Location
Limestone Crusher House
Operating pressure
2.903 kPa
Air Classifier

19. Circulation Blower Purpose Specifications Title Description
Circulate air between PL Classifier and Double Cyclone Separator
Convey limestone dust to bag filter
Specifications
Title
Description
No. of Blowers 1
Type
Centrifugal Blower
Operating Pressure
2.903 kPa

20. Belt Feeder Purpose Specifications Title Description Two belt feeders
Safe transportation of powdered limestone
Specifications
Title
Description
Horizontal Length (Pulley center to center)
11.42 m
Width
800 mm
Capacity
150 t/h
Location
Between column mills and bucket elevator 1

21. Belt Feeder Specifications: Title Description
Horizontal Length (Pulley center to center)
11.08 m
Width
800 mm
Capacity
100 t/h
Location
Between PL classifier and weighing belt feeder

22. Bucket Elevator Purpose Specifications: Title Description
Two bucket elevators
Transport powdered limestone to higher elevations safely
Specifications:
Title
Description
Type
Chain Bucket Elevator
Conveying Height
30.12 m (From el m - el m )
Capacity
150 t/h
Location
Between belt feeder 1 and PL classifier

23. Bucket Elevator Specifications: Title Description Type
Chain Bucket Elevator
Conveying Height
18.95 m (From el m to el m)
Capacity
60 t/h
Location
Between chain conveyor 1 and chain conveyor 2

24. Chain Conveyor Purpose Specifications: Title Description
Two chain conveyors
Safe transportation of powdered limestone
Specifications:
Title
Description
Horizontal Length (Pulley center to center)
7.03 m
Capacity
60 t/h
Conveying Speed
0.33 m/s
Location
Between cyclone separator and bucket elevator 2

25. Chain Conveyor Specifications: Title Description
Horizontal Length (Pulley center to center)
4.2 m
Capacity
60 t/h
Conveying Speed
0.33 m/s
Location
Between bucket elevator 2 and storage silo (450)

26. Mechanical Conveying Section
Limestone Storage Silo
Purpose
Milled Limestone Storage for 3.5 days
Continuous supply to dense phase pumps
Specifications
Title
Description
Capacity
450 ton
Shape
Cylindrical
Material of Construction
Steel
Liner
Hardox 400
Diameter
9 m

27. Dust Extraction System
Purpose
To extract limestone dust from following locations in crusher house:
Mill Feeding Silo
Belt Feeder 2
Cyclone Separator
Equipment
Bag Filter or Dust Collector
Exhaust Blower
Screw Chain Conveyor

28. Pneumatic Conveying Section
Compressor House
Purpose
To supply compressed air for pneumatic conveying of limestone
To supply air for dust extraction system
To supply air for fluidization of storage silo (450T)

29. Pneumatic Conveying Section
Compressor House
Equipment
Compression Unit for Pneumatic Conveying
Air Compressors
Air Dryers
Filters
Service Air Receivers
Instrument Air Receiver

30. Pneumatic Conveying Section
Air Supply Unit for Dust Extraction System
Air Compressor
Air Dryer
Filter
Instrument Air Receiver
Fluidization Unit for Storage Silo (450T)
Blowers
Electric Heater

31. Compression Unit for Pneumatic Conveying
Purpose
To supply compressed air to pneumatic conveying piping
Specifications of Compressor
Title
Description
Type
Rotary Screw Air Compressor
No. of Compressors
3 (2 Operational+1 Standby)
Capacity
28 m³/min
Pressure
0.75 MPa
Cooling Method
Water Cooling
Air Oil
Separator
Screw
Element
Air Inlet Pipe Motor

32. Air Supply Unit for Bag Filter
Purpose
To provide compressed air for bag filter
Specifications of Compressor
Title
Description
Type
Rotary Screw Air Compressor
No. of Compressors 1
Capacity
3.6 m³/min
Pressure
0.75 MPa
Cooling Method
Air Cooling
Air Oil
Separator
Screw
Element
Air Inlet Pipe Motor

33. Fluidization Unit for 450 T Storage Silo
Purpose
To supply fluidized air to avoid lump formation of material in silo
Specifications of Blowers
Inlet
Title
Description
No. of Blowers 2
Type
Root Blower
Capacity
3 m³/min
Pressure
50 KPa
Blower
Motor
Outlet

34. Pneumatic Conveying Section
Powder Limestone Silo 450t
Compressor
Vent
Valve
Air Injectors
Dense Phase Pump
Pneumatic Conveying Piping

35. Pneumatic Conveying Section
Dense Phase Pumps
Purpose
Receiving powder limestone
Convey it to pneumatic lines
Specifications
Title
Description
No. of Dense Phase Pumps 2
Effective Volume
2.5 m³
Pressure
< 1 MPa

36. Pneumatic Conveying Section
Pneumatic Conveying Piping
Purpose
To transfer limestone from powder limestone storage silo through dense phase pumps to limestone surge bins of CFB boilers.
Specifications
Title
Description
Material
Carbon Steel
Size mm
Elevation m
Capacity
30 t/h
Pneumatic Conveying Piping

37. Summary
Equipment Compatibility and suitability for limestone conveying and processing
Provision of standby equipment at critical point to avoid any hindrance in smooth operation of plant
Provision of sufficient space for equipment maintenance
Availability of limestone storage for emergency use
Covered Buildings for material storage and processing are considered to Avoid Air pollution