Port hopper Dust -free hopper environment friendly hopper dust collector hopper

INTRODUCTION of the port hopper: To ensure a dust-free coal unloading for a coal-fired power plant, two laterally displaceable Hopper cars have been installed at a port , During the design phase, special respect had to be paid to the low temperatures in winter.   TECHNICAL DATAS: Hopper opening: approx. 7 × 7 metres, Hopper volume: ca. 50 cubic metres Conveyed/handled material: Hard coal, Grain size: approx. 0 to 50 millimetre Average handling capacity: 750 tonnes per hour, maximum 1000 tonnes per hour, resp. 30 000 tonnes per day. The connection of the hopper cars with the customer-supplied double jib level luffing cranes is done via coupling rods DUST CONTROL: In order to reduce possible dust emissions the feeding onto the conveyor belt respectively the transfer to the longitudinal quayside conveyor has also been equipped with a fogging system. Special single-component nozzles are spraying the water with a drop size distribution of 100 to 500 microns. The booster stations required for the fogging system, valves, valve unit with solenoid valve for atomizing start and stop as well as diaphragm valves for pressure setting are located in heated pump containers. The hot-dip galvanized piping to the nozzles is protected against damage due to freezing by means of an insulation and heating. The fourth water-side front wall of the hopper is designed as spillage flap and can be opened and closed via hydraulic cylinder. The necessary hydraulic units are installed at the respective hopper car. A cover grid with a mesh size of 200 × 200 millimetres retains larger grain sizes. For noise emission reduction <94 dB(A) the hoppers are lined with wear-resistant and sound-absorbing rubber-steel sheet elements and the hopper corners with polyurethane steel sheet elements to minimise the product deposits. Additionally, two pendulum-type vibrators on the two lateral faces of the hopper are used to remove the possible coal residues. If necessary, these can be operated alternately and temporarily.   Monitoring and Weighing: The hopper is monitored with a weighing system including evaluation unit and if there is the danger that the material will pile up, the crane discharge is stopped. Weighing electronics are integrated into the control system via Profibus. For the operation in winter the hopper walls and the water atomising system are provided with an insulation and are heated with a flexible resistance heating cable. Furthermore the hoppers are equipped with the required stair accesses and maintenance platforms each.   Hopper Discharge: Hopper discharge is made with a sturdy discharge conveyor, which is suitable for use in winter, of 1600 millimetre belt width and a centre distance of 12 000 millimetres with upstream needle weir. The discharge conveyor is designed with rubberised pulleys, thick-layered rubber belt, inner and outer belt cleaners, closed bottom, corrugated steel sheet cover and all necessary monitoring and safety equipment, as well as a discharging chute with buffer idler garlands and chute walls with wear-resistant and sound-absorbing rubber-steel sheet elements for sound emission reduction <94 dB(A). The overall system is designed to be operated at ambient temperatures from -25 to +40 °C, with an air humidity of up to 100 per cent due to direct vicinity of the water. Power supply to the hopper cars is made through the cranes and the speeds of the discharge conveyors are controlled by frequency converter included in the scope of delivery. The electrical switching and control system to operate the hopper cars, as well as the fogging system, hydraulic system, heating system and lighting system were included in the scope of delivery. For handling of other bulk material, such as wood pellets, the described version of the hopper cars can alternatively be equipped with an additional dedusting system. In this case, the cover grids of the hopper opening would be replaced by a Flex-Flap System and, to reduce emissions, a dedusting system with integrated filters would be used. Initial start-up of the sturdy hopper cars combined with the harbour cranes took place in March 2010 and since then the systems proved their suitability for use in harbours.  

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