Industrial sectors \ ENERGY AND ENVIRONMENT
Innovative Material Handling Systems for Energy and Environmental Processes
Kopar has been developing solutions for demanding material transport, handling, cooling, and storage for decades. In energy and environmental processes, we help our clients improve operational reliability, manage demanding conditions, and meet tightening environmental requirements. With our applications, our clients have achieved significant savings, reduced emissions, and improved the safety of their processes.
Energy and environmental sector Requirements are constantly changing. Increasingly strict legislation, growing demands for environmental responsibility, and technological development challenge companies to develop their processes to be ever more efficient, sustainable, and safe.
At the same time, the use of solid fuels is becoming more diverse, and material handling solutions are required to be more flexible and precise. The combustion of solid fuels always produces ash, which must be carefully cooled before transport or further processing.
For example, efficient cooling of fly ash enables its safe storage and transport, which is essential in many countries due to tightening regulations. Meeting these challenges requires in-depth expertise and advanced technologies.
Various additives and chemicals, such as lime and activated carbon, are used in flue gas purification, which effectively reduces emissions. The reception, storage, dosing, and transport of these materials require reliability and operational safety, even under demanding process conditions.
The Kopar team combines technical expertise, extensive experience, and innovative thinking to offer clients solutions that improve plant efficiency, reduce environmental impact, and lower costs.
Our task is to ensure that the client's specific needs are taken into account from the very beginning, whether it concerns ash cooling, material transport, or recycling.
Bucket elevators, screw conveyors, elevators, and wet ash conveyors are designed to withstand heavy loads and demanding conditions. These systems enable the efficient transfer of bottom ash, fly ash, as well as bed materials and additives at various stages of the processes. Our mechanical conveyors also play a key role in material recycling processes.
Our high-pressure conveyor (ELMO pulse dense phase) s the most energy-efficient and low-wear conveying method for handling bottom and fly ash.Blower conveying is suitable for materials with lower wear potential and for injecting additives to ensure even spreading.
Kopar's cooling solutions, such as KRC coolers and cooling belt conveyors, offer the energy industry an efficient way to manage high temperatures during processes. They enable the rapid and energy-efficient cooling of bottom ash and fly ash before further transport or storage.
Cooling solutions combine highly efficient heat transfer, compact design, and durability, making them an excellent choice for facilities seeking an effective solution for optimising their processes. Maximum radiator efficiency opens up new possibilities for utilising generated thermal energy. For instance, in thermal power plants, the water fed into the district heating network can be heated by the energy released during the cooling process, thereby improving the overall efficiency of the plant.
The processing of wet materials, such as damp bedding sand, often requires a drying phase before the material can be returned to the process or further utilised. Kopar rotary dryers are based on direct drying, where the material to be dried is in direct contact with hot gases inside the drum. This allows for efficient heat and moisture transfer and a consistent end result, even when the moisture content of the material varies.
As a practical application, a rotary dryer is utilised, for example, in the recycling of fluidised bed sand in circulating fluidised bed boilers: the recovered damp sand is dried in the drum, after which it can be returned to the boiler as bed material. This reduces the need for new sand and the amount of waste material, and lowers the plant's operating costs.
Our crushing and screening solutions are designed to guarantee material consistency and processing efficiency. Ash crushers and screens are particularly suitable for the classification and recycling of bed materials, which improves the efficiency of combustion processes, reduces material waste, and helps achieve a more sustainable operating model.
Kopar silo systems offer a complete solution for the storage and management of dry materials. Thanks to a reliable dosing system, additives and fuels are fed into the process precisely, which reduces material waste. Carefully designed silo systems meet the high safety and environmental requirements of modern plants, making them an essential part of energy industry process management.
Energy and Environmental Processes Material Handling
In addition to individual devices, Kopar designs and implements larger material handling systems for the energy and environmental sectors. Our solutions are built around conveyors, feeders, coolers, dryers and storage systems, which are formed into reliable systems for various process stages.
We understand the specific requirements of energy and environmental processes, whether it's hot bottom ash, fine fly ash, bed materials for circulating fluidised bed boilers, or additives used in flue gas cleaning. In our designs, we consider material properties, process conditions, and safety and environmental requirements, ensuring that the entire system operates efficiently and reliably, even in demanding operating environments.
Processing of bottom ash in grate boilers
The bottom ash produced in the incinerators is removed from the process safely and in a controlled manner by wet ash conveyors. A wet ash scraper operating in a water basin effectively cools the hot ash before further transport or storage.
Bottom ash treatment in fluidized bed boilers
The bottom ash from fluidized bed boilers is cooled using dry methods, allowing the ash to be collected and stored without water treatment. KRC coolers, designed for efficient heat transfer, are suitable for large quantities of ash, while smaller amounts can be cooled using traditional cooling screw conveyors. The choice of equipment is made according to the amount of ash, temperature, and process constraints to optimise cooling capacity and operational reliability.
Fly ash processing
The processing of fly ash requires dust-tightness. The mechanical and pneumatic conveying systems of Kopar enable the safe transfer, cooling, storage, and dosing of fly ash in various energy and environmental processes.
Recycling and drying of bedding materials
In fluidised bed boilers, bedding material management is a crucial part of an efficient combustion process. Kopar's solutions enable the screening, recycling, and drying of bed sand before the material is returned to the process.
Emissions control and additive feeding
Various additives and chemicals, such as lime, activated carbon and sulphur, are used in flue gas cleaning to reduce emissions and improve the environmental efficiency of the process. Kopar's solutions cover the reception, storage, dosing, and feeding of additives into the process.
Pneumatic conveying systems and low-pressure conveyors enable a consistent and controlled supply of materials to demanding process conditions. Silos and silo accessories can also be integrated into applications, allowing additives to be stored safely and precisely fed as part of the flue gas cleaning process.
Handling of damp and wet materials
Not all recyclable side streams are dry. For the transfer of sludges, slurries and other moist bulk materials, we offer solutions using screw conveyors and belt conveyors, among others. If necessary, the material can be dried in a rotary dryer before further processing, making it easier to handle.
Read more about the options suitable for the energy and environmental process
Mechanical conveyors for the most challenging materials and conditions
Minimise operating costs without compromising quality with our flexible pneumatic conveyor solutions
