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Material Handling for the Power Industry

About the Power Industry

The power industry operates through the generation, transmission, and distribution of electricity, utilizing a variety of energy sources. These sources include fossil fuels (coal, natural gas, and oil), nuclear energy, and increasingly renewable resources like solar, wind, hydroelectric, and geothermal energy. The industry is undergoing a transformative shift from reliance on fossil fuels toward sustainable and low-carbon energy solutions, driven by environmental concerns, economic factors, and technological advancements.

Coal-Fired Power Plants: From Dominance to Decline

Coal (primarily composed of carbon (C), along with varying amounts of sulfur (S), nitrogen (N), and oxygen (O)) has historically been a cornerstone of electricity generation due to its abundance and energy density. In a coal-fired power plant, pulverized coal is burned in a furnace to produce heat, which converts water into high-pressure steam. The steam drives a turbine connected to an electrical generator, converting thermal energy into mechanical and then electrical energy.

However, coal usage is decreasing due to its significant environmental impact, including high emissions of carbon dioxide (CO₂), a major greenhouse gas. These emissions, along with pollutants like sulfur dioxide (SO₂) and nitrogen oxides (NOₓ), contribute to climate change, acid rain, and smog.

Flue Gas Scrubbing and Synthetic Gypsum Production

To mitigate environmental damage, modern coal plants incorporate flue gas desulfurization (FGD) systems. This process removes SO₂ from exhaust gases by reacting it with a slurry of calcium carbonate (CaCO₃), commonly found in limestone. The chemical reactions are:

  1. SO₂ + CaCO₃ → CaSO₃ + CO₂
  2. CaSO₃ + ½ O₂ + 2H₂O → CaSO₄·2H₂O


The end product, calcium sulfate dihydrate (CaSO₄·2H₂O), is synthetic gypsum, identical in composition to naturally occurring gypsum. This material is used in construction, particularly in the manufacture of drywall, turning a waste product into a valuable resource.

Waste-to-Energy Conversion

In some innovative applications, waste from coal combustion, such as fly ash (composed of silicates and oxides of aluminum (Al), silicon (Si), iron (Fe), and calcium (Ca)), is repurposed in concrete production. Similarly, energy can be extracted from municipal solid waste (MSW) through combustion or advanced gasification, converting waste materials into electricity and heat while minimizing landfill use.

Transition to Renewable Energy

The energy industry is undergoing a paradigm shift as renewables become increasingly viable. Solar panels (composed of semiconductors like silicon (Si)) harness photons to excite electrons and create an electric current through the photovoltaic effect. Wind turbines convert kinetic energy from air movement into mechanical energy using advanced materials like composites of carbon (C) and epoxy resins for lightweight, durable blades.

Hydroelectric systems utilize gravitational potential energy from water stored in dams, converting it into kinetic and then electrical energy via turbines. Geothermal power exploits heat from radioactive decay of elements like uranium (U) and thorium (Th) within Earth’s crust to produce steam for electricity generation.

The Role of Hydrogen and Energy Storage

Hydrogen (H₂) is emerging as a clean energy carrier. Produced via electrolysis (splitting H₂O using electricity), it can store surplus renewable energy and release it through fuel cells, combining hydrogen with oxygen (O₂) to produce water and electricity.

Energy storage technologies like lithium-ion batteries (using lithium (Li), cobalt (Co), and nickel (Ni)) enable the stabilization of intermittent renewable sources. Pumped hydro storage and emerging technologies such as vanadium redox flow batteries also contribute to grid reliability.

Future Directions

As renewable energy adoption accelerates, innovations in grid infrastructure, including smart grids and advanced superconductors, will optimize energy distribution and minimize losses. Integration of decentralized systems like rooftop solar and microgrids will empower local communities while enhancing energy resilience.

The power industry is at a critical juncture, moving from a centralized, fossil-fuel-based model toward a sustainable and diversified energy ecosystem. This transition aligns with global goals to mitigate climate change, reduce pollution, and achieve energy security.

Additionally, alternative fuels, including biomass and municipal solid waste, are gaining traction as waste products are converted into energy. Many biomass fuels derive from renewable feedstocks like corn, sugarcane, and wood, supporting a more sustainable energy cycle. Alongside these advancements, power industry organizations are taking critical steps to reduce emissions, limit methane, and engage in carbon capture, utilization, and storage initiatives to lower their overall carbon footprint.

Lastly, the main byproduct of coal burning is ash. Ash is non-combustible mineral matter. Often, it is a high source of Iron, that can be used in Cement Manufacturing.

WTW Americas Power Industry Experience

With over 40 years of experience and more than 1,070 installations across 66 countries, WTW Americas has a proven track record in designing and manufacturing solutions for storing, conveying, processing, and distributing both traditional and alternative fuels across the power industry.

Our equipment is engineered to endure the extreme conditions inherent in power industry processes, ensuring reliability and durability. As the power industry pivots toward renewable sources, WTW Americas remains committed to precision engineering, continuously monitoring new requirements and innovations to meet the evolving needs of energy conveyance, distribution, and delivery. Our deep understanding of the power sector’s unique challenges sets us apart as a trusted partner in this transformative era.

Material Receival

At the beginning of the power industry process, WTW Americas Truck Discharge Machine (TDM) serves as the ideal machine to receive raw materials. The TDM is specifically engineered to speed the unloading of materials into a processing facility, without the need for costly excavation, and requiring minimal civil work. The complete unloading facility can receive bulk material from trucks, front-end loaders, barges, and railcars. The TDM will accept a full truck load of material and can be discharged from 0 to 1,200 t/h at constant or variable rates. Our Truck Discharge Machine may also receive Alternative Fuels, Municipal Solid Waste, Refuse Derived Fuel, and Coal among other bulk materials.

Conveying

At WTW Americas, we manufacture boiler ash cooling and reclaiming systems. As boiler ash falls into a water bath, our TKF Chain Conveyors can clean out the bottom of the boiler ash cooling system by conveying material seamlessly. Standard or specifically designed, WTW Americas TKF Chain Conveyors are self-cleaning, can run horizontal, 3 inclined, and even vertical with widths from 0.25 to 2 meters. Our Chain Conveyor solutions have been rigorously tested to ensure success once installed in the field.

The bolts, pins and the tolerances transform our chain into a long-lasting trouble-free system. All connectors and pins are made of high-quality alloy steel that is subjected to special treatments to enhance their duration and resistance to wear and tear.

Sticky, hot (up to 750 ºC), abrasive materials such as synthetic gypsum, sludge, or clinker are easily conveyed from 0 to 1,000 t/h. Our single strand and double strand German engineered chain conveyors are a reliable means of transporting

Dust-Tight Discharging, Feeding, and Distribution in the Power Industry

Power plants often require specialized equipment for the storage, handling, and feeding of bulk materials. Systems must be capable of managing materials such as coal, clay, limestone (CaCO₃), and flue-gas desulfurization (FGD) gypsum (CaSO₄·2H₂O) efficiently and reliably to support the overall energy production process. Over half of our installations are in handling Limestone, Gypsum, and FGD Gypsum.

Silo Discharge Machine (SDM)

WTW’s Silo Discharge Machine (SDM) offers a versatile solution for extracting and feeding sticky bulk materials stored in silos. With diameters ranging from 1.5 to 6 meters and capacities up to 1,000 t/h, the SDM is engineered to handle challenging materials like wet, hot, and cohesive bulk substances. The rotating discharge arm moves the material toward the central discharge opening, ensuring a uniform flow and preventing issues like solidification, bridge formation, or ratholing.

The SDM is particularly suited for:

  • Coal storage and feeding to boilers.
  • Limestone handling for flue gas scrubbing.
  • Synthetic gypsum storage for later use in construction materials.


The precision design of the SDM ensures energy efficiency and uninterrupted operation, making it integral to maintaining process continuity in power plants.

Bunker Discharge Machine (BDM)

The Bunker Discharge Machine (BDM) is another essential tool, designed for reclaiming tough-to-handle materials from stockpiles, hoppers, or domed storages. It 4 can transport bulk materials like limestone, FGD gypsum, or coal with reclaim rates between 10 to 2,500 t/h. Mounted on rails, the BDM moves across bunker shelves to discharge material onto a conveyor system, enabling large-scale material handling in power plants.

Integration in the Power Production Process

The discharged materials play critical roles:

  1. Coal: Fired in power plant boilers to generate heat and produce steam for electricity generation.
  2. Limestone: Used in flue gas desulfurization to remove SO₂ from exhaust gases, converting it into synthetic gypsum.
  3. Synthetic Gypsum: A by-product of coal-fired power plants, repurposed in construction, exemplifying the industry’s efforts to minimize waste and promote sustainability.

Toward Renewable Energy: A Transformative Shift

The reliance on coal-fired power is declining as the industry transitions to cleaner, renewable energy sources like solar, wind, and hydropower. However, handling systems for bulk materials remain essential in managing renewable energy infrastructure, including materials for battery storage and hydrogen production.

Advanced equipment like the SDM and BDM continues to play a role in ensuring operational efficiency, whether in fossil fuel-based plants or emerging renewable technologies. These innovations exemplify how precision engineering supports the power industry’s broader goals of sustainability and energy efficiency.

By integrating WTW Americas’ advanced conveyor, discharge, and handling systems, cement producers can achieve a high level of process reliability, ensuring uninterrupted production and contributing to overall energy efficiency in the highly demanding cement manufacturing process. All of our equipment can be modified to meet specific industry needs.

For more information about our equipment, please visit our equipment page.

Learn More

To learn more about WTW Americas equipment and experience in the Power Industry email info@wtwamericas.com or call +1705-749-3544.

Contact Us

Email
info@wtwamericas.com

Phone
705-749-3544

Address
159 King St. Suite 208
Peterborough, ON, Canada
K9J 7H7

WTW Americas specializes in handling sticky, wet, hot (up to 750°C), abrasive and non-free-flowing bulk materials.

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