POWER INDUSTRY

Coal-fired units produce electricity by burning coal in a boiler to heat water to produce steam. The steam, at tremendous pressure, flows into a turbine, which spins a generator to produce electricity. The steam is cooled, condensed back into water, and returned to the boiler to start the process over.


  • Half of U.S. electricity is generated from coal.
  • 9 out of every 10 tons of coal mined each year in the U.S. is used for domestic electricity generation.
  • Coal is the most affordable source of power fuel per million Btu, averaging less than one-quarter the price of petroleum and natural gas.
  • There are approximately 600 power plants (1,600 units) and 1,100 manufacturing facilities using coal in the U.S., according to the U.S. Energy Information Administration (EIA).
  • Coal accounts for about 33 percent of U.S. total energy production and 22 percent of total energy consumption.
  • Power plants being built today emit 90 percent less pollutants (SO2, NOx, Particulates, mercury) than the plants they replace from the 1970s, according the National Energy Technology Laboratory.
  • Regulated emissions from coal-based electricity generation have decreased overall by nearly 40 percent since the 1970s while coal use has tripled, according to government statistics.
  • U.S. coal operations have reclaimed more than 2.2. million acres of mined land over the past 25 years.
  • Since 1978, U.S. coal mines have paid more than $7 billion to reclaim mines that were abandoned prior to laws requiring reclamation.
  • Approximately five million acres of land have been mined in the U.S. to produced coal; and most of the land not under active mining has been or is being reclaimed to the standards set by law.

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Solutions Case Studies

ASGCO® Solves Chronic Spillage and Belt Tracking Problems at Large US Waste Recycling Center.

Objective: Persistent belt mistracking at this waste-to-energy recycling facility was causing consistent and problematic spillage and belt damage. These issues lead to safety concerns from falling material, as well as the need for constant housekeeping, severely impacting employee morale. Continual…

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Objective: Persistent belt mistracking at this waste-to-energy recycling facility was causing
consistent and problematic spillage and belt damage. These issues lead to safety concerns
from falling material, as well as the need for constant housekeeping, severely impacting
employee morale. Continual belt mistracking also lead to premature belt failure and costly
repair and downtime.

Challenge: Persistent belt mistracking at this waste-to-energy recycling facility was causing consistent and problematic spillage and belt damage. These issues lead to safety concerns from falling material, as well as the need for constant housekeeping, severely impacting employee morale. Continual belt mistracking also lead to premature belt failure and costly repair and downtime.

Waste to Energy Facility_Flat Return Tru-Trainer & Dura-Sleeve Case Study - EG

Solution: Upon completing a thorough conveyor inspection, ASGCO® technicians were able
to identify several areas for improvement.  Existing rubber disc return idlers were replaced with ASGCO® Dura-
Sleeve™ Return idlers and an ASGCO® Tru-Trainer® Flat Return idler was strategically located between the
head & tail pulley to insure the belt stays centered on the return idlers.  This combination ensured that the belt
would remain centered under the load zone and throughout its travel, eliminating spillage, premature belt wear
& conveyor shutdown.  ASGCO® Safe-Guard® Return Idler Guards were installed around each return idler
to further ensure that maximum safety standards were met.

Results: Once all of the Dura-Sleeve™ Urethane Return Idlers were replaced and centered, the ASGCO®
Tru-Trainer® was installed, and fine-tuned for maximum performance.  The belt no longer gets snagged or
bounces across the rubber disc returns, and any minor belt mistracking is being corrected by the Tru-Trainer®.
Weather, wind and material loading were all factors in resolving these issues. The belt operates much
more efficiently, spillage has been virtually eliminated, and the lifespan of the belt will increase dramatically.
This plant now experiences much less downtime, requires far less clean up and promotes a much safer working
environment for its employees.

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ASGCO® Eliminates Belt Tracking Issues with Low Profile Tru-Trainer®

Objective: Eliminate belt tracking issues that are resulting in major belt damage and spillage from contact with steel conveyor supports. Challenge: For many years this conveyor had a hydraulic three return Idler belt training system that wouldn’t properly keep the conveyor belt…

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Objective: Eliminate belt tracking issues that are resulting in major belt damage and spillage from contact with steel conveyor supports.

Challenge: For many years this conveyor had a hydraulic three return Idler belt training system that wouldn’t properly keep the conveyor belt in line.  The plant was facing constantly downtime to repair the hydraulic system.  Even when operational, the belt would veer off of center and come into contact with the structural supports, leading to critical damage to the belt and costly material spillage.  To further complicate this application, the conveyor also has less than 13” of height to mount any type of return training roller.  Options for eliminating the tracking problem were extremely limited by these space restrictions.

Case Study_JS_Tracking Issue_Challenge pic_web

Solution: After surveying the conveyor and taking key measurements,
the ASGCO® Engineering department developed the Low Profile Dual
Return Tru-Trainer with a height of only 11.8”. This new low-profile
design was installed to replace the previous failing system to actively
and continually recenter the belt.

Results: After installing two Low Profile Dual Tru-Trainers® about 20′
from each stationary pulley, the belt is maintaining center alignment and
the problem of belt damage and material spillage has been eliminated.
The customer no longer has to shut down operations to repair the belt
and the hydraulic system, or to spend valuable hours cleaning up
spilled material. Performance has been greatly improved and productivity
is at an all time high. This particular customer is very satisfied with the
performance of the Tru-Trainers®, and recently placed an order for two
additional for a different 60” Stacker Reclaimer Conveyor.

 

Case Study_JS_Tracking Issue_Before After pic_web

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April Solutions 2015 ASGCO® Helps Northeastern US Coal Burning Power Station Improve Material Flow and Reduce Maintenance Costs

Objective: To improve material flow and reduce dust spillage and maintenance issues Challenge: Constant abrasion from high moisture bituminous coal was causing serious wear and plugging on flow chutes at a major Northeastern US coal burning power station. ASGCO® 3-DEM®

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Objective: To improve material flow and reduce dust spillage and maintenance issues

Challenge: Constant abrasion from high moisture bituminous coal was causing serious wear and plugging on flow chutes at a major Northeastern US coal burning power station.
ASGCO® 3-DEM® Designed Flo-Control® Chutes are custom tailored to adapt to unique challenges of any material in any environment.


A major US coal burning power plant was experiencing constant chute plugging after recent upgrades to its coal yard.
These issues were compounded by spillage due to holes being formed almost immediately in the new round chutes
that were installed. These problems led to major maintenance down time, and the round design of the newly installed
chutes proved difficult to repair. This situation prevented the silos from being stocked with coal, reducing productivity,
as well as adding a significant cost for repair and maintenance from holes in the new chute after 30 days of service.
Because of the round design of the chutes, repairing the holes and replacing the liners became cost and time prohibitive.

 

CS_Flo-Control Before-After

Solution: After surveying the loading system, ASGCO® technicians recommended a 3-DEM® Chute Analysis
program to redesign the failing chute sections.  This cutting-edge simulation identifies the optimal design for
full capacity flow under all conditions with no build up or plugging while also decreasing the wear on the
internal liners.  ASGCO® also recommended an advanced liner system that would allow for easy maintenance
and minimal stocking requirements for liner plate replacement.

Results: The redesigned ASGCO® Flo-Control® chutes completely eliminated the plugging and buildup and
allowed for increased tonnage flows even with high moisture, low quality coal.  Because of the efficient design
of the new ASGCO® Flo-Control® chutes, internal liner wear life was increased over 12 times longer in high
impact areas of the chutes.  When these wear liners are due for scheduled replacement, the installation can
be performed in as little as 3 hours, using standard sized liners that can be stocked for a very low cost.
The client is completely satisfied with the performance of this system, and has seen immediate improvements
to material flow and productivity as well as significantly reduced downtime and maintenance costs.

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ASGCO® Helps Power Plant Reduce Dust Levels by 60%

Current guidelines for combustible dust control are critical to any safe operating coal fired power plant or any operation that is handling materials that can create combustible dust. The tripper floor at this power plant had a large unhealthy volume…

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Current guidelines for combustible dust control are critical to any safe operating coal fired power plant or any operation that is handling materials that can create combustible dust. The tripper floor at this power plant had a large unhealthy volume of dust suspended in the air that would make it difficult to see from one end of the room to the other. Operators had to wear dust masks and respirators and at times that wasn’t enough.

ASGCO-Helps-Power-Plant-Reduce-Dust-by-60-percent

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ASGCO® Products Solve Fugitive Material Containment Problems at a Northwestern Coal Fired Power Plant.

Industries: Power Industry This northwestern coal fired power plant was experiencing tremendous amounts of coal escaping through the load zone area. There were several issues that needed attention. The belt was mis-tracking in the impact area of the load zone…

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Industries: Power Industry

This northwestern coal fired power plant was experiencing tremendous amounts of coal escaping through the load zone area. There were several issues that needed attention. The belt was mis-tracking in the impact area of the load zone and it was not fully supported due to impact rollers being used. Both situations resulted in excess spillage and airborne dust.

Contain-the-Fugitivesrev-WM

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ASGCO® Skalper Belt Cleaners Reduce Carry-back Dust at a Midwestern Power Plant

Objective: Eliminate carry-back, reduce housekeeping, minimize safety issues, reduce maintenance needs and extend blade life Challenge: Excessive buildup of material carry-back and dust from inadequate belt cleaners, resulting in housekeeping and safety issues, combined with OSHA’s Combustible Dust National Emphasis…

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Objective: Eliminate carry-back, reduce housekeeping, minimize safety issues, reduce maintenance needs and extend blade life

Challenge: Excessive buildup of material carry-back and dust from inadequate belt cleaners, resulting in housekeeping and safety issues, combined with OSHA’s Combustible Dust National Emphasis Program (NEP) have made things very difficult for this Mid-western coal-fired power plant.  The increased labor for housekeeping issues and the possibility of strict fines added increased emphasis for this power plant to improve its belt cleaner systems.

Recommendations: Following a complete conveyor survey and review of the systems requirements, the ASGCO® Skalper® Belt Cleaners with E-Z Torque™ Tensioner were best suited to address all areas of concern for these applications.

Skalper IV Coal Fired Power Plant Case Study_image 1

Results: After months of daily use, the Skalper® units have provided excellent cleaning. Reduced hours on housekeeping, safety issues, and wash downs. Belt tracking issues due to return idler build-up has been eliminated. Manpower and maintenance time has also been greatly reduced due to the effective performance of the E-Z Torque™ Tensioner which has also greatly extended their blade life.

  • Skalper® (patented) one piece blade maintains an effectiveSkalper IV Coal Fired Power Plant Case Study_image 2
    cleaning edge throughout the life of the blade
  • E-Z Torque™ (patented) torsion style tensioning system provides
    a constant consistent tension throughout the life of the blade
  • Quick blade change outs and minimal maintenance

Maximum Belt Speed – 1000 fpm (5.0 m/sec)
Pulley Diameter – 16” – 36” (400 – 900mm)
Applications – Coal Fired Power Plants, Hard Rock Mining,
Steel Mills, Iron Ore, Aggregate and Mineral
(Phosphate, Potash, Salt) Mining

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Improving Conveyor Belt Tracking and Reducing Airborne Dust on a Redesign of a PRB Coal-Fired Power Plant Conveyor Transfer System

This transfer point was a major problem area for the PRB coal yard. While in reclaiming operation, the chute would build- up and plug when running wet coal or during freezing conditions. Chute heaters, vibrators and internal baffles were added,…

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This transfer point was a major problem area for the PRB coal yard. While in reclaiming operation, the chute would build- up and plug when running wet coal or during freezing conditions. Chute heaters, vibrators and internal baffles were added, but the problem still remained. Due to the angle of discharge onto the 60” receiving conveyor, off center loading caused serious belt mis-tracking and constant spillage.

Improving-Conveyor-Belt-Tracking-Reducing-Airborne-Dust-on-PRB-Power-Plant-Redesign

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ASGCO Wash Box System Prevents Carry-back and Keeps Dust to a Minimum at a PRB Coal Fired Power Plant

In today’s coal burning power plants, it is essential to keep carryback and dust to a minimum. With power plants having to cut back on maintenance crews to service these conveyors, belt cleaners get overlooked, and very seldom get cleaned…

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In today’s coal burning power plants, it is essential to keep carryback and dust to a minimum. With power plants having to cut back on maintenance crews to service these conveyors, belt cleaners get overlooked, and very seldom get cleaned or re-tensioned.

Wash-Box-Case-Study

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3-DEM Solves a Major Transfer Chute Problem at Northeast PRB Coal Fired Power Plant

This transfer point was a major problem area for the PRB coal company. While in reclaiming operation, the chute would build up and plug when running wet coal or during freezing conditions. Chute heaters, vibrators and internal baffles were added…

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This transfer point was a major problem area for the PRB coal company. While in reclaiming operation, the chute would build up and plug when running wet coal or during freezing conditions. Chute heaters, vibrators and internal baffles were added but the problem still remained. Due to the angle of discharge onto the 60” receiving conveyor, off center loading caused serious belt miss-tracking and constant spillage.

PPL-Bypass-Chute-Case-Study

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ASGCO Improves Operating Efficiency of PRB Coal-Fired Power Plants Conveying System

This area of the coal handling system was a major issue for the plant for several reasons. Due to the current OSHA NEP combustible dust requirements, has made it mandatory for many PRB coal fired power plants to address any…

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This area of the coal handling system was a major issue for the plant for several reasons. Due to the current OSHA NEP combustible dust requirements, has made it mandatory for many PRB coal fired power plants to address any airborne dust issues.

ASGCO-Coal-Fired-Power-Plant-Case-Study

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3-DEM Solves Another Major Transfer Chute Problem at a Northeast Biomass Power Plant

While discussing the challenges with key employees, and doing a thorough analysis of the plant, we discovered some of the problems that were occurring, including; issues with conveyor belts not getting cleaned properly as well as tensioning systems on the…

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While discussing the challenges with key employees, and doing a thorough analysis of the plant, we discovered some of the problems that were occurring, including; issues with conveyor belts not getting cleaned properly as well as tensioning systems on the primary belt cleaners locking up (or taking a set) and causing major material carry-back problems within the plant.

3-DEM-Biomass-Power-Plant-Chute-Problem-Solved

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