Material Handling Engineering & Design.
Here are a few examples that highlight our Material Handling Engineering & Design experience
Coal Yard Expansion for High Sulfur Coal
Varo was retained to perform the structural, mechanical, electrical and controls engineering for the project, and furnish the equipment and structural steel as a supplier to the general contractor. A new 32,000 ton high sulfur coal stockpiling and reclaim system was added to allow for segregation and stockpiling of low and high sulfur coals. The project included modifications to install a fixed tripper on an existing belt conveyor; three new 42”, 800 TPH belt conveyors; two transfer towers; a 42”, 800 TPH fixed stacker; three gyrating drawdown hoppers and vibratory feeders located in a concrete reclaim pit and tunnel; and modifications to the existing Crusher Tower. As part of the project a new PLC based control system with redundant processors and fiber communications will replace the existing hard-wired controls for the entire coal handling system.
Coal Segregation System
Varo was retained to upgrade an existing Coal Unit Station with a limestone-based scrubber for reduction of certain flue gas emissions. Since the plant still employs several smaller units that do not have scrubbers, this upgrade brought about the need for the plant to receive, stock out, and reclaim two grades of coal. Varo worked with the plant from the beginning concept stage through final commissioning and startup of the new coal segregation equipment. Varo worked with a construction partner in this project to deliver a turnkey solution to the plant, resulting in a cost effective system that met all requirements and was finished ahead of schedule.
FGD Material Handling System
Varo was retained to perform the structural and mechanical engineering for this project, and furnish the equipment and structrual steel as a supplier to the general contractor. Limestone and gypsum handling systems are part of this FGD project for a midwest coal generation energy company. The project included a limestone truck dump and a 30”, 460 TPH stacking conveyor; two 30”, 345 TPH reclaim and transfer conveyors; two 24”, 100 TPH gypsum transfer conveyors; and a new gypsum radial stacker.
Coal Yard Controls System Upgrade
As a part of a Coal Segregation Project, Varo was retained to upgrade the existing control system for the coal yard and integrate this together with the new coal segregation system controls. The resulting system eliminated circa 1950's relay logic and replaced it with a state of the art redundant PLC system with touch screen controls. Through the re-use of the largely intact existing field devices and wiring, careful planning, and Varo's panel fabrication, testing and training capabilities, the system was upgraded during the plant's spring outage in three weeks, one week earlier than scheduled, with all operator and maintenance training already completed.
Soda Ash / Pebble Lime Storage & Handling System
Varo was retained to provide a turnkey installation of pebble lime and soda ash storage and handling system. The project consisted of storage silos, day hoppers, pneumatic handling equipment, packaged blowers, slide gates, diverters, dust collectors, screw conveyors, fluidized conveyors, compressor and air supply lines, rotary airlock, access platforms with a caged ladder, concrete foundation for silos, electrical controls and programming. Project involves engineering, specifications, design, procurement, inspection, expediting and installation.
Raw Coal Handling System
Varo was retained to perform engineering and design for the upgrade of a raw coal handling system. The system was upgraded and a new direct ship storage and handling system was added to an existing mine. The slope conveyor and raw handling coal system was upgraded to 1800 TPH and a fixed raw coal stacker was added to the system. The direct ship storage system included a new transfer conveyor and a radial stacker for stockpiling. The direct ship reclaim system included a new Stamler reclaim feeder and conveyor to deliver coal to the existing rail loadout. Varo performed all foundation, structural and mechanical engineering for the project.
New Stock-out Conveyor and Conversion of Existing Rotary Dumper
Varo was retained to perform preliminary engineering and project bid documents for Turnkey bids. The work covered two areas of the plant. One area included upgrading two exiting conveyors from 2000 TPH to 2500 TPH and adding a new coal yard stock-out system, also at the 2500 TPH rate. The new stock-out conveyor discharge would allow a full train to be unloaded and stocked out without pushing coal away from the stockpile. A second area included modifying the existing rotary car dumper to allow the dumper to discharge rotary coupled railcars. A portion of the project included belt feeders below the car dumper, which required upgrading for the higher capacity and modifications to limit spillage of coal.