Kingfisher Offers SAS Milling & Combustion Improvement Technologies, Delivering Environmental & Cost Saving Benefits

Leading UK wear protection specialist, Kingfisher Industrial, has extended its ability to improve the efficiency of coal-fired power plants throughout the UK and Ireland, following the company's appointment as exclusive agent for the patented milling and combustion enhancement technologies of USA- based SAS Global. The SAS technology offers both environmental and commercial benefits for coal-fired plant operators, enabling ash to be sold rather than sent to landfill.

"SAS hardware and software technologies are a perfect complement to our range of wear protection systems for improving efficiency and reducing cost in coal fired power stations," said John Connolly, MD of Kingfisher. "The twin technologies improve the efficiency of fuel processing - grinding and classification - together with improved fuel/air distribution to the boiler, thus reducing SOX, NOX and LOI (un-burnt carbon in ash content).

SAS technology provides a highly efficient solution under today's demanding operation conditions, when both plant efficiency and environmental compliance are two of the main issues facing generators. It quickly achieves the performance benefits required to offset its initial capital cost.

The technology improves both the output volume of fuel to power station boilers and the compliant grade with regard to particle size, thus reducing loss of ignition within the boiler (LOI). It also improves distribution of fuel/air ratios at the classifier outlet, resulting in reduced NOX emissions, improved combustion and a reduction in carbon in ash contamination. Last but not least, due to the patented design of the rotating vane wheel, high spin classifiers blades and feed cone extension equipment, these enhancements deliver efficiency improvements resulting in the mill being able to process a greater volume of fuel utilising the same amount of amps used to drive the rotating equipment, thus reducing energy per tonne processed.

As regards improved distribution of fuel, SAS's patented 'Ropebreakers' (Multi-outlet, Pre-riffle & Burner In-line diffusers) ensure correct air/fuel ratios are achieved. The 'Ropebreaker' systems diffuse the 'roping' effect of fuel prior to splitters, thus ensuring a greater degree of balance is achieved in the pulverised fuel (PF) pipework after the splitting device.

This process can be fine tuned with the use of patented in-line adjustable orifices, which counter the air imbalances caused by variable velocities associated to the different lengths of PF legs feeding burners in different positions on the boiler wall.

The greater overall efficiency delivered by SAS systems results not only in substantial operational cost savings, but also key environmental benefits due to the reduction in emissions achieved. The improvement in fuel to energy (calorific value – CV) ratio results in a reduction of carbon in ash content, and this allows the ash to be sold as opposed to being sent for disposal and subject to hefty landfill tax levies.

Complementing SAS technology at the last crucial interface prior to combustion is Kingfisher's own ceramic wear protection systems. At this interface, fuel is fed into the boiler via strategically positioned burners that encounter extreme wear and heat radiation. Kingfisher play an important part in making sure that these components are protected against the constant effect of conveying fuels at velocities up to 35 mps, and the radiant heat associated to the combustion process occurring within the boiler. The use of bespoke ceramic systems has been recognised as the most suitable solution to this problem by designing parts that match the contour of the assemblies whilst ensuring the correct internal geometries are maintained to compliment the need for OEM's unique operating processes.