Ash feeding station

We offer complete installation of modern systems for preparing ash-water mixtures for the reconsolidation of ceilings in the layered mining of coal beds and in fire prevention. We offer in particular:

• tanker unloading systems
• Mobile Mixture Systems

Tanker unloading systems

As part of the service we offer:

• development of a complete construction design with arrangements
• development of detailed designs concerning the architectural and construction, technology, mechanical, installation and electrical industries
• carrying out works related to the preparation of the construction site
• survey-determination of facilities
• construction of necessary facilities along with accompanying infrastructure, installation of process equipment and systems
• carrying out as-built inventory of the facilities completed under the project
• conducting tests, trials and measurements
• obtaining the necessary permits and decisions, including administrative ones, authorising the use of the facility

Part of the works performed at the construction of the station for feeding ash and water mixtures:

1. Construction and building works:
   • construction of foundations with installation of the silo and ash mixer
   • installation of the ash feeder
   • installation of the mixture tank with the pumping station
   • laying foundations together with the construction of supporting structures and the pressure pipeline for the mixture
   • installation of the process container (control room) and accommodation container
   • installation of the process water pumping station
   • installation of the electrical switchboard
2. Road works:
   • land levelling
   • hardening the manoeuvring areas
   • construction of access roads and car parks
3. Installation and mechanical works:
   • installation of the compressed air system
   • installation of the pumping station and fittings for a water-ash mixture
   • installation of the thermally insulated collector
4. Works related to the installation of a water and sewage system:
   • installation of the process water system with piping, fittings and metering
   • installation of drinking water systems for sanitary purposes and as an emergency supply for washing systems and for fire protection purposes
   • installation of a sewage system from an accommodation container
5. Electrical works:
   • installation of the area lighting system and lighting for process devices
   • installation of the power supply and control for installed machinery and devices

Elements of the system for feeding ash and water mixtures:

• silos for ash/binder with two loading stations and accessories (air filter, overpressure and underpressure valves, set of aeration nozzles, filling sensors with the upper operating platform)
• ash conveyor with a capacity of approx. Q = 50 m³
• mechanical flow mixer – capacity of at least 80 m³/h of ready mixture
• compressed air system with a capacity of Q_min = 20 m³/minute with equalizing tanks and a dryer, with an option of single blow-through of the whole filling system
• mixture transport pipeline from the system to the large-diameter hole
• process container with a room for staff
• containerised control room building with electrical systems, heating, air conditioning and computer system
• compressed air and water supply systems
• electrical switchgear with power, control and automation systems
• control and measuring devices

Mobile Mixture System

Design and principle of operation

The Mobile Mixture System (MMS) consists of four basic element subgroups:

1. equipment for transporting process materials (ash and water)
2. devices for producing and feeding the mixture
3. devices for monitoring and controlling the process
4. systems for transporting the mixture to the target point

Supply by road tankers

Road tankers can carry up to 20,000 litres. The great advantage of this type of transport is their mobility and availability. Virtually all tankers are equipped with their own unloading systems, and the driver is responsible for unloading of the material. Thanks to this, the number of personnel needed to operate the mixing plant is lower. Access to the unloading point, located at the Mobile Mixing Plant, is done via the roads provided by the user of the mixing plant. Roads must be paved and should enable the transport of materials by vehicles with a weight of approx. 20 tonnes.

Supply of process water

The Mobile Mixing System has been designed in such a way as to allow the supply of clean water from an available external water supply system. Bearing in mind the various parameters prevailing in plumbing systems, we recommend a buffer tank that allows instantaneous water storage and dosing it in a controlled manner at the required pressure parameters for the Mobile Mixer. The buffer tank also provides a partial, minimal amount of water to wash the system after completion of supplying the mixture at the target point.

Caution! The Mobile Mixing System must be washed each time after the mixture supply process is complete. The amount of water needed to wash the system depends on the total length of the piping system and should ensure that the material (water-ash mixture) is fully pushed out of the pipeline.

Technical containers

A 20′ technical container is used for installation of the control room. The container can be anchored permanently or be removable (with the option of placing it on a supporting structure). The electrical devices intended for handling the entire mixture feeding process require the container to be additionally roofed to prevent water leakage inside. The control room features a desk and seating for staff, while the central unit is equipped with process monitoring software, a control cabinet, a set of inverters and lighting. On the trailer, next to the control room container, space should be provided to install a smaller container (10′) to enable transport of all external elements and devices (e.g. flexible pipelines for transporting the mixture and water, control cables connecting the control room container to the mixer container, power supply cables etc.).

A 40′ technical container is used for installing mixing and feeding devices (a buffer tank for process water, a pump for feeding water from the buffer tank, a tank for dusty materials, a conveyor for transporting dusty materials, pumps for feeding the mixture, Dustif flotation mixer, dust collector for ash container). The 40′ container has the function of removable individual roof panels, which protect the mixing-feeding system against atmospheric factors.

All devices have been developed in compliance with applicable laws, including:

• Geological and Mining Law – Act of 09/06/2011 (Dz.U. 2011.163.981)
• Construction Law – Act of 07/07/1994 (Dz.U. 20l0.243.1623 consolidated text)
• Environmental Protection Law – Act of 27/04/2001 (Dz.U. 2008.25.150 consolidated text)
• Act of 14/12/2012 “On waste” (Dz.U. 2018.21)
• Regulation of the Minister of Infrastructure of 06/02/2003 on occupational health and safety during construction works (Dz. U.2003.47.401)
• Regulation of the Minister of Interior and Administration of 07/06/2010 on fire protection of buildings, other structures and areas (Dz.U.2010.109.719)
• Regulation of the Minister of Economy of 27/04/2000 for occupational health and safety at welding works (Dz.U.2000.40.470)
• Regulation of the Minister of Economy of 21/10/2008 on essential requirements for machinery (Dz.U.2008.199.1228), (Directive 98/37/EC), as amended
• Regulation of the Council of Ministers of 30/04/2004 on the release of products for use in mining plants (Dz. U.2004.99.1003 as amended)
• Polish standards applicable to the subject of the contract