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Telestack installs radial telescopic stacker in Chile

World Coal,

Telestack Limited has commissioned a TS 2058 Radial Telescopic Stacker for AES Genera, a coal-fired power plant in the Port of Ventanas, Chile. The stacker is part of a complete vessel unloading and import material handling system upgrade carried out to replace the existing infrastructure.

The power plant at Ventanas previously had an installed capacity of 330 MW, which increased with the additional two units, each with a capacity of 250 MW. The total capacity of the coal-fired power plant is now 830 MW.

When operating at full capacity, the consumption of the first two units was approximately 1.2 million tpa of coal, however this is expanding to almost 3 million tpa with the new units.

Currently the maximum capacity is 1300 tph discharge rate. This is made with two Kranbeau cranes with level luffing, free digging, double booms each with capacity of 750 tph. These cranes feed on two conventional hoppers, each with a capacity of 100 t, which then feed on a conveyor system rated at 1300 tph.

Once onto the conveyor system the material is transported to the coal stockyard via a series of static overhead conveyors and transfer towers. Once the material enters the stockyard it is transferred to the Telestack TS 2058 Radial Stockpiling Conveyor.

The new upgrade includes two new cranes of 1200 tph free digging with the same level luffing double boom. It is proposed the hoppers will have 150 t capacity upgraded conveyor system of 2000 nominal tph.

Image 1: TS2058 Radial Telescopic with integrated windrow stockpiling program stockpiling coal.

The TS 2058 Radial Telescopic Conveyor has a capacity of 2000 tph of coal to cater for this future expansion. The machine incorporates a 1400 mm wide conveyor belt with a 35 m outer conveyor and 23 m “stinger” extending inner conveyor to maximise stockpile capacity. The telescopic conveyor enables an additional 30% of material to be stockpiled within the same footprint. Total stacking capacity of the TS 2058 on a 180 degree radius is 136 360 m3 or 109 090 t of coal.

AES Genera were able to further increase this capacity by placing the TS 2058 unit on an elevated 2 m concrete radial plinth. With the integrated windrow stockpiling program, the machine is able to automatically stockpile coal with minimum drop height, ensuing that product integrity is maintained and dust emissions are kept to a minimum.

Image 2: TS2058 Radial Telescopic Stacker stockpiling coal from elevated plinth.

Telestack supplied the equipment to be compliant with local Chilean structural standards for earthquake conditions. This involved an internal and external audit of structural integrity in order to comply with the rigorous structural standards of the Chilean Code NCh2369.

Image 3: TS2058 Radial Telescopic Stacker stockpiling coal with minimum drop height.

In addition, the equipment had to be compliant with ATEX standards due to the combustible nature of the material being conveyed. Telestack supplied the equipment with ATEX 21 explosion proof motors, solenoid valves, glands, joints and junction boxes. The control panel was removed from the zone to an operator’s cabin therefore eliminating the requirement for the panel to be ATEX compliant and consequently significantly reducing the capital expenditure for the client.

The equipment also incorporated dual access walkways in order to allow the operators to carry out routine maintenance of the machine. Impact protection at transfer points along with TIVAR 88 liners ensured efficient and effective material flow of coal over the stacker. Telestack also included ATEX compliant lighting along the machine for 24-hour operation during unloading and stacking process.

Telestack delivered the equipment to site in Chile in seven 40 ft high containers, minimising freight costs for the client. The modular nature of the equipment with quick and easy to assemble sections enables the machine to be assembled in a short period. Telestack Installation Engineers supervised the installation and commissioning of the equipment.

Telestack is an ISO 9001:2008 certified manufacturer.

Adapted from press release by Katie Woodward

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