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Coal Pipeline Transportation

Serial No.:CPTO2013.07.03

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The First Commercial CTP in the World

1. About Us
WDRI was founded in 1954 and is now ranking as a
national Class-A survey and design institute with profound history. Over the past 60 years, WDRI has undertaken over 100 projects of master plans of mine area, completed over 500 mine shafts and accomplished over 50 coal preparation plants all over China. Among them, 29 mines and coal preparation plants boast a production capacity of 5 Mt/a or above, 14 of which standing out with a production capacity of 10 Mt/a or above.

FavorSea Industrial Channel Limited is appointed as marketing agent of WDRI. FavorSea are privileged to be partnered with some of the most highly regarded manufacturing enterprises and prestigious research & design institutes in China's mining and mineral processing sector. In our co-branding role as export channel partner, we bring world-class Designed & Made with Pride in China products, world-class technology and advanced industry solutions to the global mining community.

Construction Year: 1957 George Coal East Lake Power Plant Preparation Plant East Lake Power Plant Cleveland Distance: 173 Km Volume: 1.4 Mt Pump Station No.3 Akron Cost: $3.7/t for r a i l w a y transportation Canton $2.2/t for Pump Station No.2 p i p e l i n e transportation Ohio (58.82% of railway) Pump Station No. 1 The pipeline had been in operation for 6 years with an aggregate transportation volume of 6.3 Mt.

Unsuccessful High-Concentration CTP in Russia

In 1986, a high-concentration coal slurry pipeline from Belovo to Novosibirsk was constructed under joint effort of former Soviet Union and Italy with a designed capacity of 5 Mt/a. The pipeline totaled a length of 260km with a diameter of 530 mm. a power plant in Novosibirsk with a scale of 2220 kw. In spite of a total investment of 300 million US dollars, due to occurrence of blockage during trial operation, the pipeline failed to be put into operation hence. Up to now, there have been only 3 coal transportation pipelines in the world, two of which are general coal slurry pipelines for long-distance and high-volume transportation, ending up with sound economic benefits, while the one in Russia failed.

2. CPT Technology Development Overview

The research of coal pipeline transportation technology was initiated by American experts in late 19th century (1881), and the experiment turned out a success. At the beginning of the 20th century, London Power Plant succeeded in its trial operation with a coal transportation pipeline of short distance extending all the way to the power plant across the river of Thames, and the pipeline transportation technology was into the practical hence.

Average Concentration (normal and medium concentration) CWS Features: Weight Concentration: 50% or so Grading Composition: 0-2mm, average particle size: 0.3mm or so Slurry Viscosity: 3080 CP The coal slurry was transported in turbulence flow inside the pipe. Flow rate: 1.5-2 m/s Objective of Technical R & D: To solve the problems in long-distance and large-volume coal pipeline transportation
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transportation pipeline technologies both from home and abroad, the Institute has developed and mastered long-distance CPT technologies which are safer, more reliable and more advanced. At present, the Institute has more than one hundred proprietary technologies on long-distance coal transportation pipeline. Having experts who have 30 years of experience on researching long-distance coal transportation pipeline, engineers and technicians, the Institute also has introduced a number of experts and technicians from fields of other long-distance slurry transportation pipeline, design and research such as petroleum and natural gas transportation pipeline and project management and operation.

Features: Weight concentration: 70% or so Size Composition: 0-0.3mm, average size 0.071mm or so (200 mesh) Slurry Viscosity: 8001100 CP The coal slurry was transported in a laminar flow form inside the pipe. Objective of the technical research and development: To develop coal water mixture as a new fuel to replace oil

High Concentration Coal Water Mixture (CWM)

Chinas CPT Technology

In early 1980s, China began the research and development of coal transportation pipeline, which was successively listed as key scientific and technological projects by former Ministry of Planning and State Science Commission, and included into national strategic development plan. The coal pipeline transportation technology is in line with national policy on industrial development, and conducive to environmental protection, energy saving. In recent years, it has been listed into National Guidance Catalog for Industrial Restructuring and Catalog for the Guidance of Foreign-Invested Industries by State Development and Reform Commission and Ministry of Commerce as encouragement project, thus vigorously advancing the development of coal transportation pipeline project in China.

Academic Research & Development

WDRI Owns More Than 30 Supporting Professional Departments Related to Pipeline Transportation Projects The test center of coal slurry, pulping, the pump output system, pipelines, roads, railways, bridges, tunnels, signals, anti-corrosion; HVAC, water supply, drainage, sewage treatment and comprehensive utilization of water and soil conservation, environmental impact assessment, environmental control, power supply, control automation, machinery, mechanisms, civil engineering, construction, coal preparation, mining, surface coal mining, mine safety, measuring, surveying, geotechnical engineering, ground handling, project cost, computer software, equipment maintenance, project management, production safety.

WDRIs Contribution to the R & D of CPT Technology

Completed Pipeline R&D Projects

In early 1980s, our institute began the research, development and promotion of CPT-based technology. After three decades, WDRI has made itself the only specialized institution fully committed to coal transportation pipeline project and the only design and research institute boasting various professional personnel in CPT. We have the test center of CPT with fullest function, largest scale and best software and hardware conditions, which enabled WDRI to have undertaken the overwhelming majority of domestic CPT projects. The Institute sent the study tours of technicians to investigate almost all other slurry transportation pipelines in China, such as iron ore concentrate and bauxite mine pipeline transportation projects. The technicians also investigated the domestic long-distance petroleum and natural gas transportation pipeline projects. The Institute also sent technicians to Brazil and Australia for investigating the other long-distance slurry pipeline transportation projects. Based on the long-distance CTP technologies learned from American Black Mesa Pipeline Co., Ltd. and long-distance petroleum, natural gas and other slurry transportation pipeline technologies both from home and

Since 1981, WDRI has accomplished the planning and feasibility study of normal concentration CPT project for over 20 pipelines, including Meizhou-Shantou, Zhungeer-Qinhuangdao, Jincheng-Nantong, Jincheng-Wuhan, Huangling-Wuhan, Jincheng-Jining, Panjiang-Zhanjiang, Enhong-Fuyuan, Mengxian-Tianjin, Mengxian-Weifang-Qingdao, Shenmu-Weinan, etc. Presently, our institute is working for the EPC general contracting of Shemu-Weinan CPT Project under Shanxi Coal Industry Company Limited.

Advantages of CPT over Other Means of Transportation

strong adaptability to the terrain

Low land occupancy Low investment and freight fee

Characteristics of the CPT

Environment friendly and transportation clean Less process, higher efficiency Shorter cycle, faster recovery

More reliable resource and use

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Economical Efficiency Analysis of CPT

As a means of commercial transportation, sound economical efficiency is needed in addition to safety and reliability so as to be competitive in the market. According to documented analytical research: Generally, pipeline transportation cost is 1/21/3 of railway transportation, and 1/51/10 of highway transportation.

Cost Comparison Between CPT and Railway

Item Labor Force Power Maintenance Depreciation Pipeline Railway Transportation (%) Transportation (%) 5 13 12 70 46 11 26 15

Design code formulated by WDRI

Chinese Coal Pipeline Transportation Planning Completed by WDRI

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Rod Mill Workshop

Academic Research, Technical Exchange and Field Visit

Over 40 monographs have been published in national key journals or periodicals, and some of them have been included into China Dictionary of Practical Science Achievement, World Collection of Outstanding Patent and Technology (China Volume), and Proceedings of National Academic Exchange on Slurry Pipe Technology; We have formulated Long-distance Coal Transportation Pipeline Design Discipline We have participated in International Academic Symposium on Slurry Pipe for five times. We have dispatched in total 7 delegations to the site of Black Mesa Pipeline for observation, study and technical exchange.

3.Introduction to Black Mesa Pipeline

Black Mesa pipeline In United States
Construction Year: August, 1969 November, 1970 Kayenta Open Pit Mohave Power Plant Distance:440 Km Volume: 5.0Mt/a Cost: $16/t for railway transportation $9.55/t for pipeline transportation (59.69% of railway cost) The pipeline had been in operation for 35 years with a total transportation volume of 150.0 Mt.

The Internal Structure of Rod Mill

Slurry Preparation Plant

Raw Coal Bins In Slurry Preparation Plant

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Pump Station No.3

Large-Scale Tanks with Mechanical Agitator In Slurry Preparation Plant

Pump Station No.4 Pump Station No.2

Construction Site of Black Mesa Pipeline Major Pump Equipment

Geographic Landscape of Black Mesa Pipeline

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Terminal Power Plant in Mohave

4.Technical cooperation between WDRI & Black Mesa

WDRI has signed a long-term strategic cooperation agreement with American Black Mesa Pipeline Technologies Services Co.Ltd, the only company in the world with practical experience in large coal pipeline transportation construction and 35 years experience in the operation. The feasibility study report of Yu-Wei-Qing coal pipeline transportation has been accomplished under our joint efforts, and we have full access to the entire technical data of construction, management and operation of Black Mesa Pipeline.

Terminal Power Plant in Mohave

Large-Scale Tank with Agitator In Mohave Power Plant

This photo records the delegation headed by Lu Yaohua, the former general director of Infrastructure Department of Coal Ministry visiting Mohave power plant in 1994.

Coal Transportation Pipeline Planned by the United States

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Coal Pipeline Transportation Laboratory
CPT Laboratory was designed in August 2009, and completed by the end of that year. It covers an area of 680 square meters. The laboratory consists of 7 systems, namely: coal pulverizing system, basic test system, coal slurry preparation system, flush water system, sample test loop system, centralized control system and waste slurry discharge system. The laboratory staff team consists of 11 members, 5 with senior title, 1 with doctors degree, 5 with masters degree, and is equipped with the most fully functional, the largest scale and the best hardware and software, making it the best CPT laboratory in China.

Basic Test System

Shared Documents

The basic test (otherwise named small sample test) of coal pipeline transportation serves as an importance method for the research of coal slurry character. Basic test aims to detect the physical and chemical property of coal and coal slurry in a static state, figuring out the rheology of slurry so as to select proper rheological model and optimize the selection of coal slurry particle grading, coal slurry concentration, coal slurry viscosity, flow velocity in pipeline transportation, slip angle of coal slurry, repose angle of coal slurry, and PH value of coal slurry, which could provide accurate hydraulic parameters for pipeloop test and pipeline design.

Coal Slurry Preparation System

5.CPT Laboratory and Test Center of WDRI

Based on the recommended particle size grading and concentration from basic test, overflow rod mill could produce coal slurry eligible for the test loop sample.
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The center consist of all coal pipeline transportation technology system , which are: Slurry Preparation System, Pump System, Pipeline System, Communications System, Control System and so on.

Sample Test Loop System

Coking coal pipeline transportation

Test loop system is mainly used for: Measuring hydraulic parameters transportation;

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the

pipeline

Coal Pipeline Transportation Research

Since the coal to be transported varies in type and quality, so does its physical and chemical properties, which may result in fluid state difference, and consequently lead to variation in the character and features of hydraulic parameters for the coal transportation pipeline, impacting directly to the safety and smoothness of slurry pipeline transportation. Therefore, it is necessary to conduct tests for specific coal type and coal property before the design of transportation pipeline in order to optimize the design parameters. Scientific and prudent mathematical analysis should be conducted for the coal slurry flow character and hydraulic property stemming from experiments, and only in this way we can obtain optimum parameter for pipeline transportation so as to ensure its safe and economical operation. The Pipeline Coal Transportation Research Center of our institute is now under construction in order to promote the development and construction of pipeline coal transportation in China, provide scientific basis and technical support for the design, construction, safe and economical operation of coal pipeline transportation projects, and enhance our strength and core competitiveness in coal pipeline transportation technology.

1 Coarse particle would be adopted for coking coal slurry pipeline transportation. In the process of coal for coking, there are certain requirements for the particle size of the coke production. General, the upper limit of the particle size will be piped in 6-10mm. As long as select the appropriate particle gradation, the coal slurry can be made with good flow pattern. Therefore, the pipeline transportation of the coarse particles coke coal is feasible technically. 2 According to our study results that: 6-10mm coarse coking coal transport by Pipeline fully meet the requirements of coking process. 3 After mechanical dewatering of coal slurry that reaches the terminal transport by pipe, generally do not need to dry to granulation. For coking coal, based on the experiments what we have done proved no any impacts on its coking characteristics after piped transportation dehydration, drying experiments. So, the experiments show that it is also feasible to granulate molding directly for transportation without a drying treatment. 4 However, in view of varies in physical and chemical characteristics, we recommend that the coking experimental and briquette processing experiments after dried should be focused on Mozambique coal samples, so that it would be more practicality.

Coking coal pipeline transportation

According to the purpose of Mozambique project, here are some descriptions for the characteristics of coking coal 1. Coarse particle would be adopted for Coking Coal slurry pipeline transportation 2. According to our study results that: 6-10mm coarse coking coal transport by pipeline would fully meet the requirements; 3. Do not need to special drying for briquette molding 4. The experiments will be necessary and crucial
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Coal Pipeline Transportation Research Center

The center mainly researches on the test of coal slurry and molded coal, focusing on normal concentration coal slurry, coarse particle coal slurry, and high concentration coal slurry. The test system consists of basic test, slurry preparation test, pumping test, dewatering test, coal slime wastewater treatment test and molded coal test. The structure of the research center: Coal sample and dump sample storing and transporting department, basic test department, industrial test department, centralized control and data processing department, R&D department of utilization and transfer of CPT technology, technical training department.

Channel for Quality

The China National Design Specifications of Coal for Coking Process GB50432--2007

Current progress of the Shen-Weiproject

6.Shen-wei CPT Project Overview

Pipeline Capacity: 10.00Mt/a Starting: Hongliulin Coal Mine , Shenmu County, Shanxi Province Terminal: Pucheng, Weihua, Shanhua Span: The pipeline totals a length of 729km with 206 in plains and mild hills and the rest 523 in mountains and rolling hills.

SHEN-WEI Projects across the three regions of Yulin, Yanan and Weinan. Allworks in Yanan and Weinan have been started, works inYulin region will be started in the near future; The pipeline laying has been completed amount of 18000m, the tunnel construction has been completed amount of 1335m. The permanent site construction work will be started to carried out in the near future, the large equipment bidding has been completed so far.

The System Diagram of Shen-Wei Project

There are a total of 6 pump stations in whole line, pump station No.1 to No.5 are mainline pump stations with pipe diameters of 610mm and 559mm. The 610 pipe lasts 525km while the 559 pipe extends 67km, and the capacity is 10Mt clean coal per year. Pump station No.6, the transfer pump station, is situated in Pucheng terminal 1, it distribute the coal slurry to Shanxi Coal Chemical Industry Group (terminal 2) and Weinan Coal Chemical Group (terminal 3), distributing volume of 1.2Mt/a to the terminal 2 and 1.8Mt/a to the terminal 3. Pipeline distance from terminal 1 to terminal 2 is 66km, while that of from terminal 1 to terminal 3 is approximately 73km.

Site Construction

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Site welding

After Manual Primer Paint Welding

Completion of Welding

Tunnel Construction

Tunnel construction

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