Issue and challenge:

The steam generators of coal-fired power stations are fired by coal dust consisting of particles that are small enough to be transported by streams of air. It is made in tube ball mills by grinding and drying coal. The operators' coal-fired power station has 2 steam generators, each with a power of 600 MW. They are supplied with coal dust by 12 tube ball mills. The harsh operation and the high levels of dust generated by the grinding process in the grinding chamber place extreme stresses on the sealing system. It must be possible to mount the shaft seals easily without the need to dismantle the tube ball mill or its components. They are fitted to the inlet and outlet equipment between stationary and rotating components. Each mill needs 4 shaft seals: two serve as mill end seals for a shaft diameter of 1605 mm, while two serve as end bearing seals for a shaft diameter of 160 mm.

Solution from EagleBurgmann Espey:

Espey designed a combined Espey WD200/500 with barrier gas connection and 4 sealing rings for the mill end. It can be fitted easily, thanks to the split casing. The internal diameter of the seal is 1605 mm (63.19 “). The barrier air seal for the end bearing is provided by an Espey WD200 with 4 seal rings. Both seals are designed for a temperature of 110 °C (230 °F), a pressure of 1.08 bar (15.66 PSI) and a rotation speed of 15.8 rpm. Both seals achieve full prevention of the escape of dust to the atmosphere by supplying air as barrier gas. No additional supply systems are therefore needed. The Espey sealing system easily copes with axial and, in particular, with radial shaft movements such as are found in ball mills as a result of the high mechanical stresses, as well as trapping the high levels of dust.

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