Flow-Curve Transfer Chute
Engineered bulk material transfer that controls material velocity, reduces fugitive dust, and extends wear component service life in bulk material conveying applications.
FLOW-CURVE TRANSFER CHUTE
THE PROBLEM
Conventional Transfer Points
In a conventional gravity-drop transfer chute, bulk material free-falls from the discharge pulley of the feeding conveyor to the receiving belt below. The material falls onto the loading zone with a trajectory and speed that rarely matches the receiving belt. The freefall induces airflow into the material stream and the resulting impact generates dust, creating more wear, dust, and maintenance headaches.
Downstream suppression equipment can help reduce dust at the exit of the guide trough, but that targets the symptoms rather than the cause.
BEFORE: Accumulated coal dust in the air at a coal power plant transfer station — a common consequence of conventional gravity-drop chutes.
AFTER: The same transfer station following the installation of the Flow-Curve chute. Airborne coal dust is virtually eliminated.
dust generation
The free-falling stream entraps air as it moves so that when it impacts the conveyor belt, the kinetic energy forces the air out, creating dust.
Chute plugging
At conventional rectangular transfer chutes, the chute geometry creates steep impact angles, naturally forming dead zones at the corners. These stagnation zones are the first to clog and plug when particle sizes change or in high moisture conditions.
Impact loading
High velocity material streams create impact, wear, and damage on the frame, rollers, and belt.
Off-center loading and belt tracking
Uncontrolled material flow can cause off-center loading. Material placement on the receiving belt varies randomly, causing belt drift, spillage, and edge damage.
THE SOLUTION
Flow-Curve Transfer Chute
The Flow-Curve system replaces freefall with controlled sliding. Material moves along a curved, enclosed path, with exit velocity matched to receiving belt speed. Dead zones are minimized, velocity mismatch is eliminated at the loading zone, and impact and dust are dramatically reduced.
A video showing DEM modeling for a coal power plant transfer station. Note the lack of red, no velocity dead zones.
A 45 meter (148 feet) drop retrofit at a 2×1000MW capacity power plant. DEM Modeling helps smoothly control material flow even under demanding conditions.
DEM Simulation
Each system is designed using Discrete Element Method (DEM) simulation, which ensures effectiveness before fabrication and installation. Material properties specific to the application, including particle size distribution, bulk density, and moisture range, are modeled together with the chute geometry at the transfer point.
OPERATING RESULTS
Third-Party Dust Measurement, Wushashan Power Plant
Zhejiang Zhongyi Testing Research Institute, an accredited occupational health testing laboratory, conducted post-installation airborne dust sampling at the coal pulverization room of Wushashan Power Generation Co., Ltd., a 2,400 MW coal-fired power plant. All 12 respirable dust concentration measurements passed the occupational health reference value following installation.
Sampling Conditions
| Belt | Date | Temp | Pressure | Humidity |
|---|---|---|---|---|
| Belt 1 | 2015-03-20 | 14 °C | 102.0 kPa | 52% |
| Belt 2 | 2015-03-24 | 16 °C | 102.0 kPa | 42% |
Respirable Dust Concentration
GBZ/T 192.2-2007 · Gravimetric · Reference value (8-hr TWA): 2.5 mg/m³ · Respirable particles are the primary metric for coal dust disease
| Pt | Location | mg/m³ | vs ref |
|---|---|---|---|
| 7 | Belt 1 Head (1) | 1.92 | Pass |
| 8 | Belt 1 Head (2) | 1.83 | Pass |
| 9 | Belt 1 Mid (1) | 1.42 | Pass |
| 10 | Belt 1 Mid (2) | 1.33 | Pass |
| 11 | Belt 1 Tail (1) | 1.33 | Pass |
| 12 | Belt 1 Tail (2) | 1.42 | Pass |
| 19 | Belt 2 Head (1) | 1.75 | Pass |
| 20 | Belt 2 Head (2) | 1.67 | Pass |
| 21 | Belt 2 Mid (1) | 1.25 | Pass |
| 22 | Belt 2 Mid (2) | 1.58 | Pass |
| 23 | Belt 2 Tail (1) | 1.33 | Pass |
| 24 | Belt 2 Tail (2) | 1.83 | Pass |
These measurements characterize dust concentrations at fixed points in the loading zone under normal operating conditions. The testing laboratory conducted supplementary CTWA analysis and noted that workers with time-in-zone below 8 hours per shift would meet the national standard at all measurement points.
Zhejiang Zhongyi Testing Research Institute Co., Ltd. Report No. WT15033-01. Standards GBZ/T 192.1, 192.2, and 192.4-2007.
WEAR PERFORMANCE
Custom Alloy Liners
Flow-Curve liners are custom-alloy panels made to conform to the circular chute. Our custom alloy has documented service life of up to 8 years while handling highly abrasive coal. Modular chute and liner design supports easy maintenance and inspection.
SELECTED INSTALLATIONS
installed at 100+ power plants and bulk solids handling facilities
FROM 300 MW single-unit installations to 4,800 MW FULL RETROFITS
| Project | Capacity | Type |
|---|---|---|
| Shenhua Guohua Guangdong Taishan Power Plant | 5×600 + 2×1000 MW | New build |
| Guohua Shandong Shouguang Power Plant | 2×1000 MW | Retrofit |
| Datang Toketo Power Generation — Coal Handling System | 8×600 MW | Retrofit |
| Zhejiang Guohua Zheneng Ninghai Power Plant | 4×600 + 2×1000 MW | Retrofit |
| Shenhua Guohua Suizhong Power Plant | 2×800 + 2×1000 MW | Retrofit |
| Shanxi Datang Linfen Power Plant | 2×300 MW | Retrofit |
| Liaoning Datang Fuxin Coal-to-Gas Plant | Coal to gas | New build |
| Shenhua Coal Storage & Transportation Center, Zhuhai Port | Coal storage | New build |
| Shenhua Guohua Indonesia Java 7 Power Project | 2×1050 MW | New build |
GET IN TOUCH