Product Brochure

Gravimetric Belt Feeder

Pfister GBF

Highly accurate feeding of

crushed coal for power plants
Watch here how Pfister dosing solutions work!

Tradition & progress

FLSmidth Pfister has almost 120 years of experience in

manufacturing of industrial weighing equipment. It has been
member stock quoted FLSmidth Group/Denmark since 1998.
The patented rotor weighfeeder was invented by Pfister
in 1984 to feed pulverised fuels for the cement burning
process. This state-of-the-art dosing device has proved its
properties in more than 2,500 installations worldwide.
FLSmidth Pfister additionally supplies know-how for equipment, related to the coal feeding process in order to ensure
problem-free material handling and optimal pneumatic
transport of the coal.

Pfister weighfeeders are

- engineered
- designed
- assembled
- tested
with the experience
of almost 120 years.

Fuels have a wide variety of material characteristics. Thus,

FLSmidth Pfister helps to design individual installation
solutions.

German Ludwig Pfister founded

the company in 1894
Above: Historic scale

Customer benefits of
gravimetric belt feeders Pfister GBF
Gravimetric belt feeders Pfister GBF are advanced and highly developed systems. Their benefits are described in the following comparison of
gravimetric and volumetric feeders. These benefits
are essential for the firing of the boiler and a big
step towards more economical and ecological
operation of coal fired power plants.
Volumetric feeding vs.
gravimetric feeding
The main difference between gravimetric and
volumetric feeders is the high accuracy of gravimetric feeders regarding the calorific (energy)
troughput.

The accuracy of volumetric feeders is mainly

influenced by the variations in the following coal
characteristics:
- Density
- Calorific value
- Displacement volume (lump size)
Gravimetric feeders are able to reduce the influence of most of the variations as shown in the
chart below. This results in a much higher accuracy in the feed rate of calorific (energy) value.

30
25
20
% Variation in
Energy Feed

18

15
10
5
0

2,5
5

0,5
2,5

Volumetric Feeder

Gravimetric Feeder

Density Variation

18

0,5

Calorific Value Variation

2,5

2,5

Displacement Volume Variation

(Source: internal surv ey )

Any efficient combustion process has three

primary requirements:
1. Feeding of the right amount of fuel to
meet demand for energy input.
2. Provide an exact amount of air to ensure
complete combustion of the fuel.
3. Ensure a stable process in order to get
the highest efficiency.
For burners it is necessary to supply a sufficient
excess-air cushion to avoid dangerous conditions
due to a potentially incomplete combustion. A
combustion with too much fuel (coal dust) and/or
lack of combustion air creates carbon-monoxide
(CO) which can react with oxygen (O2) in an
explosion.
On the other hand, too much excess-air wastes
energy because the excess air is heated and lost in
the atmosphere. Using less excess air is therefore
significantly more economic. The amount of
excess air is depending on the possible variations
of the fuel-feed rate. Based on the gravimetric
weighing principle Pfister weighfeeders are
doing exactly that: supplying high accuracy in
fuel feed rate.

All assets
result in:
- overall increase
of the power plant
performance
- increase of process
efficiency

Further benefits:
- Less slagging
Reduced variation in the feed rate results
in less variance in excess air between the
burners. This results in consistent gas
temperatures and less slagging of the burner
environment.
-

Less corrosion of furnace walls

Combustion of fossil fuels creates complex
sulphur (H2S). Together with carbon-monoxide (CO), which itself results from an incom-
plete combustion, it causes corrosion of the
furnace walls.

Less NOX formation

To minimise NOX formation in the burning
process when running with a low excess-
air cushion, accurate control of excess air is
necessary. This can be accomplished when
the amount of fed fuel is measured accurately.

- Accurate energy accounting

With using gravimetric feeders for feeding
crushed coal to the coal mill, it is also possible
to produce a highly accurate record of coal
consumption (energy accounting) and to
calculate the efficiency of all units and burners
independently.
-

Fast and stable boiler load changes

Gravimetric feeders have a high accuracy in
the whole feed range of 1:10 of the maximum
feed rate. Therefore, the feed rate is instantly
and accurately adjustable which makes load
changes of the boiler process very fast, stable
and more efficient.

Customer benefits of
gravimetric belt feeders Pfister GBF
High flexibility
- Modular design with a large variety in lengths
and widths can be adapted optionally
- Different types of inlet chutes guarantee excel
lent silo extraction for a variety of material
properties
- Feed rate adjustment (t/h) in a range of up to
a turn down ratio - 1:10
Easy maintenance
- Lifetime lubricated idler
- Easy calibration and adjustment of zero point
High reliability
- Belt and pulley strippers ensure no dirt is
sticking to the rollers or to any side of the belt
- Spherical v-grooved machined pulleys for
optimal belt guidance

High accuracy
- Advanced belt tensioning by tension roller
which supports highest feeding accuracy
- Digital tachometer (incremental encoder). This
results in accurate values for the controller to
calculate the needed speed of the motor
- Impressive feed rate accuracy

Functioning principle of
gravimetric belt feeder Pfister GBF
The picture below displays a gravimetric belt feeder
Pfister GBF and its weighing and dosing principle:
Crushed coal is extracted out of the material silo and fed
into the infeed hoppers.
The gravimetric belt feeder Pfister GBF consists of a
conveyor belt with integrally moulded side skirting which
is equipped with moulded V guide at the bottom of the
carrying side ensuring no swaying of the belt, thus maintaining accuracy. A belt scraper scrapes coal off the top surface
of the conveyor belt. Its blade is kept pressed against the
surface of the belt by a counterweight.
The weighing zone of gravimetric belt feeder Pfister GBF is
defined by two rollers precisely located at a fixed distance.
The weighing roller is at the center of these two rollers and
suspended directly through load cells on both sides. The

load on the weighing zone is measured by dual load cells

which are barometrically insensitive and environmentally
sealed. These load cells yield a very high linearity.
The signal from the load cell is fed to a microprocessorbased Pfister gravimetric dosing controller. Thus, the speed
of the belt is controlled inverse to the momentary load.
From there the crushed coal is discharged into the further
processes.
Gravimetric belt feeder Pfister GBF is auto calibrated by
integrated calibration sensors. In case of load cell disrepancy
an automatic change over switches to a volumetric weighing
mode automatically. In the volumetric mode, the feeder runs
based on historic density. It reverts automatically to gravimetric mode if load cell data show no more discrepany.

Technical drawing of a
gravimetric belt feeder Pfister GBF:

Structure of the dosing system:

Pfister Gravimetric Dosing Controller

Pfister gravimetric dosing controller was especially

developed to guarantee high dosing precision for
gravimetric belt feeder Pfister GBF
The microprocessor-controlled Pfister gravimetric dosing
controller works with a 16 bit processor and offers the
following main features:

configurable functionality of inputs & outputs.

field-programmable logic controller can quickly implement
features required on the field
7 touchscreen colour display HMI
optional field interface module through CAN communication
network for reduced cable cost
variable frequency drive.
integrated multiple microprocessors, which allow true parallel
processing
Memory on EEPROM basis and a battery
backup RAM with inbuilt real time clock (RTC)
16 digital inputs and 16 digital outputs as well
as 3 analog inputs and 3 analog outputs
Support of Modbus and Profibus protocols

7 touchscreen colour display (left)

and control cabinet (right) of
Pfister gravimetric dosing controller

Technical facts of
gravimetric belt feeder Pfister GBF
Application fields: Feeding to pulverizers and mills
Material: Crushed coal, bituminous coal
Feeding capacity: up to 150 t/h
Design example:

Inlet collar
Head and tail pulley
Flat type idlers with mounting brackets
Discharge hoppers with shut-off devices
Gravimetric belt feeder Pfister GBF
Belt and scrapers
Drive unit with shaft mounted gearbox
Cleanout conveyor

Features:

- Stable material dosing

- Outstanding reliability
- High short- and longterm accuracy
- Compact, robust machinery
- Custom-made lengths and widths
- Large feeding range
- Easy to maintain through 4 inspection doors
- Pressure-proof design up to 3.5 bar as per NFPA 85

Dosing control:

- Gravimetric dosing control Pfister GDC

- VFD drive
- User oriented interfaces

Certificates: ISO 9001

10

Applications with Pfister GBF:

Power station

In this application in a power station crushed

coal is dosed with gravimetric belt feeders Pfister
GBF with a feed rate of up to 150 tph and
an impressive accuracy. The bulk density varies
between 0.8 1.2 t/m3.
The belt of the gravimetric belt feeders Pfister
GBF is executed with integrally moulded side
skirts.

11

In this application the gravimetric

belt feeders Pfister GBF are built
with a centre distance of more than
2.000 mm.
The feeders are controlled by microprocessor-based dosing electronics
located in the control cabinet.

12

Applications with Pfister GBF:

Oversize solutions
Gravimetric belt feeders Pfister GBF
can be built for extra sizes according
to the customers needs.
The drawing on the right side shows
a solution for an oversize silo inlet
with 3,500 x 1,000 mm in size.
The picture below displays the belt
feeders Pfister GBF just before
delivery to the client.

13

Applications with Pfister GBF:

Inhouse accuracy testing facility
As one of the first companies in India, FLSmidth
Pfister is executing their accuracy tests for gravimetric belt feeder Pfister GBF at their own test
facilities on a complete feeder assembly.
For these tests the feeder is connected with the
remote and the integral cabinets and calibrated
according to the feeder calibration procedure.
The feeder is operated for 10 minutes with a
quantity of test material for ten rotations.
Thus, accuracy as well as functionality is controlled.

14

State-of-the-art design & assembly

of Pfister weighfeeders

Based on the more than a century

long experience of the German
engineers at the FLSmidth Pfister
headquarters in Germany, gravimetric belt feeders Pfister GBF are
engineered, designed and assembled
at the brand new FLSmidth Pfister
production facilities in Bawal / India.

FLSmidth Pfister production facilities in Bawal / India

15

Engineering & design

FLSmidth Pfister engineering

services comprise:
- Silo design
- Installation of equipment
- Calculation of pneumatic
transport

FLSmidth Pfister does not only supply

the single dosing machines. FLSmidth
Pfisters know-how includes the
complete setup and surrounding of
the installation like silo engineering,
intermediate material transport and
safety equipment.
That ensures that customers get all
engineering from one experienced
partner and one single source.

16

One-stop shop:
FLSmidth Minerals Group
Installation example
- FLSmidth Wadgassen:
Building, KochTM bin with
extraction unit, KochTM screw
conveyors
- FLSmidth Pfister:
4 x rotor weighfeeders
Pfister TRW-D 4.14 with
pre-hoppers; capacity 6 t/h,
multifuel application
- FLSmidth Hamburg:
MllerTM conveying transport

FLSmidth is the leading supplier of

equipment and services to the global cement and minerals industries.
For the power generation industry
FLSmidth combines its know-how
and expertise as a supplier for complete systems and components from
the entire group - all in keeping our
slogan: One Source.

FLSmidth brand names for the

power industry:
-






-

-

-

Dorr-Oliver, Eimco, Krebs world market leaders in

machinery and equipment
for liquid/solid separation,
principal suppliers for gypsum
dewatering systems in
power stations
KochTM, MVTTM - material handling technology
MllerTM - pneumatic conveying
systems and silo technology
Pfister - experts for continuous
gravimetric weighing and dosing

17

Pfister customer service &

after sales support
Thousands of FLSmidth Pfister systems are currently in
operation worldwide and require global presence. Therefore FLSmidth Pfister operates sales and service offices in
eight countries on four different continents.
Experienced service technicians stand by your side and
provide first-class service. A 24-hour hotline and online
trouble-shooting provide worldwide support. Also available
are telesupport packages.
FLSmidth Pfister not only keeps a large number of spare
parts in stock. Skilled spares specialists are looking forward
to assist you in optimizing your own spare parts management.
FLSmidth Pfisters services are rounded up by service contracts, which can be adapted individually to the customers
needs.
Customer training on-site or at FLSmidth Pfisters training
center ensures the best possible knowledge transfer.

Pfister after sales support:

- 24-hour hotline
- Telesupport
- Modern maintenance
management
- Trainings and seminars
- Service contracts

FLSmidth Pfisters headquarters

are located in Augsburg / Germany

Headquarters:
FLSmidth Pfister GmbH
Staetzlinger Str. 70
86165 Augsburg, Germany
T. +49 821 7949 0 | F. +49 821 7949 524
Sales Department: sales@flsmidthpfister.com
Technology Department: engineering@flsmidthpfister.com
Service Department: service@flsmidthpfister.com

Branch offices:
FLSmidth Pfister GmbH

Pfister Operations

6, Rue de Bretagne

3235 Schoenersville Rd., Bethlehem, PA 18017, USA

38070 St. Quentin Fallavier, France

p. +1 610 2645110 | f. +1 610 2645537

p. +33 4 74 95 55 44 | f. +33 4 74 94 50 75

pfister.usa@flsmidthpfister.com

pnl@flsmidthpfister.com

FLSmidth Pfister Ltda.

FLSmidth Private Ltd.

Rua Jos Dolles, 264 - Jardim Clarice II

i-Think Techno Campus, A-Wing, 6th Floor, Office No. 2

CEP 18116-710 - Votorantim, S.P. Brazil

Pokhran Road II, Thane West - 400 607, India

p. +55 15 3416 7438 | f. +55 15 3416 7599

p. +91 22 6117 2555 | f. +91 22 6117 2862

uwe.richter@flsmidthpfister.com

twsales-in@flsmidthpfister.com

FLSmidth Pfister GmbH Malaysian Branch

FLSmidth Pfister China

C-3A15, Centre Wing, Metropolitan Office Suite

No. 8, Taisu Road,

Metropolitan Square, Jalan PJU 8/1

Beiguan Industrial Park,

Damansara Perdana, 47820 Petaling Jaya

Jiaozhou City, Qingdao 266309, P.R. China

Selangor, Malaysia

p. +86 532 8526 6706 | f. +86 532 8526 6699

p. +60 3 7728 2039 | f. +60 3 7727 2039

24-hour-hotline: 400 612 3636

sales@flsmidthpfister.com

info-china@flsmidthpfister.com

Copyright 2014 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth, Pfister, ProsCon and all other product names used herein are (registered) trademarks of FLSmidth A/S.
This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time.

www.flsmidthpfister.com

IB.101.01-a-GB

FLS-No. CM 02-16-700-033 ENG

FLSmidth USA, Inc.