STEEL BELT CONVEYORS FOR SEVERE CONDITIONS since 1929

ENI

THE CHALLENGE

Eni S.p.A. is an Italian multinational oil and gas company headquartered in Rome. Eni is the owner of the Gela plant, a large oil refinery located in the southern part of Sicily. The refinery was in operation till 2014 before starting its conversion into a bio-refinery. The refinery was also provided with a power plant, comprising 3x150 MW downshot boilers burning pet-coke. The power plant supplied heat & power to the refinery and electricity to the grid.
In the late ‘90s, Magaldi Power carried out the wet-to-dry conversion of the bottom ash handling systems on the Units #1 thru 3, aiming at avoiding the enormous O&M burden of the existing submerged chain conveyors. These wet systems suffered heavy corrosion problems due to a high-sulphur content in the handled bottom ash.

 

THE CUSTOMER

Eni S.p.A.has operated over the years in a large number of fields including contracting, nuclear power, energy, mining, chemicals and plastics, refining/extraction. Eni owns the Gela refinery, built in the early ‘60s in the southern part of Sicily. Up to 2014, the Gela plant was a leading refinery in the Mediterranean area. With a balanced primary refining capacity of 100,000 barrels/day, it represented an upstream integrated pole with the production of heavy crude oil obtained from Eni’s nearby offshore fields , while downstream it was integrated with Eni’s nearby petrochemical plants. The refinery produced fuels for automotive use and residential heating purposes as well as petrochemical feedstocks.
In 2014 the refinery was shutdown in order to activate the plan of reconversion into a bio-refinery for the production of highly environmentally sustainable bio-fuels.

 

THE SOLUTION

At the Gela refinery the 3x150 MW pet-coke fired boilers of the integrated power plant were originally equipped with a wet bottom ash handling system. It was comprised of a water-filled submerged chain conveyor (SCC) to quench and extract bottom ash. Despite a pH-control, the SCC water bath was acidified by a high-sulphur bottom ash. This problem led to fast corrosion of the SCC components and the boiler throat pressure parts. In addition, large quantities of polluted waste water were produced and had to be treated.
In consideration of these problems, in 1998 Magaldi Power and Eni signed a 12-year BOT (build-operate-transfer) contract for the wet-to-dry conversion of the bottom ash handling systems on Units #1 thru 3. Eni allocated to Magaldi Power a part of its previous yearly budget for the bottom ash handling O&M, while Magaldi Power operated and maintained the systems until 2010.
Thanks to the installation of the MAC® (Magaldi Ash Cooler) systems, Eni succeeded in:

 

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