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Refining PlantSchwarze Pumpe
High-quality fuelsmade of Lusatian lignite
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2 Refining Schwarze Pumpe
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3Refining Schwarze Pumpe
The refining site Schwarze Pumpe
is located in lower Lusatia, about
130 km south of Berlin in the
border triangle to Poland and
Czech Republic. With the erectionof Europe’s largest lignite refin-
ing complex in 1955, Schwarze
Pumpe gained superregional
importance.
Facing the structural changes in
the energy industry during the
90ies of the 20th century, the
refining plant Schwarze Pumpe
fulfilled a consequent re-orienta-
tion.
Lignite means energy. Nearly 40 per cent of the
German energy generation is allotted to lignite.Vattenfall refines about 5 per cent of the annual
output of raw lignite from the Lusatian area to
high-quality fuels like briquettes, pulverized lignite
and fluidized bed lignite.
Control center of refining plant
Today, this refining site is the
most modern and most innovative
of its kind in Europe. Raw material
production and electricity genera-
tion, fuel production as well as
research and development are
connected closely and lead to an
efficient and environment-friendlyvalue-added chain.
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4 Refining Schwarze Pumpe
Vattenfall has a precise ambition:
Using local lignite as efficient
and eco-friendly as possible and
simultaneously providing a reliable
and competitive energy solution
to our costumers.
The production of high-energy
fuels using environment-friendly
combined heat and power tech-
nology is a main component of
our venture.
Overview of refining plant Schwarze Pumpe and the power plant in the background
Refining means: to accentuate a
particular quality of a raw mate-
rial. Due to preparing, drying and
molding of lignite, an increase of
the caloric value and an easier
handling are achieved.
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5Refining Schwarze Pumpe
Lignite briquettes in different
sizes and formats as well as pul-
verized lignite and fluidized bed
lignite are produced in the refin-
ing plant Schwarze Pumpe:
• Lignite briquettes are prevail-
ingly used in small firing sites
of private households and in
full-automatic boiler combus-
tion systems of medium-sized
industries and businesses,
• Pulverized lignite is being used
by the cement-, lime- and
asphalt industry and communal
and industrial heating plants
and combined heat and power
plants,• Fluidized bed lignite is utilized
in combined heat and power
plants.
The coal wood “xylite” enlarges
the lignite variety with an innova-
tive product. It is being used as
peat-like substrate and mulching
material in garden and landscapeconstruction.
Standard values of energy sources
RML Run-of-mine lignite
LB lignite briquettes
FBL fluidized bed lignite
PL pulverized lignite
water (per cent)
caloric value (MJ/kg)
60
50
20
15
10
5
0RML LB FBL PL
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6 Refining Schwarze Pumpe
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7Refining Schwarze Pumpe
Briquettes, pulverised lignite and
fluidised bed lignite are manu-
factured at the Schwarze Pumpe
refining plant. They are made of
run-of-mine lignite from nearby
opencast mines at Welzow-Süd
and Nochten. The most important
properties of this run-of-mine
lignite are its low ash and sulphurcontents.
The main process in refining
run-of-mine lignite is the dry-
ing process. It is interlinked with
the power plant process of the
nearby lignite-fired Schwarze
Pumpe power plant. The result
is a cogeneration of power andheat, which ensures a high rate of
utilisation of the fuel lignite in the
power generation process.
Process steam and district heat
are supplied to the production
units of the refining site.
At the refining plant, state-of-
the-art dedusting plants (high-
performance bag-type filters and
venturi-precipitators, electro-gas
purification filters) assure a low-
emission operation.The respective requirements are
to be found in the German Techni-
cal Air Pollution Control Regula-
tion (“TA Luft”). It stipulates the
limits for dust emissions. Since
the 1990s a number of compre-
hensive measures were imple-
mented at the Schwarze Pumpe
refining plant in order to furtherreduce dust emissions.
Even after the completion of the
revamping and investment meas-
ures of the filter plants, extensive
efforts are made to maintain the
capacity of the dedusting plants.
The requirements of the Technical
Air Pollution Control Regulation are
met and even fall below the limit.
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8 Refining Schwarze Pumpe
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9Refining Schwarze Pumpe
The run-of-mine lignite of the
opencast mines reaches the
refinery by train via the railway
network of Vattenfall Europe
Mining AG.
Every day, up to 12,000 tons of
lignite are transported and stored
in the bunker, which has a capac-
ity of 24,000 tons.
According to the demand, the
run-of-mine lignite is taken from
the individual bunker sections.
Thereafter, the lignite is crushedto a maximum grain size of 250
mm in the blade crushers before
it is transported to the raw lignite
treatment by conveyor belts.
The processing section is also
called “wet section” because,
at this stage, the lignite’s water
content is approx. 57 per cent
which means, it is still as wet as in
the mine.
The run-of-mine lignite is crushed
in hammer mills and thereafter
classified on screens. The raw fine
coal yielded this way has a grain
size of up to 6.3 mm.
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10 Refining Schwarze Pumpe
Vapour
1 Storage bunker
2 Belt conveyor
3 Blade crusher
4 Jigger screen
5 Hammer mill
6 Rotary tube dryer
7 Electrostatic filter
8 Conveying line
9 Mill
10 Troughed-chain conveyor
11 Hose belt conveyor
12 Screen-chain conveyor
13 Briquetting press
14 Loading Briquettes loose
15 Loading
Briquettes palletised
16 Loading
Fluidised bed lignite
17 Loading
Pulversed lignite
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11Refining Schwarze Pumpe
Afterwards, the raw fine lignite is
dried in tubular dryers. These are
cylindrical drums with a diameter
of 5 m and a length of 8 m. Each
drum consists of 1,580 single
pipes, approx. 4,000 sqm. That
equals the size of half a football
field.
A total of 16 tubular dryers are
in use in the briquette plant.
Depending on the programmed
remaining water content, the dry
lignite is then fed to the individual
product lines, i.e. the production
of briquettes, pulverized lignite,
and fluidised bed lignite. In ad-
dition to the main product, drylignite with varying water content,
a mixture of air, steam and coal
dust, called “vapours” is produced.
The vapours are purified in high-
performance filters. The dust col-
lected this way is direcly sold as
pulverized lignite on the market.
Dry lignite treatment
In order to be able to manufac-
ture high-quality briquettes from
dry lignite with a grain size of
up to 6.3 mm and water content
of approx. 19 per cent, a further
refining stage is required.
For this purpose, the lignite isagain crushed in hammer mills
and classified on special screens.
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12 Refining Schwarze Pumpe
This produced dry briquetting lig-
nite has a grain size of up to 2.5
mm and a calorific value which is
twice that of raw fine coal.
Pressing
It is done by applying high pres-
sure without adding binders.
The granular material called dry
briquetting lignite is pressed to a
briquette with a high density and
compressive strength.
Briquettes are manufactured in
a total of 19 electrically driven
presses each being equipped with
four production lines.
Depending on the working speedat which the presses are running,
up to 80 briquettes can be pro-
duced per minute and per line.
Packaging and loading
of briquettes
The form into which a briquette is
pressed depends on its respective
use. Industrial briquettes, half-
brick-size briquettes and whole
brick-size briquettes are offered
in bulk products. Via conveyor
systems, these briquettes are
transported to the loading station
for railway and road transporta-
tion.
However, there is an increas-
ing share in the production of
briquettes, which are prepacked
consumer friendly in bundles of25 kg, bags of 10 kg, or in 10 kg
film packages.
The packaging and palletising
process is fully automated done in
the newly built packaging facility.
In order to meet peak demands,
packaged briquettes can be
stored in two warehouses with a
total capacity of 35,000 tons.
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13Refining Schwarze Pumpe
Pulverized lignite is processed in
the grinding section and yielded
during the dedusting processes
of the technological equipment in
the drying section.
Milling
Dry lignite with a water content
of approx. 11 per cent is the feed
material for the grinding process.
Via conveyor belts and distribu-
tion systems, the lignite is trans-
ported to two bowl mill crushers,
which pulverise the material from
a grain size of 0 - 6.3 mm to 0- 0.2 mm. The grinding capacity
of the three mills adds up to 180
tons per hour.
Loading of pulverised lignite
The pneumatic belt system con-
veys the pulverized lignite into 5
storage and loading silos with the
capacity of 4 x 1,100 cbm and1 x 1,000 cbm.
Underneath the silos are the
loading facilities for road and rail
transportation installed. Up to
3,500 tons of pulverized lignite
are consigned daily.
Fluidised bed lignite is manu-
factured in the drying process,
its grain size is 0 - 6.3 mm and
the water content is 16 - 18 %.
It is transported to the silo and
loading facilities via mechanical
conveyor systems.
Loading of fluidised bed lignite
The silo and loading facilities for
fluidised bed lignite consist of two
silos with a capacity of 1,200 cbm
each and a loading facility for
railway transports. Fluidised bed
lignite for domestic sales is takenfrom the mechanical conveyor
systems and loaded directly into
the silo road vehicles, according
to demand.
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P21
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4
5
2
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7 89
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13214
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17
1918
9
Site plan
of Schwarze Pumpe refining plant
1 Main entrance
2 Management production
3 Sales and distribution
4 Row lignite bunker
5 Wet section
6 Dry section
7 After-treatment8 Central control room
9 Milling plant
10 Continuous flow bunker
11 Press house
12 Chute and cooling unit
13 Bundling and palletising unit
14 Stacking hall and pallet stockyard
15 Loading of briquettes – road transportation
16 Loading of briquettes onto trains
17 Loading of fluidised bed coal
18 Loading of pulverised lignite on trucks
19 Loading of pulverised lignite on trucks/trains
20 Transport company TSS
21 Central truck terminal
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J a n u a r
y
2 0 1 2
Production
Lignite Mining & Generation
Refining
An der Heide
03130 Spremberg
T +49 3564-69 41 00
F +49 3564-69 20 04
www.vattenfall.com/refining
Vattenfall Europe Mining AG