PULVERIZED FUEL SYSTEMS
HODGE, LOUISIANA
DUAL PETROLEUM COKE DENSI-FEED™ SYSTEM
Matrix provided the complete engineering package for a dual discharge petcoke delivery system for Smurfit Stone Containerboard Division in Hodge, Louisiana. The system was designed to feed two lime kiln burners from a common 180 ton silo. A dual discharge hopper bottom was specifically designed for two petcoke feeders. It included dual pneumatic convey systems with variable rate blowers to deliver petcoke to the Coen burners in accordance with the manufacturer's specific air flow requirements. The convey distance of the petcoke was in excess of 600 feet. The system allowed the mill to substitute up to 90% ground petcoke for natural gas in each of their lime kiln burners. The control of the Matrix feed equipment was integrated into Smurfit Stone’s existing DCS. Matrix provided all the civil/structural, mechanical, and electrical engineering for the project.
PERDUE HILL, ALABAMA
DUAL PETROLEUM COKE DENSI-FEED™ SYSTEM
Matrix provided the system engineering and critical equipment packages with silo for a dual discharge petcoke delivery system at Alabama River Pulp (ARP) in Perdue Hill, Alabama. This system was designed to accept petcoke from rail or truck and feed two lime kiln burners from a common 180 ton silo. A dual discharge hopper bottom was specifically designed for two petcoke feeders, though initially, ARP chose to implement the project in two phases and only installed one of the two petcoke feed systems. Matrix Engineering commissioned the second line in late Spring 2008. A pneumatic conveying system with a variable rate blower delivers petcoke to the burner in accordance with their specific air flow requirements. Control of the Matrix system was integrated into ARP’s existing DCS. Currently they are able to fire petcoke and fuel oil as well as natural gas.
The first kiln’s system at ARP was proven and tested to 3.0 tph and is currently burning in excess of 2.4 tph of petcoke in combination with fuel oil. Below is a picture of the flame at 2.5 tph with fuel oil.
SPRINGFIELD, OREGON
PETROLEUM COKE DENSI-FEED™ SYSTEM
Matrix implemented an engineering and equipment supply contract for a storage silo and petcoke feed system for Weyerhaeuser in Springfield, Oregon. The system consisted of a 180 ton storage silo and a variable feed system specifically designed for the discharge of ground petcoke. A variable rate blower was used to transfer the petcoke approximately 350 feet to the existing “coke-ready” burner. All controls and display panels were integrated into the mill’s existing DCS system. Matrix provided the civil/structural, mechanical, and electrical engineering for the project. System startup was conducted in December 2006.
BENNETTSVILLE, SC
PETROLEUM COKE DENSI-FEED™ SYSTEM
Matrix was awarded an engineering and complete equipment supply contract for a single discharge storage silo and petcoke feed system. The system is designed to supply in excess of 3 tons-per-hour of petcoke to the burner.
PANAMA CITY, FLORIDA
PETROLEUM COKE DENSI-FEED™ SYSTEM
Matrix provided the system engineering and critical equipment package for Smurfit-Stone in Panama City, Florida. This system was designed to accept petcoke from trucks and feed a lime kiln burners from a 180 ton silo. A pneumatic conveying system with a variable rate blower delivers petcoke to the burner in accordance with their specific air flow requirements. Control of the Matrix system was integrated into their existing DCS. Currently they are able to fire petcoke and fuel oil and are feeding at rates as high as 3.80 tons per hour (115 MMBtu/hour).
WICKLIFFE, KENTUCKY
PETROLEUM COKE DENSI-FEED™ SYSTEM
Matrix was awarded a complete turnkey contract for engineering, equipment supply, and installation of a single discharge storage silo and petcoke feed system for NewPage Corp. in Wickliffe, Kentucky. The system is capable of unloading both truck and rail. Startup for this project was completed ahead of schedule in May 2007.
 
LUKE, MARYLAND
PETROLUEM COKE DENSI-FEED™ SYSTEM
Matrix Engineering was recently awarded a contract to provide a pulverized petcoke fuel delivery system for one kiln utilizing a truck or rail unloading system, storage silo, feed system, pneumatic conveying system, and all the necessary instrumentation. We commissioned this project in October 2008. The system utilizes natural gas and petcoke. The petcoke system provides 90 MMBtu/hour (3.0 tons per hour) to the kiln.
CAMPTI, LOUISIANA
PETROLEUM COKE DENSI-FEED™ SYSTEM UPGRADE
Matrix provided the consultation and engineering necessary to upgrade an existing petcoke feed and convey system. Matrix employed its new 3rd generation design to double the feed rate of petcoke. The existing silo was re-used and retrofitted with the Matrix feed system. We also replaced the existing convey system and instrumentation for delivering the petcoke to the burner nozzle.
BOGALUSA, LOUISIANNA
PETROLEUM COKE DENSI-FEED™ SYSTEM
Matrix received a contract for the engineering and equipment necessary to upgrade an existing petcoke feed and convey system. The Matrix System will more than triple the petcoke feed rate and provide instantaneous feedback on system performance. The existing silo was re-used and retrofitted with the Matrix feed system. We also replaced the existing convey system and instrumentation for delivering the petcoke to the burner nozzle. Commissioning of the system will occur in November 2008.
VALLIANT, OKLAHOMA
PETROLEUM COKE DENSI-FEED™ SYSTEM
Matrix provided a total Petcoke Delivery System at Weyerhaeuser Corporation in Valliant, Oklahoma. The system allowed the mill to substitute up to 80% ground petcoke for natural gas in their lime kiln burner. The system consisted of a 180 ton storage silo and a variable speed feeding system specifically designed for the discharge of ground petcoke. A variable rate blower was employed to precisely meet the air flow requirements of the KFS burner. An existing AB Control Logic PLC was used to control the process. Matrix provided an I/O control panel in conjunction with our feeding equipment. Matrix provided all the civil/structural, mechanical and electrical engineering for the project.
PINE HILL, ALABAMA
PETROLEUM COKE DENSI-FEED™ SYSTEM
Matrix provided a total Petcoke Delivery System at Weyerhaeuser Corporation in Pine Hill, Alabama. The system allowed the mill to substitute up to 80% ground petcoke for natural gas in their lime kiln burner. The system consisted of a 180 ton storage silo and a variable speed feeding system specifically designed for the discharge of ground petcoke. A variable rate blower was employed to precisely meet the air flow requirements of the KFS burner. All controls and display panels were integrated into the mill’s existing DCS system. Matrix provided the civil/structural, mechanical, and electrical engineering for the project.
HAWESVILLE, KENTUCKY
PETROLEUM COKE DENSI-FEED™ SYSTEM UPGRADE
Matrix provided the consultation and engineering necessary as well as much of the equipment to replace an existing petcoke feed and convey system. Matrix provided new features into the 3rd generation design to double the feed rate of petcoke. The existing silo and chisel bottom were re-used and retrofitted with a dual inlet feeder utilizing Matrix’s new pulverized fuel feed system. We also replaced the existing convey system and instrumentation for delivering petcoke to the burner nozzle.
BREWTON, ALABAMA
PETROLEUM COKE DENSI-FEED™ SYSTEM
Matrix has been awarded an engineering and equipment supply contract for a single discharge storage silo and petcoke feed system for Georgia-Pacific’s Mill in Brewton, Alabama. Engineering is complete and we are awaiting release to procure the equipment.
EVADALE, TEXAS
PETROLEUM COKE DENSI-FEED™ SYSTEM WITH RAIL UNLOADING
Matrix is currently providing engineering services and critical equipment to MeadWestvaco for a 270 ton dual discharge petcoke delivery system with rail unloading capabilities. The rail unloading line will extend in excess of 600 feet to the delivery silo where petcoke will be fed to two lime kilns.
PORT HUDSON, LOUISIANA
PETCOKE CONVEYING & FEED SYSTEM TROUBLESHOOTING
Georgia Pacific contacted Matrix while experiencing problems during start-up of their on-site grinding facility. Our Engineering Department provided assistance for an existing petcoke feed system that was not functioning as designed. We were able to quickly diagnose the problem which involved the conveying air flow for the delivery silo dust collector. The convey air flow was overwhelming the dust collector filter area. We quickly engineered a new 4” line, provided and expedited a positive displacement blower to replace a centrifugal fan, which conveyed the same coke rate using 20% of the original air. This completely eliminated the problem.
Georgia Pacific then asked Matrix to look at some chronic feeding problems they were experiencing with their existing burner delivery system. Matrix Engineers evaluated the situation, and determined that it was due to a “bridge and flush” phenomenon, which caused a 20% swing in the average feed rates. Matrix issued a complete report on the problem and recommended improvements.
PeTroCoke, Inc.
OWENSBORO, KENTUCKY - GRINDING PLANT UPGRADE
Matrix Engineering provided a complete electrical system upgrade and the modernization and controls automation of PeTroCoke, Inc.’s Owensboro, Kentucky plant. The entire electrical system was replaced from the main service disconnect to all of the equipment and instrumentation. The new control system consisted of an Allen Bradley PLC and RSView32 computer operator interface. The electrical upgrade controls a mill feed system, a hammer mill, and a gas-fired burner system for drying the petcoke. Ultrasonic instrumentation continuously monitors the finished product silo and controls a bulk truck load-out system. Matrix personnel assisted in complete system check-out and start-up and were able to minimize downtime without affecting delivery of customer orders. Due to automatic control of product feed and burner temperature, the plant throughput was improved dramatically.
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