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WHAT SGS CAN DO FOR YOU
We know that being in the power generation industry you face problems with consistent coal qualities because of a need for consistent quality for your boilers. In addition, increased environmental regulations for S02 and particle emissions present further challenges to the power industry. This results in increased need for Real Time Analysis at power plants. Real Time Analysis will to enable you to blend your coal to meet required specifications and help increase plant efficiency through a decrease in forced outages and de-rates. SGS will work with you to ensure that your On-Line Analyzer System optimizes your operation and helps you meet the challenges facing power generators today.
As an independent, leading supplier of innovative, technologically advanced services to the power generation industry, SGS is uniquely positioned to partner with you to improve your efficiencies, and enhance your profitability. All SGS work is done in accordance with internationally accepted standards such as ASTM, EPA, ISO and JIS. We are dedicated to providing you with value-added solutions that reduce risk, enhance value and maximise returns at each step in your power generation value chain. Our reputation depends on your complete satisfaction.
Through our global network of operations, SGS can deliver a broad spectrum of independent evaluation services to coal producers worldwide. This is aimed at reducing your risks and maximizing your profits. Through our team of professionally qualified engineers and support staff we can provide you with technical expertise in the areas of:
- On-Line Analyzer Systems
- Blending And Sorting
- Loading And Discharge
- Mechanical Sampling Systems
- Manual Sampling
- Inventory Systems
- On-Site Lab Set Up
- Environmental Services
ON-LINE ANALYZER SYSTEMS
SGS is a global leader in the field of on-line analyzer systems (OLA), providing complete design, installation and support services for your new or existing OLA System. An OLA system will allow you to monitor, control and optimize your processes as they occur and allow you to undertake process modifications when they are beneficial to operations. This can have a substantial, often overwhelming impact, on your facility’s profitability.
By properly blending your coal with an SGS designed on-line analyzer system, you can:
- Control and possibly eliminate your slagging and fouling problems resulting in a reduction of forced outages and de-rates
- Ensure maximum operational efficiency through consistent blending of coal
- More easily comply with environmental regulations including S02 and particle emissions
- Operate nearer your design capacity without an increased risk of power fluctuations and environmental pollutant surges
SGS is unrivaled when designing and supporting OLA Systems for the coal industry. Once designed, our technical experts will install, commission, and calibrate the On-line System in accordance with globally recognized standards. Experienced SGS personnel using a continuous surveillance program will then provide ongoing support for your OLA System, including on-site inspections and recommendations for enhancements and improvements to your systems and procedures.
Blending and Sorting
Traditionally, coal producers use online coal analyzers to meet tight specifications for sulfur. However, given the power of On-line Analyzer Systems to sort coal consistently and accurately based on multiple quality factors (sulphur, ash, moisture, etc), there are many opportunities for coal producers to realise additional value from these systems.
Sorting based on quality allows raw coal that meets shipping specifications to be bypassed around the preparation plant. The yield of the preparation plant will increases, resulting in a more efficient and profitable operation. The ability to reliably blend various coal qualities to arrive at a specific product allows to:
- Blend lower cost poorer quality coals with high quality coals to exactly meet contract specifications
- Market and sell your coal to power generators more easily due to consistent quality
- Avoid rejected loads and quality penalties
Loading master
With our experience in maritime logistics, SGS is able to supply “loading masters” to shippers and terminals. A loading master supervises the transfer of materials to and from marine vessels. He is in-charge of all paper work and dock operations that ensure the transfer is done safely. He also checks that all environmental laws and regulations are obeyed and verifies that the said cargo is the one actually being handled.
Our loading master will coordinate all activities linked to the loading, discharge or transshipment of your cargo. He ensures that operations are managed to optimize berth time and are completed in a timely and efficient manner. The SGS loading master is the key link between the vessel, terminal operators and third-party surveyors, providing unique expert knowledge on vessel operations from a marine point of view, and an understanding of associated shore operations.
During the entire operation of loading and inspection, the SGS loading master handles all the documentation needs and keeps you directly informed on the progress of operations.
SGS provides inspection and supervision services such as weight certification, sampling, chemical and quality analysis of coal and coke at most ports and major inland trans-shipment points. Whether you are selling, buying or transporting coal or coke, SGS is ready to assist and independently verify shipment weight and quality.
Mechanical Sampling Systems
Risk associated with inaccurate evaluation of coal is managed by selecting the proper Mechanical Sampling System (MSS). SGS has a team of professionally qualified engineers and support staff that have the experience needed to provide services related to your new or existing Mechanical Sampling Systems. We have 25 years experience in the design, supply, installation and commissioning of client-dedicated, site-specific MSS, with more than 300 SGS-designed systems operating in over 20 countries worldwide.
Qualified SGS personnel perform technical audits and provide on-going maintenance to ensure the best possible sampling from your equipment. SGS will maintain a quality assurance program for your Mechanical Sampling Systems in accordance with international standards including:
- Inspection of the Mechanical Sampling Systems
- Bias testing of the Mechanical Sampling Systems
- Collection and analysis of the samples from your Mechanical Sampling Systems
- Modification of the existing MSS to improve the performance and/or eliminate bias
- Technical advice on the operation of the sampling system
- Breakdown repairs
To design an effective MSS, detailed information about the location of the MSS and the material to be sampled is needed (including its top size, surface moisture content and material handling characteristics). A site visit is often required to ensure your MSS design meets the design criteria defined by ASTM, ISO or other global standards. SGS will use tried and proven designs and modify these, where necessary, for each new application. Through this process we provide you the best and most cost effective solution to your sampling problems.
Manual Sampling
SGS provides the highest level of manual sampling integrity to produce the most representative sample for further analytical testing. SGS manual sampling services include:
- Stationary sampling from stockpiles, railcars, trucks and barges
- Full and part-stream sampling from moving stream of materials
- Stopped belt sampling of materials on conveyors
Auger Sampling
SGS offers two different types of auger sampling systems. The first is a truck mounted mobile auger sampler that is easily transported and can go to wherever the coal is located. The second system is the Johnson Industry stationary coal auger system. This unit, mounted on a trailer, is very economical for longer term projects such as incoming truck or train receipts at a plant. Both systems can be fitted with augers of varying diameter and length to meet individual coal requirements for topsize and depth of sampling. They can also be easily fitted with sub-systems to allow the efficient crushing and division of samples collected.
SGS Minerals Services pioneered this sampling concept and remains the leading provider of these innovative sampling solutions. Whether your dealing with large static piles or railcars that have limited access to mechanical sampling equipment, you can trust SGS to economically collect samples of coal in representative fashion and in accordance with ASTM standards.
Inventory Services
SGS provides the resources required to determine the quantity and quality of coal in storage. SGS has provided physical inventory related services for 100 different customers, at 230 separate sites, and over 1800 individual piles. The accepted method for determination of coal quantity is to ascertain the density of the coal and the volume of the stockpile, from which the total weight may be calculated.
SGS uses a state-of-the-art nuclear depth density gauge to determine your coal pile density. Once the density is determined, SGS will acquire ground level or photogrammetry data to satisfy the requirements of a TIN (Triangular Irregular Network) creating software package. The volume of coal within the TIN is then computed by electronically filling the volume of the TIN above the base datum with prisms of known volume. Once density and volume are known, Total Tons of Coal in the stockpile are readily determined.
Lab Services
SGS provides the complete range of laboratory procedures to meet all your coal testing requirements. All laboratory analysis is performed in accordance with recognized global standards such as American Society for Testing and Materials (ASTM), International Standards Organization (ISO) and Japanese Institute of Standards (JIS). Quality assurance standards are constantly monitored through participation in numerous industry and standards body correlation programs, as well as in our own, unique round robin program administered through the Institute for Inter-laboratory studies. Our labs use concepts of total quality management (TQM) to ensure consistent operation on a daily basis.
Our qualified technicians operate in laboratories with state-of-the-art instrumentation, using industry best practices to provide you with complete, accurate and timely coal analysis. SGS coal analysis capabilities include:
- Proximate Analysis
- Ultimate Analysis
- Calorific Value
- Elemental Analysis
- Toxicity Testing
- Hardgrove Grindability Testing
- Complete Ash Analysis Including:
- Fly Ash Receptivity
- High Temperature Ash Viscosity Analysis
- Ash Elemental Analysis
- Ash Fusion
Onsite Labs
SGS designs, staffs and operates hundreds of onsite laboratories globally. Many businesses out-source their lab operations because specific expertise is needed to run such facilities. Labs provide critical, operational, environmental and processing data that guide site activities. With our extensive experience in this area, SGS can design and operate your lab, allowing you to focus on your core business.
Subcontracting your lab operation to SGS allows you to allocate capital and staff more efficiently and ensures that the data you base important decisions upon is accurate and consistent. Partnering with SGS allows you have an impartial third party monitoring your results and ensuring that they meet reporting requirements.
Environmental Services
SGS is a trusted provider of specialized technical expertise and support globally. We are independent of industrial or sector organizations, authorities, and pressure groups within the coal industry, allowing us to provide you with trusted, impartial results. We provide a complete range of laboratory analysis to meet the environmental requirements of power generators in accordance with recognized standards such as ASTM, EPA, ISO and JIS. Our expertise includes:
- Analysis of:
- water (waste water, groundwater, process water, drinking water)
- soil (soil, sludges and water bottoms)
- waste (hazardous waste, industrial waste)
- air samples (gas bags and adsorption tubes)
- Sampling On-site
- Testing hi-res Dioxin and PCB
- Examining Leachate
- Microbiology and Parasitology Testing
- Identification and Reduction Toxicity Studies
- Environmental Sampling and Analysis Program
Stack Emissions Control
Emissions from coal generating stations and mine sites operating under controlled circumstances (using filters, scrubbers, chimney stacks or other discharge channels), must satisfy certain environmental limits and concentrations. SGS conducts air measurements according to the highest quality standards. Our expertise includes:
- Determining of flue gas parameters (O2, CO, NxOy, SO2, CxHy, VOC, CO2)
- Calibration and certification of continuous on-line measuring equipment
- Measuring emissions of inorganic components (chlorine, HCl, HF, metal, acid vapors)
- Measuring emissions of organic components (dioxins, furans, solvents, PAH)
- Measuring emissions (air pollution at population level)
- Measuring dust particles (total dust and particle size distribution)
- Measuring moisture level, flow rate and temperature
- Calculating dispersion (according to various international models)
- Measuring odor
- Monitoring fugitive emissions
SGS also offers technical advice relating to emission-reducing techniques.
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