Automated Coal Washdown Delivers Safer and Faster Operations

Automated Coal Washdown Delivers Safer and Faster Operations

The Challenge: A large coal-fired power plant was struggling with coal dust buildup inside its coal transfer building. Fine coal dust is extremely hazardous – it creates a serious explosion risk if allowed to accumulate.

The old cleaning method relied on two operators using fire hoses to wash down the entire interior – walls, floors, equipment, and structural steel. The process took up to two hours, left operators exposed to airborne coal dust, and was surprisingly ineffective. High beams and supports more than 20 feet (6 m) overhead were almost impossible to reach properly from the floor.

The Solution: The plant worked with Spraying Systems Co. to install a fully automated washdown system using TankJet® 80 tank cleaners.

Twelve TankJet 80 units were mounted on the ceiling along the centerline of the building (480 ft long × 40 ft wide × 50 ft tall / 146 m × 12 m × 15 m), spaced 40 ft (12 m) apart. The system was divided into three independent zones to keep pump size and power requirements reasonable.

Each TankJet 80 is fluid-driven and uses two powerful solid-stream nozzles that rotate in multiple planes, delivering full 360° coverage with excellent impact and reach.

Now, just one operator follows up with a hose for any small spot cleaning if needed. The entire automated cleaning cycle takes just over 30 minutes – a dramatic improvement.

The Results:

• Labor savings: Dropping from two operators for two hours to one operator for about 30 minutes saves the plant approximately US$25,000 per year in labor costs. The system paid for itself in roughly 16 months.
• Water savings: Water consumption dropped by about 20%, supporting the plant’s sustainability goals.
• Safety improvement – the biggest win:
  – Much less coal dust is kicked up into the air during cleaning
  – Operator exposure time inside the building has been slashed
  – The explosion risk from airborne coal dust is significantly reduced

By switching to an automated, high-impact washdown system, the plant achieved better cleaning, lower operating costs, improved sustainability, and – most importantly – a much safer working environment for its people. Automated coal washdown