PROJECTS

GRAND VILLAGE TOWN HOUSES

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Grand Village is a 3 story, European Standard Townhouse Complex for 119 household.

The Complex has 23 buildings of townhouses, shopping malls and service centers that provides all kind of demand for complex residents, green garden with artificial stream, running and bicycle roads, soccer field, basketball and badminton courts. The main advantage of the Townhouse Complex is that it delivers residents a convenient, safe living environment all in one.

Project Location, feature and advantage

  • Location at 14km distance from Ulaanbaatar Center
  • No air and soil pollutions
  • Connection with Central Heating and Electrical System
  • Prefabricated reinforced concrete structure of building
  • 2 garages and 2 parking spaces for each family
  • Own land to plant flowers and trees around house for each family
  • Green garden with artificial stream and pond
  • Sport area with playpit, soccer field, basketball and badminton court
  • Running and bicycle roads
  • Service center /with Day Care Center, Pharmacy, Supermarket, Beauty Salon, Coffee Shop, Sport Pub, Billiard Club, Fitness Center, Swimming Pool with 3 lines, and VIP Cinema/

Project overall plan

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PROVIDE HEATING BOILERS BY COAL GAS AND AIR POLLUTION REDUCTION

Project objectives

In the scope of the project, 3.5km long gas pipeline was installed from the Coal Gas Plant of the Grand power LLC, to the end-user location to supply heating boilers by product gas.

Project objectives:

  • To reduce emissions from heating boilers, and increase thermal efficiency of the boilers.
  • To supply heating boiler by cheap coal gas and prove its reduction amount of air pollution.
  • To learn lessons and experience during gas pipeline distribution.

Project rationale

According to the research of National Committee of Air Pollution Reduction, 50% of the total pollution is caused by the raw coal usage of ger district consumers, and the combustion flue gas of enterprises ‘low-pressure boilers’ causes 10% of pollution. While combustion of raw coal, not only flue gas but also coal dust, fly ashes and other particulate matters increase air pollution. UB city residents’ sickness rate of congenital acromicria and respiratory disease is increasing gradually due to the air pollution.

The best solution of the air pollution problems is shifting solid fuel of Ger Districts into gas fuel and building a gas pipeline distribution system. However, the residents are not confident that gas could be safe and reliable fuel for the domestic heating. There is necessity to introduce gas advantages to the residents by implementing small gas supply system and to learn from the real experience for us.

Project Benefits

The project has termendous social and environmental benefits. In the frame of the project, 3 enterprises of Unit 0151 of Border Troops, Workshops of Grand Power LLC, and Precast Concrete Plant of Grand Baishin LLC is supplied by coal gas and is reduced toxic emissions from their heating boiler combustion. Also the project has folllowing objectives:

  • To introduce advantages of gas application to reduce an air pollution of the raw coal combustion in UB city.
  • To solve an enterprises’s heating only boilers by coal gas, and save the investment of conventional heating pipeline system.
  • To reduce solid wastes of coal combustion, accordingly enable convenient environment to the residents.
  • To reduce sickness rate of residents , which caused by air pollution.

The results of emission analyse that is conducted by Monitoring and Controlling Department of the Capital Air Quality Bureau in 13th of December 2014 is shown below.

Parameters g/kg MNS 5216-1:2011 Standard limits For coal gas fuel of Grand Power In comparison with the standard
NOₓ emission no standards
CO emission 10g/MJ 0,23g/MJ 43 times lower
SO₂ and H₂S emissions Up to 2g/kg 1,78g/kg 1,1 times lower

Table 1. The toxic gas contents in the flue gas that produced from coal gas combustion

From the above table, CO emissions in flue gas during coal gas combustion is 43 times lower and sulfuric oxide emission is 1.1 times lower than the standard limits. In the UB city, heating only boilers and ger district’s stoves produce much more emissions than standards.

Project Location

The pipeline starts from territory of 32nd khoroo of Songinokhairkhan District and continues at 22nd khoroo of same district. The figure below shows location of the project.

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In the scope of the project, enterprises that marked yellow on the figure would be supplied by coal gas, and enterprises that marked green are available to be supplied easily, if the capacity of Coal Gas Plant was extended. Gas pipeline is installed across to the flood protection dam. It crosses central paved road one time and railway 2 times.

Strengths of the project

The Coal Gas Plant has an annual capacity of 20 million cubic meters of gas. Currently, the plant is providing gas to only heat only boilers of Grand baishin LLC. It means that it’s using 25% of production amount. There are no customers that have constant operations around the plant area. A Clean Air foundation has supported private sectors that work to reduce UB air pollution and has assisted to put 3.5km long gas transmission pipeline until public enterprises with constant operations during heating seasons. It is contributed a lot to introduce advantages of gas fuel, to increase the gas consumption and so forth to reduce an air pollution. The Coal Gas Plant enables following advantages for the project.

  • Lower investment
  • Experienced and skillful labors
  • Steady operation

Project legal environment and safety issues

There are several laws, standards and norms on gas application and supply. In example:

  • Law on Crude Oil Products
  • Law on Energy
  • Law on Construction
  • “Gas Supply” Construction Code 42-01-04
  • “ Erection of Gas Supply” Construction Code 42-02-04
  • Regulation of technical applications for Gas Enterprises
  • Safety Codes for Gas Enterprises
  • “General Planning of Industrial building” Construction Code 30-02-07

In terms of the project safety, a project owner has to develop an Operation Manual on gas distribution, Safety Codes and Manual on gas application as well as on Monitoring and Controlling progress of pipeline system. Product Sales Contract should be made with customers.

Technology Description

Coal gas plant has a two-stage coal gasifier from China. The gasifier has flexible operation to gasify all kind of coal; flexible feed coal consumption, 5% more productivity than one stage gasifier and hasn’t got any phenol waste. Its producer gas has a heating value more than 5800kJ/m³. The gasifier type is fixed-bed, air and steam mixture blown. It has an ash discharger and a steam jacket.

Parameters Unit Amount
Diameter of furnace mm 2000
Particle size of combustion material mm 20–40, 25–50, 30-60
Consumption of combustion material kg/hr 800-900
Coal gas production m3/hr 2500-2800
Coal heating value (minimum) HHV kJ/m³ 7000
LHV kJ/m³ 5300
Mixed kJ/m³ 6400
Output temperature of furnace Upper stage °С 90-150
Lower stage °С 400-550
Output pressure of furnace Upper stage Pa 2000-3700
Lower stage Pa 2000-4000
Lower aeration pressure of furnace Па 6000
Air-steam mixture temperature °С 50-60
Heating area of steam jacket 13.9
Steam pressure of water jacket MPa 0.3
Steam amount of water jacket kg/hr 300
Type of combustion materials Lignite, sticky or non-sticky bituminous coal

Table 2. Technical specifications of coal gasifier

The “mixed gas gasifier” is manufactured under the patent of the Shanxi Institute of China. The average coal gas content is that СО: 20-25%, Н₂: 9-14%, СН₄: 1-4%, СО₂: 5-10%, О₂<0.8%.

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The plant has 1 set of gasifier, dust cyclone, air cooler, 2 sets of electric filters of coal tar, 2 sets of dryers, and 3000m³ gas container.

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In the frame of the project, 2 sets of HDSR200 type gas root blowers with capacity of 35kPa each are installed to transfer gas by pipeline. Gas sensor, automatic safety valve, and gas flowmeter is installed for protection of consumer.

CONSTRUCTION OF PRECAST CONCRETE FABRICATION PLANT

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Project objectives

The objective of the project is a turnkey construction of Precast Concrete Fabrication Plant with a capacity to manufacture 5 apartments, within 4 months on high quality level and testing for technology line.

Project location and accomplishment

The plant has an extruder machine with couple of 100m long rail bed that produces hollow core roof slabs, railway sweeper machine, vibrating tilting tables for concrete walls, folds of beams and girders, concrete mixing plant, concrete distributing machines, and individual heat supply system. The complete plant is procured from Weiler Company, Germany. Our engineering team installed all equipment, constructed plant buildings, and tested operations.

Project Achievements

In the results of the project, our company has acquired many experiences of the project management and turnkey construction. Moreover, heating supply of the plant was coal gas, which gave us more opportunity to practice on coal gasification technology, and to make different tests. The coal gas heating has advantages of high thermal efficiency and low consumption of raw coal.

ASSEMBLY OF ELECTRICAL SHOVEL EXCAVATOR
HR495

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Project Objectives

Our engineering team has assembled 2 sets of electrical shovel excavators HR495, which are 20.1m high, 1300tons of weight, 3300kW of installed capacity, 61.2m³ of bucket volume that is supplied to Oyu Tolgoi project from Bucyrus Asia LLC.

Project location and accomplishment

This excavator assembly project was implemented under the supervision of experts of Bucyrus Asia Company. GP team with 22 members that comprises of 10 mechanics, 5 welders, 5 electricians, and 2 english translators, and has assembled those 2 excavators with 108 days by 28/14 shifts.

Project Achievements

The most useful practice during the assembling work was that our welders made perfect welding that satisfied international high standards and granted by certificates of international level welders. Significantly, we approved that Mongolian company can assemble excavator professionally on time and on internationally high standard level.

Further development

During the assembly work, we noticed that Mongolian engineers have knowledge and experience with same level of international experts. So that our engineering team is working on to build own designed excavator with good operation functions, combining Russian cheap excavator body with modern western excavator monitoring systems. Consequently, we deliver you several maintenance services of excavators in professional high level.

COAL HANDLING PLANT

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Project Objectives

Our company exlusively constructed Coal Handling Plant with annual capacity 9.6 million tons of ROM coal. The main objective was either to perform construction and installation services within scope, time and budget, or within international level of quality and complying health and environmental safety standards.

Project location and accomplishment

The project client was Ovoot tolgoi coal mine that owned by Southgobi Sands LLC of Canada and the project management enterprise was Ausenco Taggart LLC of USA and Australia and GP was constructed plant building, installed all equipment, made civil structure mechainical piping and electrical connection, and tested and commissioned whole plant. The Coal Handling Plant locates in Gurvantes village, Umnogobi Province.

Technology Description

Run-of-mine coal is loaded to the coalbunker. From bunker, it goes to belt conveyor with 90m lengths and 2m widths through plate feeder. Further it goes to rotary breaker with hourly capacity of 2000tons and breaks into smaller fraction lower than 50mm and separates from other solid wastes and stones. 2 different mobile stacker conveyors are used to load fraction coal and waste stones out.

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Project Achievements

That we completed firmly the project in time, gave positive perception to the foreign companies about Mongolian company operation and management. Accordingly, it enabled us to receive many cooperation proposals from them. Moreover, in the results of close cooperation with foreign professional project management company and other experts, our engineers and technicians learned lessons to manage projects, to strictly comply health and safety regulations.

Summary

The project was a Coal Handling Plant project with 3 stages of development. Due to shortage of finance, the first stage of the project is only constructed. However, the rotary breaker that was built in the project first stage beneficiates coal within 70% efficiency and breaks it until 50mm. The Ausenco Taggart company showed us great examples of project planning, implementation and communication of the world big project management company.

LIGNITE DRYING PLANT AND 2 KM LONG BELT CONVEYOR

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Project Objectives

The objectives of the lignite drying and transfer dried lignite by belt conveyor in 2 km are listed below.

  • To increase value of coal, reducing moisture content of the Shivee-Ovoo lignite and accordingly increasing calorific value of coal from 2800 to 3500 kcal per kilogram.
  • To decrease conventional coal drying expenses of throwing method.
  • To solve coal-freezing problem, during transportation in wintertime.
  • To save coal transportation cost in the field of coal mine.

Project location and accomplishment

Lignite drying plant locates in the Shivee-Ovoo coalmine. 2km long conveyor was been put from the Lignite Drying Plant to the coal unloading station straightly. GP made Screening Analysis and Feasibility Study of the Lignite Drying Plant, constructed plant building, and installed the belt conveyor. Total investment cost of the project is 6 billion MNT. Investment return period is 1.3 years.

Technology Description

Main drying furnace type of the plant is rotating furnace that reduces moisture of the lignite by hot flue gas of coal combustion. The chosen technology is much simple and low investment required in comparison wth steam drying one. The drying furnace could reduce coal external moisture from 40% to 20% of content, but it will exceed from the requirement limit of the main customer “Power Plants”. As such, we selected a regime to reduce coal moisture only by 10%.

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Flue gas from fluidized bed coal combustion boiler passes through rotating drying furnace and saturates coal moisture, further goes to the cyclones to be cleaned from dusts and blows out from the chimney. Belt conveyor transfers coal dust from the bottom of cyclone to the product coal pile. The dried coal is transferred by 2 km long belt conveyor and is piled in the end by stacker conveyors.

Project Achievement

On the behalf of the project, Shive-Ovoo coalmine saved 1billion MNT of transportation cost per year. The lignite sales cost increased along with the calorific value increase until 3500kcal/kg, as well as coal freezing problem while transportation is solved.

The long belt conveyor system decreased transporting cost 10 times. The design solution of the conveyor with cover that protects from desert vivid sun shining and strong wind and opening door for maintenance was really convenient to operate it. To make Screening Analysis of the drying technology, our engineers have met around 10 technology owner companies throughout 4 provinces of China. As such, learning lessons from the project has contributed to foreign communication expansion and knowledge fund of our company.

SMOKELESS FUEL (SEMI-COKE) PLANT

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Project Objectives

The objectives of the Smokeless Fuel Plant are below.

  • To increase fuel combustion efficiency of ger district residents and consequently to reduce toxic gas emissions from the raw coal combustion.
  • To create clean, fully combustable fuel with high calorific value.

Semi-coke has low content of volatile matter, and its consumption is much lower than coal due to high calorific value, so that it is called “Smokeless fuel”.

Project location and accomplishment

In 2008, GP built Smokeless Fuel Plant in the industrial zone of Darkhan city for Sharyn Gol Energy LLC. In that plant, 30 operators work in 3 shifts. We conducted screening analysis of the technology and feasibility study furthermore was responsible for equipment procurement and testing.

Technology description

Raw bituminous coal is crushed by jaw crusher, and coal fraction between 10 to 50mm goes to the semi-coking furnace. The furnace reaction temperature is 200 to 3500C. Coal syngas from semi-coking furnace is cooled by air cooler, is separated from coal tar and sulfuric gas by 2 sets of electric filters and desulfurizer tower. Such cleaned gas is suitable to transfer through pipeline in long distance or to produce electricity in gas engine.

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Semi-coke from the bottom of the furnace falls down into cooling water, passes through semi-coke dispatcher and comes to the product pile. The smokeless fuel with fraction bigger than 10mm is packed directly, while semi-coke with fraction lower than 10mm is loaded into mill and afterwards it is mixed with binder in the mixer and is pressed tight in oval shape.

The raw bituminous coal of Sharyn Gol coal mine with 4500kcal/kg converts to semi-coke with calorific value of 6500kcal/kg, and coal syngas with calorific value of 1700kcal/m³. 10kg of coal tar is produced from 1ton of raw coal and it is used as mazut in power plants.

Project Achievements

Core achievement of the project was in that we approved the semi-coke fuel could reduce significantly incomplete combustion of fuel and reduce visual smoke of the combustion. By the results of air quality analysis of Air Quality Bureau, CO content is reduced by 80%, SO₂ content is reduced by 50% in flue gas in comparison with standards of emissions.

Ger district residents were contented dust free clean coal briquette, and were used to use such fuel in their conventional stove. Consequently, several private entities have built Smokeless Fuel Plants and have processed related standards.

COAL GAS PLANT

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Project Objectives

The Coal Gas Plant project of GP has following objectives.

  • Penetrate coal gasification technology to the Mongolia
  • Introduce advantages of coal gas
  • Create individual Energy System to the small remote towns and villages
  • Conduct research of gasification process on all kinds of Mongolian coal.

In 2005, the first Coal Gas Plant with 200kWh capacity in Mongolia was built in cooperation with Energy Research and Development Center of the Ministry of Energy.

Project Location and Accomplishment

The first Coal Gas Plant was commissioned and tested successfully in 2005-2006 and was relocated to Bukhmuron soum, Uvs Province in 2006-2007. The Plant operation was tested 5000hours in Ulaanbaatar and was conducted gasification tests on 10 deposits’coal. The project was built in cooperation with Shanxi Coal Institute of China, and in support of Energy Research and Development Center.

Technology Description

The Coal Gas Plant has Lurgi fixed-bed gasifier, coal gas cooling tower, electric filter that filters coal tar from syngas, desulfurizers, gas electric generator and heat exchamger that exchange heat of flue gas. Firstly, screen raw coal and feed 15-50mm bulk coal to the through coal feeder with 2 valves with specific amount.

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Coal is gasified through zones of baking, pyrolizing, burning in the gasifier and is carried out in ash zone finally. Inner temperature of the gasifiying process is 3000C to 5000C. During gasification process, steam and air mixture is blown appropriately to set regime of gasifier contant. Syngas from the gasifier is chilled out in the water-cooling tower, is cleaned from coal tar in electric filter and separated from sulfur in the desulfurizer towers.

Gas compressor that located between of gas cleaning section regulates the gas pressure into gas generator. The 2 sets of gas generators with 100kWh capacity each, are designed specially for low calrofic value gas. The heat exchanget that is installed in the flue gas of those generators produces 50kWh heat and provides inner consumption of the plant.

Project Achievements

The project achieved many results such as replaced expensive diesel fuel sources by local cheap coal, renovated local diesel stations that run with the Government subsidy by a local plant that operates by own resources, created 15 work positions, and introduced advantages of provding heat by gas etc. The plant has 5 times less expenses than diesel station and it has possibility to return the original investment in 5 years.

The Coal Gas Plant is the best solution of power supply for small remote towns and villages with coal deposits. The project saves hundreds of kilometer electricity transmission lines to connect those villages with Central Energy System and produces much cheaper energy than conventional diesel fueled stations. Consequently, the coal gas plant has tremendous social benefits that giving opportunity to develop other small industries of bitum, bricks, and metal processing and to have employed in the country for the local residients.

Lessons Learned

The most difficult issue during project implementation was training of local people as operators. We were prepared 20 youngest of Altai soum, Gobi Altai Province and trained them during 6 months. However, the location of the project is changed suddenly, so it was big challenge for us to prepare new people within short period. Especially, the Bukhmuron soum hasn’t got any coalmines and industries, so no any local labors had got experienced in such fields.

The project has contributed a lot to our company knowledge resources and has enabled to develop further on Coal Processing Industry that understanding principle of coal gasification and main and byproduct product applications, realizing coal gas advantages, practicing during 2 years on the coal gasifier operation, and learning lessons from foreign professionals.

WIND POWER STATION
100 KWH

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Since the investment cost of the brand new wind power plant is extremely high, the company Avtor introduced a project of second-hand wind turbines from developed countries that dismantled to increase unit capacity. Our company installed this wind power station of 100 kWh from Germany in Erdenetsagaan soum, Sukhbaatar Province.

Project Description

Erdenetsagaan soum, Sukhbaatar Province was not connected to the Central Energy System and was produced electricity from diesel station with installed capacity of 3x100 kWh by 343 MNT per kW. This soum has around 430 households. Erdenetsagaan soum relates to windy zone, since the windy days of Erdenetsagaan soum were 233 to 360 days per year, the strongest speed of wind was 24 m/s, and the average wind speed was 5.1 m/s.

Wind Power Station is consists of wind electricity turbine that generates electricity; battery storage that saves electricity and distributing facility that transfers electricity to the end consumers. Asynchronous generator starts to rotate by the force of turbine rotation when wind speed teaches at 3m/s. When generator rotations are reached to specific numbers, the frequency converter of generator activates asynchronous generator and wind generator starts to produce electricity. The driving force of the wind turbine generator “wind” is renewable energy of nature, so that this technology hasn’t got any reverse affects in the environment.

Project Achievements

Since the commissioning date of the Erdenetsagaan Wind Power Station, our engineers fixed some technical problems due to shortage of professional local operators once. Henceforth, it had been running reliably many years. The wind power station had been produced 700,000 kW of electricity per year that was provided 50% of the soum. In terms of Erdenetsagaaan soum is connected to the Eastern Electricity System, it stopped to be used in 2008. The residents of soum weren’t feeling good that it was supplied only half of electricity demands of the soum; it saved 3 years’ diesel fuel consumption of the soum that totals 330 million MNT.

Summary

Mongolia can be named a Wind country, since 70% of our country territory is windy with speed at least 5 to 6m/s. Even the most of towns and villages of Mongolia connected to Energy System with high voltage transmission lines, energy resource is still not enough to provide all. Also there are hundreds of coalmine towns, tourist camps that use diesel generators as sole power resource.

That renewable energy is the best environmental friendly technology is accepted globally and developed countries have policy to shift existing energy resources into renewable energy. It’s unfortunate that Erdenetsagaan soum didn’t realize economical and environmental benefits of renewable energy resources and run the Wind Power Station simultaneously, even it is connected to Central Energy System.

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Our company operates in several sectors of Mining, Mineral Processing, Power Generation, Installation and Supply of energy facilities, Installation and Adjustment of Technology Equipment, Construction of Infrastructure and Industrial Building, and Consulting Services.