Crane Selection for Thermal Power Plants: Boiler & Coal Handling
Summary: Kelude Heavy Industry provides crane configuration solutions for thermal power plants, covering hoisting and maintenance operations across the boiler, turbine, desulfurization, and coal handling areas. These solutions accommodate lifting capacities from 5 to 100 tons and spans from 12 to 36 meters, with a total crane equipment investment of approximately $75,000 to $750,000. The boiler area is equipped with a heat-resistant double-girder bridge crane (20–50t), the turbine area with a QD type double-girder bridge crane (50–100t), the desulfurization area with a corrosion-resistant bridge crane (10–20t), and the coal handling area with an explosion-proof crane (5–16t). This setup fulfills the full-process lifting requirements of a coal-fired power plant—from fuel supply to power generation—as well as construction lifting needs during environmental retrofits.
Crane Selection for Thermal Power Plants
Boiler Area | Turbine Area | Desulfurization Area | Coal Handling Area
Thermal power plants are prime environments for industrial cranes. Each operational area presents distinct technical demands—from heat-resistant lifting in the boiler section to heavy-load precision installation in the turbine hall, from corrosion-resistant handling in the desulfurization unit to lightweight, dust-tolerant operations in the coal yard. With 15 years of expertise in lifting equipment, Kelude Heavy Industry delivers a tailored crane selection scheme for every zone, ensuring each unit is precisely matched to its operating conditions.
Scenario 1: Boiler Area
• Lifting capacity 5t–32t, LH type explosion-proof hoist bridge crane
• Designed for high-temperature environments above 80°C in the furnace front zone
• Dustproof rating IP54 or higher, with coal dust explosion-proof configuration
• Work duty A5~A6, suited for frequent start-stop cycles
• Dual operation: remote control + operator cabin
• Kelude Heavy Industry offers a heat-resistant protection upgrade package for the furnace front area
Heat-Resistant 80°C+ | Explosion-Proof | Dual Control
Scenario 2: Turbine Area
• Lifting capacity 20t–100t, QD type double-girder bridge crane
• Work duty A5~A7, meeting heavy-load lifting standards
• Variable Frequency Drive (VFD) with inching for precise control
• Optional double lifting points / upending function
• Specifically for steam turbine / generator installation and maintenance
• Kelude Heavy Industry equips with Anti-Sway System + precise positioning system
Large Tonnage 20–100t | VFD Inching | Anti-Sway System
Scenario 3: Desulfurization Area
• Lifting capacity 3t–16t, MH type gantry crane / electric hoist
• Corrosion protection level C4–C5, resistant to acid and alkali
• Outdoor operation with wind protection device
• Moisture-proof motor with IP55 protection
• Stainless steel wire rope option available
• Kelude Heavy Industry provides a full stainless steel anti-corrosion upgrade solution
Anti-Corrosion C4–C5 | Outdoor Wind Protection | Stainless Steel Wire Rope
Scenario 4: Coal Handling Area
• Lifting capacity 5t–16t, explosion-proof crane
• Dust-proof design for coal dust environments
• IP55 protection rating
• Variable Frequency Speed Control for smooth operation
• Remote control operation
• Kelude Heavy Industry offers a dust-proof upgrade package
Dust-Proof | Explosion-Proof | VFD
• Lifting Capacity 2t–10t, LD type single girder / jib crane
• Dusty Environment Service with IP54 or higher guards
• Designed for coal dust explosion-proof requirements
• Frequent start-stop and inching operation
• Remote control operation from ground level — compact and lightweight
• Kelude provides coal dust explosion-proof certification
Dust explosion-proof | Lightweight & efficient | Ground remote control
Selection Parameters Comparison Across Four Zones
| Parameter Item | Boiler Area | Turbine Area | Desulfurization Area | Coal Handling Area |
|---|---|---|---|---|
| recommended model | LH Type Explosion-Proof Hoistoverhead type | QD Typedouble-girder bridge crane | MH type gantry crane/Electric Hoist | LD type single girder/jib crane |
| lifting capacity range | 5t~32t | 20t~100t | 3t~16t | 2t~10t |
| Work Duty / Classification | A5~A6 | A5~A7 | A4~A5 | A4~A5 |
| special requirements | High Temperature Resistant80℃+ | variable frequency inching/anti-sway control | Anti-corrosion C4~C5 | dust explosion-proof |
| control mode | remote control+Operator Cabin | remote control+Operator Cabin | remote control/Floor | Floorremote control |
| Kelude Advantage | heat-resistantguards Upgrade Package | Precisionpositioning system | stainless steel anti-corrosion Solution | Dust Certification Adaptation |
Boiler Area Crane Selection: Heat Resistance & Explosion Protection
The boiler area is the hottest and most demanding crane duty zone in a thermal power plant. Ambient temperatures around the furnace front frequently exceed 80°C, and heavy coal dust exposure places extreme demands on heat resistance, explosion protection, and sealing integrity. The LH-type explosion-proof hoist bridge crane is the preferred solution for this zone, with a lifting capacity range of 5 t to 32 t and work duty classification A5–A6 to handle the frequent start-stop cycles of pulverizer maintenance, grate replacement, and dust collector servicing. Kelude equips boiler-area cranes with a heat-resistant protection package that includes high-temperature resistant motors, heat-resistant cables, and a thermally insulated operator's cab, ensuring reliable long-term operation in high-temperature, dust-laden environments.
Turbine Hall: Precision Lifting for Heavy Rotating Equipment
The turbine hall is the core power generation zone of a thermal plant, requiring installation and maintenance lifting for large precision components such as steam turbines and generators. The QD-type double-girder bridge crane—with its high lifting capacity (20 t–100 t), heavy-duty classification (A5–A7), and variable-frequency speed control for micro-motion—has become the standard configuration in this area. Kelude equips turbine-hall cranes with an anti-sway system and precision positioning devices, enabling millimeter-level alignment of heavy equipment during installation. This significantly reduces the risk of component collision and shortens maintenance downtime.
Corrosion & Dust Explosion Protection for FGD and Coal Handling
Flue gas desulfurization (FGD) equipment is subject to severe acid and alkali corrosion. MH-type gantry cranes and electric hoists in this zone require surface treatment rated C4–C5 corrosion protection, moisture-proof motors, and stainless steel wire rope to achieve a reasonable service life in wet FGD environments. In coal handling areas, dust explosion protection is the top priority. LD-type single-girder bridge cranes are fitted with dust explosion-proof certified electrical systems and hermetic motors, combined with radio remote control operation, delivering a simple and flexible lifting solution for coal yard and conveyor belt maintenance. Kelude can issue a unified crane configuration plan across all plant zones—one brand, one maintenance contract, and a lower total lifecycle cost.
Why Power Plants Choose Kelude for Crane Solutions
FAQ
Q: Why do cranes in the boiler area of a thermal power plant need to be high-temperature resistant?
A: Temperatures in front of the boiler typically exceed 80°C. Under such conditions, the insulation materials in standard crane motors and cables age rapidly, which can lead to insulation breakdown and motor burnout in severe cases. Kelude Heavy Industry's heat-resistant protection upgrade package uses Class H insulated motors (rated for 180°C) and heat-resistant silicone rubber cables, ensuring reliable long-term operation in 80°C+ environments.
Q: What lifting capacity is required for cranes in the turbine hall of a thermal power plant?
A: The required lifting capacity depends on the heaviest single component of the steam turbine or generator. For small-to-medium power plants (300 MW class), turbine rotors typically weigh between 20 t and 40 t, making a QD type 32 t or 50 t overhead crane sufficient. For large plants (600 MW–1000 MW class), a QD type 75 t to 100 t overhead crane is required. Kelude Heavy Industry recommends sizing the crane with a 1.25× safety margin based on the heaviest component, leaving room for future expansion.
Q: What corrosion protection level should be selected for cranes in desulfurization areas?
A: Due to the corrosive acid-base environment in desulfurization zones, the minimum corrosion protection level for cranes is C4 (high-corrosivity industrial environment). Kelude Heavy Industry recommends a C5-grade anti-corrosion coating system with three layers of protection: hot-dip galvanizing, epoxy zinc-rich primer, and polyurethane topcoat. Wire ropes should be made of 316 stainless steel, and motors should have an IP55 or higher protection rating.
Q: What special requirements apply to cranes in the coal handling area of a thermal power plant?
A: The primary risk in coal handling areas is coal dust explosion. All electrical equipment on the crane must meet dust explosion-proof requirements (Ex tb IIIC T120°C). Kelude Heavy Industry's dust explosion-proof adaptation package includes hermetic motors, explosion-proof electrical control boxes, explosion-proof remote controls, and grounding carbon brushes, along with a dust concentration monitoring system that automatically shuts down the crane when triggered.
