Location: Maidsville, WV

Services: Multidiscipline Design and Supply


Gypsum and Limestone Handling System Design-Supply

River Consulting provided complete multidiscipline design-supply for a new gypsum and limestone handling system and associated storage at the Longview power plant in Maidsville, WV.

The project scope provided the necessary material handling systems for the new FGD system being supplied by Siemens Energy. Design included providing not only initial through final design for shop fabrication but also providing 3D layouts and custom design utilizing SolidWorks. Both the belt tripper and gypsum shuttle conveyor were custom designed, detailed for fabrication and supplied solely by the River Consulting team.

The supplied handling systems allow for limestone to be trucked into the site for building storage for later reclaim or direct feed to the day silo conveyor. The limestone system was designed to comply with plant air permits requiring dust suppression at the indoor storage pile and all limestone transfer points. The gypsum conveyor was designed with deck plates with all chutes requiring UHMW polymer lining for material flow.

River Consulting provided a superior handling system package to the client with successful start-ups and material throughput for both limestone and the specified gypsum material.


  • 1,070 feet of limestone belt conveyor and 105 feet of gypsum shuttle belt conveyor
  • Gypsum conveyor was a specially designed shuttle belt conveyor
  • Limestone feed rate was 150 tph to feed day silo
  • Gypsum feed rate was 88 tph of 20% max moisture material
  • 20 foot long belt feeder for limestone to day silo feed conveyor and 38 foot long belt feeder to bucket elevator
  • Supplied storage building able to hold 14,000 tons of limestone
  • Gypsum shuttle belt was designed to travel 21 feet to build a 32,240 CUFT pile in a very restricted area with provision for three days of storage
  • Electrical operation and safety switches including positioning switches with associated conveyors and equipment
  • Necessary shop surveillance including weekly visits during milestone deliverable time frames to help enforce quality and schedule compliance
  • Provided post construction commissioning service system walkdowns and punch list generation