Presentation

to

ETEs 2015-16
Trends in Ash Handling Systems
Date: 3rd September 2015

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INDEX
Challenges of Ash Handling System
in India
Criteria for Selection of systems
Bottom Ash Handling
Fly Ash handling
Auxiliary System

CHALLENGES OF ASH
HANDLING SYSTEMS
IN INDIA
Highashcontent
Inconsistent Coal Properties
Systemhastobeenvironmentallyfri
endly.
Systemhastobereliablewithleast
maintenance problems.
Systemhastobeenergyefficient.

CRITERIA FOR SELECTION OF SYSTEM

Commercial Utility of Ash
Site Specific Limitations:
Facility Age
Physical Layout
Boiler Design
Water Availability

Ambient Conditions
Environmental Issues
Zero water discharge
Emission Regulations

Economic analysis

BOTTOM ASH HANDLING

EXISTING TECHNOLOGIES
WaterImpoundedBottomAshHoppe
rwith Jet Pump System
Lean Slurry Disposal System
Dewatering Bin System

BottomAshHopperwith submerged
scraper chain conveyor system

WATERIMPOUNDED BOTTOMASHHOPPER
WITH JET PUMP SYSTEM

LEAN SLURRY DISPOSAL SYSTEM

For disposal of ash slurry in dilute form, generated at various power plants and are still in demand.
Such systems comprise centrifugal slurry pumps for disposal and clarifloculator or tube settler for recovery of the water.

DE-WATERING BIN SYSTEM

It is used for bottom ash available in slurry form to be disposed off through trucks or through high
concentration slurry disposal system along with fly ash.
De-watering bins with the decanting system removes water from the bottom ash and this water can be
recycled through a set of settling tanks, surge tanks, transfer pumps, etc.
The bottom ash collected in the bin can be either periodically removed through trucks or can be fed to high
concentration slurry disposal system for disposal in paste form along with fly ash.

BOTTOMASHHOPPERWITH
SUBMERGED SCRAPER CHAIN
CONVEYOR SYSTEM

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Dry Bottom Ash Conveying

System Description

Advantages

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DRY BOTTOM ASH CONVEYING

SYSTEM DESCRIPTION
Unique system for dry extraction, air cooling and mechanical handling of
bottom ash from pulverized coal-fired boilers.
Ash cooling is carried out by ambient air, naturally drawn into the system by
the furnace negative pressure. That air recovers a significant amount of
energy in the form of ash sensible heat, ash chemical energy from unburned
particles and boiler radiation flux through the throat.
The dry cooling process has been proven to have no negative effects on the
main combustion. Thesystem,compared to conventional wet systems, can
improve the boiler efficiency by a factor in the range 0.1-0.6%.
Facilitates lower operation & maintenance costs

ADVANTAGES
The table below shows the main factors which compare
between the two methods of conveying:

FLY ASH HANDLING

TRADITIONAL TECHNOLOGIES
PNEUMATICCONVEYING

Vacuum Conveying
Pressure Conveying
Disadvantages of Conventional
Pressure Conveying
WET ASH CONVEYING

FlushingApparatusforFlyAsh
Lean Slurry Disposal System

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Image Courtesy: lbindustrial

systems

1. Sequential Extraction with Low Ash to Air Ratio

2. Continuous Power Consumption Points => Vacuum
Pump, Fluidizing System, Vent System
3. Redundancies & Line maintenances increase Conveying
Time/Power
ENERG
OPTIMIZING OPERATION SEQUENCES AND TUNING
O
SYSTEM DESIGNS CAN RESULT IN SIGNIFICANT
EXPERT
REDUCTION IN TIME/POWER !!!
ISE

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1. Continuous Power
Consumption Points =>
COMPRESSOR/BLOWER,
Fluidizing System, Vent
System
2. Redundancies & Line
maintenances increase
Time/Power
eamlining Flow, Multiple Air InjectionConveying
Practices
ENERG
Higher Material Conveying
O
esser Time/POWER
EXPERT
ISE

WET ASH SYSTEMS

ADVANTAGES
LESS DUST CREATION

ADVANTAGE
GH WATER & POWER REQUIREMENT
DDITIONAL REQUIREMENTS OF RECOVERY WATER SYST
ARGE AREAS FOR SLURRY DUMPING

ADVANCED TRENDS IN FLY ASH

HANDLING
By-Pass Pneumatic Conveying
Advantages

High Concentration Slurry Disposal

System
Economical Advantages
Ecological Advantages
Comparison (Positive Displacement
Pumps used in HCSD System Vs
Centrifugal Pumps)

BY-PASS PNEUMATIC CONVEYING

The most common by-pass systems employ a small pipe running
inside the conveying line, having fixed ports, or flutes, at regular
intervals along its length. An alternative arrangement is to have the
by-pass external to the conveying pipeline and connected to it at
intervals along the length.
The by-pass pipe allows air to be advanced to a point where it is
capable of splitting up the plug at the forward end and so allow
conveying to continue. As the by-pass pipe is much smaller in
diameter than the conveying pipeline, the air will be forced back
into the pipeline through subsequent flutes, and this will effect a
break-up of the plug of material causing the blockage. A long plug of
material is thus divided up into short slugs that are readily
conveyed.

REDUCED AIR CONSUMPTION INCREASED EFFICIENCY

ADVANTAGES
1. EnergyEfficient
2. Highreliability
3. LongPlantLife
4. Leastmaintenance
5. Environmentconcern:
Inaperiod,whenenvironmentalprotectionandawarenes
s is a major industrial and social concern,Dense Phase
pneumatic conveying, bytotally enclosed handling
system, Is particularlyamenable tothe environment.
Allconventionalproblems of spillage, dust, contamination
and storage are efficiently and successfully eradicated.
Planthousekeepingisgreatlyimproved.

HCSD SYSTEM
ECONOMICAL ADVANTAGES
Substantial energy savings to run system.
The volumes transported are smaller and pipeline sizes can be
reduced by more than 50%.
By discharging from a central ramp or side-hill, it is possible to
avoid raising perimeter dams altogether.
Theself-draining, sloping (2-6%) deposit offers long-term stability
and can be reclaimed progressively at minimum cost.
Significant cost savings in disposal area and dyke construction of
up to 60%.
Method allows for the creation of small hills by stacking the
disposed ash.
Extending life time of existing landfill area under restricted slurry
conditions.

HCSD SYSTEM
ECOLOGICAL ADVANTAGES
Water consumption: high concentration ash slurries
use up to a factor 12 less water than dilute slurries.
No or minimal contamination by water leaking to the
environment.
Pipeline transportation is safe, silent and reliable
without ash spills.
No or minimal run-off water and water reclaim system
capacity.
Thickened ash is not subject to run-out.
Dusting is substantially reduced.
Slurry hardens out allowing rehabilitation.

COMPARISON

Positive Displacement Pump

Centrifugal Pumps

AUXILIARY SYSTEM
Compressor Optimization
High Capacity compressor unit to
accommodate for air requirement of
entire plant, with medium/low capacity
stand-by compressors for instantaneous
requirement, to optimize air supply.

TOPICS FOR PRESENTATION

1. Traditional Bottom Ash Technologies (Covering the entire
process and various types)
2. Latest Trends in Bottom Ash Handling Systems (Covering
the entire process and various types)
3. Vacuum Based Fly Ash handling Systems (Covering the
entire process)
4. Pneumatic Conveying Systems (Lean and Dense)
5. Latest Trends in Pneumatic Conveying Systems (Pipe in
Pipe & Molar, Pipe Over Pipe)
6. Silo Systems and Unloading Systems to Barge & Train with
multiple discharge points
7. Water Pumping Systems, Slurry Pumping System & HCSD
Systems (Covering the Operational Philosophy)

 THANK YOU !!!