Ash Handling System

What are the types of Ash in Thermal Power Plant ?

Bottom Ash

Fly Ash
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Bottom Ash
The ash which is directly collected from

bottom of boiler.

Bottom ash directly falls down in water

filled bottom due to gravity.

Bottom ash is 20% of total ash.

Fly Ash
It is collected from :-

1-ESP hoppers 2-Air preheaters hoppers 3-Economiser hoppers

It is 80% of total ash.

Wet system
In this system ash conveying media is

water. It has two main component:1-Hydro-vactor 2-Hydro-ejector

Hydro-vactor
Working Principle:-

Hopper ash is directly sucked by vaccum, which is created by high water Jet (hydrovactor). This ash mix with water in collecting tank and finally slurry collects in slurry sump.

Hydro-ejector
Working Principle:-

High pressure water jet carries slurry from the bottom to slurry sump.

This system operates once in a day (24 hrs).

Final disposal of slurry

Finally slurry from slurry sump is

conveyed by pair of big centrifugal pumps to Ash ponds.

This slurry system is common

1-for D & E station 2-for C & F station

Fly Ash in Forestry

Ash pond No 1

Fly Ash in Forestry

Ash pond No 1

Fly Ash in Forestry

Ash pond No 2

Different Auxillaries in wet system (Fstation)

1-H.P. pump 3 Nos. 11 kg/cm2 2-L.P. pump 3 Nos. 6 kg/cm2 3-Ash slurry pump 3 Nos. in each path 2.5 kg/cm2 4-Air washer pump 2 Nos. 5 kg/cm2 5-Seal water pump 2 Nos. 18 kg/cm2

What is the need of dry system?

It has some good characteristics over

the wet system:1-Huge quantity of water is saved. 2-Power consumption is less. 3-Reduction in surface pollution. 4-Earning, by selling dry ash to cement factory & bricks manufacturer.

Components of dry system

K-pump P.D.pump Centac compressor Acher silo

K-pump
It is nothing but the combination of

silo,Transfer vessel,Dispencing vessel & Centrifugal compressor. D & E station has common K-pump C & F station has another common Kpump.

Working Principle of K- pump

It works on the principle of pressure

difference.

Its operation is sequential ,because

Dome Valves from DV-1 to DV-6 operate in sequence.

Acher Silo
Finally Dry ash is disposed to acher silo

which is located in AEC campus.

These are 2 in nos.

Each has capacity of 750 ton .

INTEGRATED FLY ASH HANDLING SYSTEM: (Schematic flow diagram)

Stage- I
C stn. Fly ash Hoppers
Exist. Recip Compr Compr. Fine Ash

30 TPH

C 1 Existing Silo (Cap:350 T)

Silo (New) 130 Cu.Mtr. ( 'C' stn)

F stn. Intm. Hopper

F stn. Fly ash Hoppers

(After rehibilitation)
Stage II CentrifugalCo mpr.

Stage-II
80 TPH

80 TPH

Stage I Centrifugal Compr.

Stage-I

Fine Ash

FINAL FLY ASH FINAL FLY ASH STORAGE SILO AT STORAGE SILO AT ACHER ACHER Capacity : 750 Cu.Mtr. Capacity : 750 Cu.Mtr.

Silo (New) 130 Cu.Mtr. ('D/E' stn)

D/E Exist. RCC Silo (Cap :450 T)

E stn. Fly ash Hoppers

D stn. Fly ash Hoppers

80 TPH
Stage I Centrifugal Compr.

80 TPH

Stage-II 80 TPH

Stage II Centrifugal Compr.

To final ash disposal area by closed tanker / truck

Loading of trucks & tankers at acher

There are 2 system of loading :-

1-For truck - water spray system 2-For tankers by gravity

Dry Ash unloading at Acher

Ash collection in closed tanker at Acher silo

Dry Ash unloading at Acher

Ash collection in closed tanker at Acher silo

Use of Fly Ash

For building construction
For Cement manufacturing For bricks manufacturing Ash customers:-

1-Gujrat ambuja cement 2-Binani cement, laxmi cement 3-GCL (RCC pipe mfg.)

Fly Ash used in Bldg. Mat.

Private Private Private Bungalow Gadhinagr

Fly Ash used in Bldg. Mat.

Ghodasar Shriji Complex

Construction

RCC road near D.M. Plant area

Construction

RCC road from Crusher house to Coal JN - M

Future strategies
Now a days we are using almost dry

system. In future our planning is to stop whole wet system except bottom ash which is only 20%. For loading trucks & tankers we are thinking about loading in night shift too.