Case: Design of an alternative conveyor (Screw Conveyer) to remove fly ash in an emergency

blockage on existing air ash conveyor system at Electro Static Precipitators at Lakvijaya Power
Station

Background
The Lakvijaya Power Station is the largest power station in Sri Lanka, that has capacity of supplying
900MW power to the national grid and it is about 50% of the total power requirement of the
country.
Boiler is the most basic energy transformation device among the three (Boiler, Turbine and
Generator) main devices in the power station. Its function is heating feed water by utilizing the heat
energy released by the coal combustion in the furnace, generating the steam complying with the
stipulated parameters and sending the steam to turbine to work. The boiler mainly consists of boiler
body and auxiliary Systems.
Ash handling System is a major auxiliary system that consists of Bottom ash handling, Fly ash
handling and Pyrites Handling systems.

Fly Ash Handling Systems

Fly ash handling system is started from Electro Static Precipitator (ESP). main function of the ESP is
grabbing of the ash particle from flue gas and convey to ash silo to accumulate.

Problem Identification
Most of the time ash conveying system which is operated with compressed air is getting block, Due
to some sluggish property of the fly ash. When the conveyor system is not working properly, fly ash
is accumulated at hoppers (around 100 tons). Then they have to be discharged and clean the ash
hoppers and conveying system by manually.
Following problems were identified during manual discharged of the ash to the open area
1. Ash dust is getting spread all over the area when it is discharging from the hopper(there
were some complain from villages regarding fly ash)
2. It course contamination of the motors, oil stations, electrical panels and instruments
3. Ash dust is hazardous for human beings

Design Constrain
Proposed conveyor system should be very simple and light weight, because this system is operated
frequently, and they should not disturb the other operation and maintenance works of the existing
system.

Project outcome
Design and construct a screw conveyor (that can be installed quickly when required) to deliver fly
ash from ash hopper to dump truck as alternative way in emergency ash blockage at air ash
conveyor line.

Design Concept

R.N.P Rajapaksha
Lakvijaya Power Station
Ceylon Electricity Board
September 10, 2015