Presented By : ETE s Date: 09-08-10

Ash
y Fly Ash & Bottom Ash y Fuel, combustion methods,

flue gas treatments and boiler designs y Fly Ash composition:

Some Statistics
y Hourly consumption of ash is 33 tons. y The most common types of ash include bottom ash

(30-40% in FBC) and fly ash (60-70% in FBC) resulting from the combustion y Less than 1% of ash produced y 65% of fly ash produced is disposed of in landfills and ash ponds y Area under ash in India: 160 km2
y Fly Ash reuse: y Bricks, Portland cement, Embankments and structural fill,Stabilization of soft soils, etc.

ASH HANDLING
y Method of collection, conveying, interim storage and

load out of various types of ash residue

y y

y Ash handling can be of two types

Dry Wet

y Fly ash handling can either be dry or wet y Bottom ash handling is generally wet until recently because of its higher particle size (around 25 mm ) y Fly ash can either be fine or course y Fine fly ash has particle size form 50 200 micron whereas coarse fly ash has particle size greater than 200 micron .

BOTTOM ASH HANDLING

BOTTOM ASH HANDLING SYSTEMS
WATER IMPOUNDED HOPPER SUBMERGED SCRAPER CONVEYOR

DRY BOTTOM ASH SYSTEMS

WET DISPOSAL

WET DISPOSAL

DRY COLLECTION

WATER IMPOUNDED HOPPER

y Old process y Huge water consumption y Receives, quenches,

stores crushes and remove bottom ash y Ash is discharged once in 6 to 8 hours y Clinker grinder is situated below it

RECIRCULATION SYSTEM

BOTTOM ASH HANDLING-SSC

y SSC is placed

beneath

the furnace y Slurry is taken up to a de-watering slope before discharging y Water serves as cooling medium y Water also acts as airlock for ash hoppers to avoid air to enter the furnace

SSC contd.
y Reduced water usage y Reduced power

consumption y Reduced operational and maintenance cost

Dry bottom ash handling

y Water is not used y Increased boiler

efficiency y Reduced impurities in stack y Low maintenance cost and no water required

ADVANTAGES OF DRY HANDLING OVER SSC

FLY-ASH HANDLING

FLY-ASH HANDLING
FLY ASH SYSTEMS

PRESSURE CONVEYING SYSTEM

VACUUM SYSTEM

DENSE PHASE

DILUTE PHASE

DILUTE PHASE

PRESSURE SYSTEM

OPERATING PRESSURE IS 5 Kg/cm2

VACUUM SYSTEM

OPERATING PRESSURE IS 530mm

COMBINED PRESSURE AND VACUUM SYSTEM

Comparison

Dilute Phase
y Both vacuum & pressure

pneumatic systems y High velocity y low ash - to - air ratio

Dense phase
y Pneumatic pressure

system conveying dense ash y Low velocity y High ash concentration y Less energy due to its smaller amount of conveying air

GENERAL DESIGN ASPECTS

y Boiler design and configuration y Disposal conditions y Water availability y Type of coal y Design capacity

ASH DISPOSAL SYSTEM

S.I. NO 1. ALTERNATIVE Lean Slurry Disposal System(LSDS) MERITS Silo area layout is simple Cheaper Less water consumption Less disposal area is required DEMERITS Large quantity of water required Civil cost is high Requires more space near silo

2.

High Concentration Slurry Disposal System(HCSDS)

High Concentration Slurry Disposal (HCSD)

y Controlled and monitored

feeding for fly ash and bottom ash y Agitator Retention Tank (ART). y Carbon steel pipelines y Higher concentration of about 60%

Advantages
y Ash spreads in layers enabling vertical filling, hence y y y y y y

land requirement is reduced. Pumping at higher concentration, hence low water consumption. Slurry flow rate is drastically reduced. Literally no water releases out, hence no water retaining dams or recovery system is required. Reduced leaches at the ash disposal area. Lower operating power consumption. Lower velocity, hence longer life for pipe line.

FLY ASH DISPOSAL SYSTEMS

Landfill: big bags

Embankment: ash placement

Embankment: top liner

Foundation: asphalt cover

Landfill: cover soil removed

Workshop Implementation of the Landfill Directive, 15th May 2009, Tallinn, Estonia

Ash Bricks

ASH PONDS

SLURRY DISOPOSAL AND ASH WATER RECOVERY SYSTEM

HOPPER SLURRY PUMP SETTLING POND STILLING POND VERTICAL TURBINE PUMP CLARIFLOCULATOR

ASH WATER TANK

ASH STORAGE SILOS

The Ash coming out of the unloading chute is transferred to waiting trucks for various uses

ADVANTAGES OF SILO SYSTEM

y Commercial utilization of ash in :

Cement additives. Brick plants. Road making, etc. y Saving of water a precious commodity. y High reliability y Least maintenance

Contd .
y Environment concern:

In a period, when environmental protection and awareness is a major industrial and social concern, Dense Phase pneumatic conveying, by totally enclosed handling system, is particularly amenable to the environment. All conventional problems of spillage, dust, contamination and storage are efficiently and successfully eradicated.

ASH GATE & HOUSING

The Ash Gate and Housing installed below the bottom ash storage hopper. It controls the discharge from the storage hoppers. The gate operation is controlled hydraulically, providing a smooth operation when opening and tight seating when closed.

CLINKER GRINDER
y Coarse bottom ash or

other coarsely sized material y Reduce size for pneumatic conveyance or other means of ash handling.

CYCLONES
y Centrifugal ash receiver y Top of a silo or storage hopper y The gases after reaching the end of the conical portion changes its direction and moves upwards towards the outlet forming an inner vertex. y Control high concentration.

PULSE JET DUST COLLECTORS

y Receives the overflow airstream

from the ash receiver y Collects ash particulates on the surface of multiple fiber bags y Clean (filtered) air overflows the top of the dust collector, passing to the atmosphere or other processing.

ASH CONDITIONERS
y The ash conditioner is a totally

enclosed, paddle type mixer designed to condition fly ash, bottom ash, and other abrasive or dusty materials. y The unit (coupled with a rotary feeder) features the ability to accurately control both the material feed rate and the water supply flow rate, as well as ensure a complete and controlled mixing prior to discharge.

SLURRY PUMPS
y The slurry solution is pumped using it

to land fill or transported to a slurry to lagoon for storage/disposal.

y Agitator pumps deliver kinetic energy

(energy of motion) to slurry solids surrounding the pump intake, re-suspending them into a fluid state.
y The slurry may be subsequently used

for a number of applications such as in the building industry, for Cement and Block production

High Pressure Ash Jet Pumps

y High pressure ash jet pumps

are used to remove the clinker formed on the wall of furnace by supplying water jet.

y Jet pumps works on a venturi

principle. High pressure water delivered through the nozzle creates vacuum.

ASH UNLOADERS
y Telescopic Unloading Chute y A knife gate is fitted to the ash silo

bottom y Telescoping interlocking cones which are encapsulated by a fabric/elastomeric dust annulus y Induced air flow generated by a suction fan y Bag type pulse jet dust collector.

PIPELI E PRODUCTS
y Terminal Box : Used as a low profile

y y y

conveying pipeline termination to divert the material flow tangentially into the top of a silo / hopper. Standard size range to accommodate 50mm to 400mm diameter pipelines. Dump Valves : Used as a silo / hopper feeding valve within the conveying pipeline. Located on the silo / hopper roof it diverts the material flow into the top of a storage hopper / silo or in it's by-pass position allows the material flow to pass through to a second storage hopper / silo. The sleeve design of Valves auto cleans with every cycle of operation on the gate or valve port because the sleeve will flex to allow grits and solids to pass through .

Valves and Bends

y Switch Valve y To connect pipelines together either y y y y y

in converging or diverging configurations. The most commonly used for the Power Industry is the Dome Switch Valve Bends Size range 50mm to 400mm diameter pipelines Cast Ni-hard, Grade 250 iron or basalt-lined mild steel bends are used. For very abrasive slurries alumina ceramic-lined mild steel bends are used

PIPES
y Pipe : Standard Size range 50mm to 400mm diameter

pipelines. y Conveying Pipeline : Seamed mild steel pipe work (BS1387; BS3601; DIN2441/8; ANSI 836.1 standard pipe or equivalent) to construct the straight pipe sections . For long straight sections the pipeline is usually constructed by welded joints using 6-12 meter random pipe lengths depending on availability.

Requirement of BOPs During 11th Plan

No. of Vendors In our Country