DESCRIPTION OF ASH HANDLING SYSTEM

除灰系统说明

REV. DATE DESCRIPTION DESIGN CHECK REVIEW APPROVAL

PT.PLN(PERSERO) OWNER'S
DWG. NO.
PT.PLN(PERSERO)

JOB NO. E07007

除灰系统说明
 CONTENTS

目 录

1．DESIGN BASIS & MAIN DATA

设计依据及设计原始资料

2．MAIN PRINCIPLE

主要设计原则

3．SYSTEM DESCRIPION

系统概述

4．SYSTEM COMMISSIONING & OPERATION

系统调试及运行
1. Design basis & main data

1.1 Design basis

1.1.1 The contract signed by CECC and PLN.

1.1.2 Minutes of meetings.

1.1.3 Basic design approved documents.

1.1.4 The contract signed by CECC and SWEPDI.

1.1.5 Basic design documents.

1.1.6 Technical agreement.

1.2 Main Design data

1.2.1 data

(1) Boiler type : pulverized fuel boiler.

(2) Bottom ash discharge equipment: dry ash conveyor, 1 set for each

boiler.

(3) Precipitator: ESP with 4 fields and efficiency more than 99.5%.

(4) Fly ash quantity: Bottom ash quantity=90%:10%.

(5) Ash discharge point

ESP hopper 16 for each boiler

Eco. hopper 4 for each boiler

(6) 5 sets mills for each boiler, four in operation, one standby.

(7) Coal analysis and quantity

Description Symbol UNITS Average Range
Coal category Lignite
Moisture as received Mar % 30 25～35
Proximate Analysis

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 Moisture as Air dried basis Mad % 18 15~25
Ash as received Aar % 5 3~6
Volatile matter as received Var % 34.45 29.25~39
Volatile matter as dried free of ash
Vdaf % 53 45~60
basis
Gross Calorific Value Qgr.ar MJ/kg 19.19
Net Calorific Value Qnet.ar MJ/kg 17.585
Ultimate Analysis (% as received)
Carbon Car % 46 45～60
Hydrogen Har % 3.77 3.4～3.8
Oxygen Oar % 13.9 10～25
Nitrogen Nar % 1 0.5～1.5
Sulfur Sar % 0.33 0.1～0.35

Coal consumption(one boiler):162.61t/h(design coal)

(8) Ash Analysis

No. NAME SYMBOL UNIT DESIGN RANGE
1 Silica SiO2 % 11.7 10~32
2 Ferric Oxide Fe2O3 % 34 8.3~38.5
3 Alumina Al2O3 % 12 2.63~29.2
4 Calcium oxide CaO % 14 4.18~20
5 Magnesia MgO % 12 8.30~16
6 Titanium TiO2 % 0.3 0.10~0.7
7 Sulfur trioxide SO3 % 13.67 0.12~15
8 Phosphorous pentoxide P2O5 % 1.15 0.5~22.7
9 Natron Na2O % 0.19 0.15~2
10 Kali K2O % 0.98 0.05~2.4
11 Ash Fusion Temperature
Initial deformation temperature DT ℃ 1150
Softening temperature ST ℃ 1200
Hemispherical temperature HT ℃ 1250
Hemispherical temperature FT ℃ 1300

2. Main design principle

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2.1 One bottom ash and fly ash and pyrites handling system will be

designed for two units. Inside the power plant, dry type system will be

adopted for bottom ash handling, pneumatic pressure conveying system

for fly ash handling and manual system for pyrites handling.

2.2 Ash discharged will be transported to ash yard by trucks.

3. System description

3.1 Ash Quantity

Item Quantity (t/h)

Fly ash Bottom ash Pyrites sum

Unit

1x300MW design 7.93 0.88 0.81 9.62

2x300 MW design 15.86 1.76 1.62 19.24

3.2 Bottom ash handling system

Dry type system will be used for bottom ash handling in this project. For

details please see drawing F289S-C0103B-02 “Bottom Ash Handling

System diagram”.

The continuous bottom ash produced by each boiler shall be removed

from beneath the furnace by means of a dry ash conveyor for onward

conveyance. The ash will be reduced to a manageable size by means of a

crusher located at the discharge of the dry ash conveyor and into a bucket

elevator and then into the bottom ash silo.

One dry ash conveyor and one crusher will be installed for each boiler.

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The dry ash conveyor capacity is 1t/h (normal) to 5t/h (max.) while the

crusher is 6t/h. Slag hopper under which hydraulic isolation gate installed

can hold slag for about 12 hours when conveyor being maintained. One

bottom ash silo is equipped for one boiler. The bottom ash silo will has

the capacity to retain 48 hours of bottom ash. One bag filter will be

located on the silo roof for vent air cleaning. One twin-paddle

mixer/unloaders will be installed under the bottom ash silo. Ash

discharged will be transported to ash yard or to an end users destination

by trucks.

3.3 Fly ash handling system

Pneumatic pressure conveying system will be used for fly ash

handling, including each ESP hopper and ECO hopper. One system will

be designed for two units. For details please see drawing

F289S-C0103B-03 “Fly Ash Handling System diagram”.

There are four fields for ESP, and four hoppers for each field. 4

hoppers will be equipped for ECO. Fly ash from each hopper will fall into

a pressure vessel (transmitter) through inlet valve, being conveyed

afterward to fly ash silo by compressed air. The volume of the transmitter

for the first and the second field is 1.25 cu.m, and the volume of the

transmitter for the third and fourth field as well as for ECO hopper is 0.5

cu.m. There are three fly ash pipes for each boiler, one for the first field,

one for the second, third and fourth one and another for ECO. The work

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circulation will be controlled by PLC. Distance between ESP and silos is

about 250m. The capacity for ESP system is 11.89 TPH which is about

1.5 times of the ESP ash quantity. The ECO ash will be conveyed to the

bottom ash silo. Distance between ECO and bottom ash silo is about

200m.

Compressed air will be used for transmitters to convey ash to silos

through ash pipes. The compressed air will be provided by the screw air

compressors. For two boilers, three screw air compressors will be

installed (two in operation and one stand), and each compressor capacity

is 16.9m3/min. In addition, air dryers will be provided to reduce

conveying air moisture, hence reduce the possibility of plugging in the

ash pipe. There are two air dryers (one in operation and one stand by).

The capacity of air dryer is 42 m3/min each.

There are two steel fly ash silos for this project，and one for coarse

ash, one for fine ash. The capacity of each silo is about 500cu.m. The

coarse ash silo will accept coarse ash from 1st field. The fine ash silo will

accept fine ash from 2nd &3rd &4th fields. But when accident happened to

operation, the coarse ash silo can accept fine ash and fine ash silo can

accept coarse ash also.

One twin-paddle mixer/unloader and one dry ash unloading spout will

be installed under each silo. Ash discharged will be transported to ash

yard by trucks. Air cannon and fluidizing device will be provided for each

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fly ash silo. One bag filter will be located on each silo roof for vent air

cleaning.

3.4 Pyrites handling system

Manual system will be used for pyrites handling. For details please

see drawing F289S-C0103B-04 “ Pyrites Handling System diagram”

In each shift, pyrites discharged from each mill will be hold in a

movable hopper which has volume of 0.5m3 for a period until a fork truck

come to move the hopper out of bunker bay. The hopper will then be

lifted to make pyrites discharge into a truck for further transportation to

ash yard.

Pyrites will be periodically discharged by mill, and discharged one

time every 4 hours. The actual operation time will be according to

quantity of pyrites.

4. System commissioning and operation

4.1 Strict rules for operation and maintenance should be made, and

personnel should be trained to familiar with equipment property and

design intention.

4.2 The equipments should be commissioned by manufacturer during

plant commissioning.

4.3 Air-tight test should be done to all pipes before commissioning.

4.4 Foreign materials inside all equipment should be cleared out

completely before commissioning.

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4.5 The pneumatic conveying system (except air compressor system) is

supplied by Tianjin ASM equipment manufacture installation engineering

Co, Ltd. china. Parameters in the program and transmitters should be

commissioned by manufacturer during plant commissioning.

4.6 Before system start, air compressors, buffer tanks and air dryers

should be drained and operation.

4.7 The fly ash handling system operation steps also should read the

explanation of Tianjin ASM equipment manufacture installation

engineering Co, Ltd. china.

4.8 Silo fluidizing system should be started 10 minutes early before ash

discharging, and air distributors shall be drained first. Attentions should

be paid to that bag filter should be in operation whenever fluidizing

system starts. (Bag filter can be start on site).

4.9 After silo running, the paddle mixer inside should be cleaning

completely. Wet ash on the ground should be moved into trucks.

4.10 Personnel should clear the ground after the pyrites discharging.

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1.设计依据及设计原始资料

1.1 设计依据
1.1.1 中国成达工程公司（CECC）与印尼方业主（PLN）签定的合同
及附件。
1.1.2 谈判会议纪要。
1.1.3 业主咨询工程师对概念设计的审查意见。
1.1.4 中国成达工程公司（CECC）与西南电力设计院（SWEPDI）签
定的工程勘测设计合同。
1.1.5 初步设计文件。
1.1.6 除灰系统及设备技术协议。

1.2 设计原始资料

1.2.1 原始资料

（1） 锅炉型式： 固态排渣煤粉炉

（2） 排渣装置： 干式排渣机，每炉配置 1 台。

（3） 除尘器：双室四电场电气除尘器，除尘效率>99.5%。

（4） 灰、渣分配比 灰:渣＝90％:10％

（5） 落灰点数量

电除尘器灰斗 16 个/炉

省煤器灰斗 4 个/炉

空预器灰斗不排灰

（6） 每台炉配 5 台磨煤机，四运一备。

（7） 煤质资料及耗煤量

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 名 称 符 号 单 位 设计煤种 煤种变化范围

煤种 褐煤
收到基含水份 M t.ar ％ 30 25～35
空气干燥基内在水份 MAD ％ 18 15~25
收到基含灰份 Aar ％ 5 3~6

干燥无灰基挥发份 Vdaf ％ 53 45~60

收到基高位发热量 Qner.ar MJ/kg 19.19
收到基低位发热量 Qner.ar MJ/kg 17.585
元素分析

收到基含碳量 Car ％ 46 45～60

收到基含氢量 Har ％ 3.77 3.4～3.8
收到基含氧量 Oar ％ 13.9 10～25
收到基含氮量 Nar ％ 1 0.5～1.5
收到基含硫量 St.ar ％ 0.33 0.1～0.35

耗煤量(一台炉)：设计煤种 162.61t/h

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1.2.2 设计煤种灰渣成份

序号 名 称 符 号 单 位 设计煤种 煤种变化范围

1 二氧化硅 SiO2 % 11.7 10~32

2 三氧化二铁 Fe2O3 % 34 8.3~38.5
3 三氧化二铝 Al2O3 % 12 2.63~29.2
4 氧化钙 CaO % 14 4.18~20
5 氧化镁 MgO % 12 8.30~16
6 二氧化钛 TiO2 % 0.3 0.10~0.7
7 三氧化硫 SO % 13.67 0.12~15
8 氧化钠 Na2O % 0.19 0.15~2
9 五氧化二磷 P2O5 % 1.15 0.5~22.7
10 氧化钾 K2O % 0.98 0.05~2.4
11 灰熔点

变形温度 DT ℃ 1150
软化温度 ST ℃ 1200
半球温度 HT ℃ 1250
熔化温度 FT ℃ 1300

2 主要设计原则
2.1 本期工程 2X300MW 机组厂内除灰渣系统为一独立单元，设置 1
套除灰、渣、石子煤系统。除渣系统采用干式排渣系统，排灰系统采
用浓相气力输送系统，石子煤输送系统采用人工叉车方式。
2.2 厂外灰渣输送采用汽车外运至灰场。

3.系统概述

3.1 灰渣量

锅炉额定负荷运行时按设计煤种计算，每台炉灰渣量如下表：

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 小时灰渣量（t/h）
项目
灰 渣 石子煤 合计

1×300MW
7.93 0.88 0.81 9.62
设计煤种

2×300MW
15.86 1.76 1.62 19.24
设计煤种

3.2 排渣系统概述

除渣系统按干式除渣系统设计，系统工艺流程见

F289S-C0103B-02“除渣系统和省煤器灰输送系统 P&ID 图”

炉底渣经由渣井下落到干式排渣机不锈钢输送钢带上，高温炉渣

由不锈钢输送带向外输送。炉渣由干渣机出口处的破碎机破碎到合适

的大小，经斗提机输送到底渣仓。

每炉设一台干式排渣机和一台碎渣机。干式排渣机出力为 1～

5t/h，碎渣机出力为 6t/h。渣井下装有带大渣破碎装置的关断门，当

需要检修时，渣井能存 12h 的渣量。一台炉设有一个渣仓，能储存

48h 的锅炉排渣量。渣仓顶部设有布袋除尘器以清洁排气。渣通过湿

式搅拌机定期装车运至综合利用或贮灰场。

3.3 飞灰系统说明

飞灰系统包括电除尘器每个灰斗的排灰。飞灰系统按天津阿斯米

公司的浓相输送系统设计，下面叙述其工艺流程（除尘器部分参见

F289S-C0103B-03“电除尘器除飞灰系统 P&ID 图”
；省煤器部分参见

F289S-C0103B-02“除渣系统和省煤器灰输送系统 P&ID 图”
）。

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 电除尘器为双室四电场，每电场 4 个灰斗；省煤器每炉 4 个灰斗。

灰斗内的飞灰通过进料阀进入仓泵，然后有压缩空气输送至灰库。电

除尘器部分，一、二电场每个灰斗下设一台 1.25m3 的仓泵，三、四

电场每个灰斗下设一台 0.5m3 的仓泵。一电场出一根输灰管，二、三、

四电场合并出一根输灰管。省煤器部分，每个灰斗下设一台 0.5m3 的

仓泵，每台炉出一根灰管。因此，每台炉输送系统共设三根灰管。运

行时，系统采用连续程序控制自动输送，电除尘器飞灰由输灰器沿管

道输送至灰库存放，输送距离约为 250m。电除尘器浓相输送系统设

计出力为每炉 11.89t/h，为设计煤种排灰量的 150％。当电除尘器上

一电场事故时，下一电场的系统出力仍能满足上一电场校核煤种灰量

的出力要求。省煤器的灰输送到锅炉房旁边的渣仓内，输送距离约

200m。

系统所需输送用气由螺杆式空压机供给。两台炉共设 3 台

16.9m3/min 的空压机，2 台运行、1 台备用。为保证输送空气的品质，

采用干燥和过滤等后处理设备进行除油、除水、除杂质处理，冷冻式

干燥机共设 2 台 42m3/min，1 运 1 备。

本工程共设置 2 座联体钢制灰库，1 粗 1 细，每座灰库容积为

500m3，电除尘器每个电场的灰可进粗灰库，也可切换进细灰库。

每座灰库下设有 2 个卸料口，干灰分别经双轴搅拌机调湿后装车

和汽车散装机直接装车，运往灰场堆放。为保证放灰通畅，灰库锥体

部份设有空气炮和气化箱（气源为输送空压机站来的压缩空气），用

以排除库内积灰起拱或堵塞。灰库顶部装有布袋除尘器用于净化排

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气。

3.4 石子煤系统

本工程石子煤系统采用人工方案。系统流程参见

“F289S-C0103B-04 石子煤处理系统 P&ID 图”。

磨煤机排出的石子煤由磨煤机石子煤排出口排出，排出的石子煤

先进入布置与磨煤机下的排渣箱（有效容积为 0.5 m3）中暂时储存。

排渣箱通过一个上部闸门与磨煤机相连。正常情况下，上部闸门打开，

石子煤直接排入排渣箱，当排渣箱装满需要排放时，上部闸门关闭，

打开排渣箱出口门，将石子煤排放到活动的石子煤斗中，然后通过叉

车将活动石子煤斗送至汽车上，将石子煤排出，由汽车运至灰场。

石子煤系统为定期运行，每 4 小时运行 1 次，其实际运行时间可

根据实际运行中磨煤机排出的石子煤量的多少来确定。

4．系统调试及运行

4.1 电厂要制定出科学的运行、检修规程。运行检修人员必须经过培

训，掌握设备性能和领会设计意图，并严格按规程操作。

4.2 设备试运行应严格按照设备制造厂家提供的说明进行，可请厂家

派员到现场指导调试。

4.3 设备全部安装完毕，管道水（气）压试验合格，作好现场清理后，

方可进行调试。

4.4 所有设备试运前应检查杂物是否清理干净。

4.5 气力输送系统（不包括空压机系统）由天津阿斯米公司设计并供货，

系统调试时，应通知该公司派技术调试人员到场参加，并严格按照设

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备供货商的说明进行。

4.6 每次启动输灰系统前,应先对除灰输送空压机系统内设备进行疏水，

包括输送空压机、冷干机和储气罐。并核实是否已投入正常运行。

4.7 飞灰输送系统启动顺序及步骤参见天津阿斯米公司提供的说明。

4.8 灰库排灰前十分钟应投入气化加热系统。冬季或潮湿季节灰库不排

灰时，也可定期投入热空气，以便保温防潮。注意系统启动前，应核

实灰库除尘器应处于运行状态（若未运行，可就地启动）
。

4.9 每天运行完毕后，应彻底清扫搅拌机内部灰浆，防止湿灰附着内部

形成灰垢。并将地面的湿灰铲入车内。

4.10 石子煤系统采用人工方案，石子煤装车后，装车周围地面较脏，

需立即清扫，以免石子煤粉污染锅炉房内的环境。