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Ash Handling PDF
Ash Handling PDF
Method of Collection
Conveying
Pneumatic
Mechanical
Interim storage
Disposal of various types of ash residue
Bottom ash
Crushed in clinker grinder
Bed ash
Fly ash
Dust Collectors (Baghouse)
ESP
Ash Clinkers
System Components
1.Air Intake
2. Fully Enclosed, Quick Acting, Swing Disc valve
3. Pipe Fittings with Replaceable, Reversible, Interchangeable
Wearbacks (550 BHN)
4. Paddle Type Ash Conditioning Unit
5.Abrasion Resistant centrifugally Cast
Conveyor Pipe
6. Silo Vent Filter
7.Centrifugal Receiver/Separator
8. Pulse Jet Bag Type Dust Collector
9.Continuous Ash Collecting Double Dump
Gates
10. Silo Relief Valve
11. Ash Storage Silo
12. Air Pipe
13. Fugitive Dust Filter
14. Telescopic Dry Unloader
15. Vacuum Breaker
16. Guard Filter
17. Mechanical Exhausters
ALTERNATIVES
Silo
Slurry Pump
Settling Pond
Stilling Pond
HDPE Lining
70% water recovery
Slurry settles
Partial clear water to stilling pond
Stilling Pond
Remaining ash settles
Vertical Turbine Pump
Clariflocculator
Suspended particle limited to 20 ppm
Clear water to Ash Water Tank
Ash Water Tank
• In Thermal Power Plant’s coal is generally used as fuel and hence the ash is
produced as the byproduct of Combustion. Ash generated in power plant is about
30-40% of total coal consumption and hence the system is required to handle Ash
for its proper utilization or disposal.
• Ash generated in the ESP which got carried out with the flue gas is generally
called Fly ash. It also consists of Air pre heater ash & Economiser ash (it is about
2 % of the total ash content).
• Ash generated below furnace of the steam generator is called the bottom ash.
The ash handling system handles the ash by bottom ash handling system, coarse ash
handling system, fly ash handling system, ash disposal system up to the ash disposal area
and water recovery system from ash pond and Bottom ash overflow. Description is as
follows:
Bottom ash resulting from the combustion of coal in the boiler shall fall into the over
ground, refractory lined, water impounded, maintained level, double V-Section type/ W
type steel- fabricated bottom ash hopper having a hold up volume to store bottom ash and
economizer ash of maximum allowable condition with the rate specified. The slurry
formed shall be transported to slurry sump through pipes.
Ash generated from APH hoppers shall be evacuated once in a shift by vacuum
conveying system connected with the ESP hopper vacuum conveying system.
1. D. Fly Ash Handling System
Fly ash is considered to be collected in ESP Hoppers. Fly ash from ESP hoppers
extracted by Vacuum Pumps up to Intermediate Surge Hopper cum Bag Filter for further
Dry Conveying to fly ash silo.
Under each surge hopper ash vessels shall be connected with Oil free screw compressor
for conveying the fly ash from Intermediate Surge Hopper to silo. Total fly ash generated
from each unit will be conveyed through streams operating simultaneously and in
parallel.
Bottom Ash slurry, Fly ash slurry and the Coarse Ash slurry shall be pumped from the
common ash slurry sump up to the dyke area which is located at a distance from Slurry
pump house.
Stats
ASH HANDLING
Dilute Phase
Both vacuum & pressure pneumatic systems
High velocity
low ash - to - air ratio
Dense phase
Pneumatic pressure system conveying dense ash
Low velocity
High ash concentration
Less energy due to its smaller amount of conveying air
Ash Disposal
Advantages
Ash spreads in layers enabling vertical filling, hence 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.
CLINKER GRINDER
Coarse bottom ash or other coarsely sized material
Reduce size for pneumatic conveyance or other means of ash
handling
CYCLONES
Centrifugal ash receiver
Top of a silo or storage hopper
The gases after reaching the end of the conical portion changes
its direction and moves upwards towards the outlet forming an
inner vertex.
Control high concentration.
ASH CONDITIONERS
The ash conditioner is a totally enclosed, paddle type mixer
designed to condition fly ash, bottom ash, and other abrasive or
dusty materials.
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
The slurry solution is pumped using it to land fill or transported
to a slurry to lagoon for storage/disposal.
PIPELINE PRODUCTS
Terminal Box : Used as a low profile 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
PIPES
Pipe : Standard Size range 50mm to 400mm diameter pipelines.
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.
Modes of conveying:
a) Dilute phase: If the material is conveyed in suspension in the
air through the pipeline it is referred to as dilute phase conveying.
b) Dense phase: If the material is conveyed at low velocity in a
non suspension mode, through all or part of the pipeline, it is referred
to as dense phase conveying
In dense phase conveying two modes of flow are recognized.
Moving Bed Flow: Moving bed flow is only possible in a
conventional conveying system if the material to be conveyed
has good air retention characteristics.
Plug Type Flow: Plug type flow is only in a conventional
conveying system if the material has good permeability. This
type of flow is typically limited to the materials that are
essentially mono-sized, since these allow the air to pass readily
through the interstices between the particles.
Thermal Power stations using pulverized coal or lignite as fuel generate large quantities
of ash as a by-product. There are about 82 power plants in India, which form the major
source of flyash in the country. With the commissioning of super thermal power plants
and with the increasing use of low grade coal of high ash content, the current production
of ash is about 85 million tonnes per year. This figure is likely to go upto 100 million
tonnes per year by the year 2000 AD and pose serious ecological problems.
Appreciating the overall concern for the environment and the need for the safe disposal
and effective utilisation of flyash, Department of Science & Technology (DST) as the
nodal agency and Technology Information and Assessment Council (TIFAC) as the
implementing agency commissioned a Flyash Mission in 1994. Flyash Mission: a
Technology Project in Mission Mode (TPMM) is being implemented with participation of
Ministry of Environment & Forest, Ministry of Power, Thermal Power Stations, R&D
institutions and Industry. The focus is on demonstration of coal ash related technologies
for developing confidence and thus ensuring large scale adoption. A number of projects
taken up by the industry, R&D institutions and academia have shown encouraging
results. Some of these projects have been completed, multiplier effects have started and
other projects are heading towards meaningful completion. A judicious mix of select
thrust areas have been taken up for concerted efforts. These include Flyash
Characterisation, Hydraulic Structures, Handling and Transportation, Agriculture related
studies and Application, Ash Ponds and Dams, Reclamation of Ash Ponds for Human
Settlement, Roads and Embankments, Underground Mine Fills and related research
projects.
Although the scope for use of ash in concrete, brick making, soil-stabilization treatment
and other applications has been well recognized, only a small quantity of the total ash
produced in India is currently utilized in such applications. Most of the ash generated
from the power plants is disposed off in the vicinity of the plant as a waste material
covering several hectares of valuable land. The bulk utilization of ash is possible in two
areas, namely, ash dyke construction and filling of low-lying areas. Coal ash has been
successfully used as structural fills in many developed countries. However, this particular
bulk utilization of ash is yet to be implemented in India. Since most of the thermal power
plants in India are located in areas where natural materials are either scarce or expensive,
the availability of flyash is bound to provide an economic alternative to natural soils.
The properties of ash are a function of several variables such as coal source, degree of
pulverization, design of boiler unit, loading and firing conditions, handling and storage
methods. Thus, it is not surprising that a higher degree of variation can occur in ash, not
only between power plants but within a single power plant also. A change in any of the
above factors can result in detectable changes in the properties of the ash produced. The
degree to which any change affects the utilization potential of ash is a function of the
nature and degree of the change and the particular application for which the ash might be
used. The physical, geotechnical and chemical parameters to characterize flyash are the
same as those for natural soils, e.g., specific gravity, grain size, Atterberg limits,
compaction characteristics, permeability coefficient, shear strength parameters and
consolidation parameters. The procedures for determination of these parameters are also
similar to those for soils.
Primarily, the flyash is disposed off using either dry or wet disposal scheme. In dry
disposal, the flyash is transported by truck, chute or conveyor at the site and disposed off
by constructing a dry embankment (dyke). In wet disposal, the flyash is transported as
slurry through pipe and disposed off in impoundment called "ash pond". Most of the
power plants in India use wet disposal system, and when the lagoons are full, four basic
options are available: (a) constructing new lagoons using conventional constructional
material, (b) hauling of flyash from the existing lagoons to another disposal site, (c)
raising the existing dyke using conventional constructional material, and (d) raising the
dyke using flyash excavated from the lagoon ("ash dyke"). The option of raising the
existing dyke is very cost effective because any fly ash used for constructing dyke would,
in addition to saving the earth filling cost, enhance disposal capacity of the lagoon. The
constructional methods for an ash dyke can be grouped into three broad categories: (a)
Upstream method, (b) Downstream method and (c) Centerline method. Fig.1 shows
typical configurations of embankments constructed using the different methods. The
construction procedure of an ash dyke includes surface treatment of lagoon ash,
spreading and compaction, benching and soil cover.
Upstream Method
Downstream Method
Centreline Method
An important aspect of design of ash dykes is the internal drainage system. The seepage
discharge from internal surfaces must be controlled with filters that permit water to
escape freely and also to hold particles in place and the piezometric surface on the
downstream of the dyke. The internal drainage system consists of construction of rock
toe, 0.5m thick sand blanket and sand chimney. After completion of the final section
including earth cover the turfing is developed from sod on the downstream slope.
Large scale use of ash as a fill material can be applied where (a) flyash replaces another
material and is therefore in direct competition with that material, (b) flyash itself is used
by the power generating company producing the flyash to improve the economics of the
overall disposal of surplus flyash; and (c) at some additional cost, flyash disposal is
combined with the rehabilitation and reclamation of land areas desecrated by other
operations.
Fills can be constructed as structural fills where the flyash is placed in thin lifts and
compacted. Structural flyash fills are relatively incompressible and are suitable for the
support of buildings and other structures. Non-structural flyash fill can be used for the
development of parks, parking lots, playgrounds and other similar lightly loaded
facilities. One of the most significant characteristics of flyash in its use as a fill material
is its strength. Well-compacted flyash has strength comparable to or greater than soils
normally used in earth fill operations. In addition, lignite flyash possesses self-hardening
properties which can result in the development of shear strengths. The addition of illite or
cement can induce hardening in bituminous flyash which may not self-harden alone.
Significant increases in shear strength can be realized in relatively short periods of time
and it can be very useful in the design of embankments.
Environmental Considerations
The environmental aspects of ash disposal aim at minimizing air and water pollution.
Directly related to these concerns is the additional environmental goal of aesthetically
enhancing ash disposal facilities. The ash produced in thermal power plants can cause all
three environmental risks - air, surface water and groundwater pollution. The pathways of
pollutant movement through all these modes are schematically represented in Fig.2.
Air pollution is caused by direct emissions of toxic gases from the power plants as well as
wind-blown ash dust from ash mound/pond. The air-borne dust can fall in surface water
system or soil and may contaminate the water/soil system. The wet system of disposal in
most power plants causes discharge of particulate ash directly into the nearby surface
water system. The long storage of ash in ponds under wet condition and humid climate
can cause leaching of toxic metals from ash and contaminate the underlying soil and
ultimately the groundwater system. However, most of these environmental problems can
be minimised by incorporating engineering measures in the design of ash ponds and
continuous monitoring of surface and groundwater water systems.
IIT Kanpur has pioneered the development of the ash dyke design in India. A number of
ash disposal facilities across the country have been designed at this Institute. Currently, a
major technology demonstration project on Ash Dyke Design: Raising, Maintenance and
Monitoring sponsored by Flyash Mission with active support from NTPC is being
executed at the Department of Civil Engineering. As a part of this project, a detailed
manual on ash disposal practice has been prepared to standardize the procedures for ash
disposal across the country. Another Flyash Mission sponsored project involving detailed
geotechnical and environmental investigation of an ashfill site near Badarpur, New Delhi,
is nearing completion. Based on field and laboratory investigations, detailed guidelines
have been prepared for constructing ashfills and possibility of groundwater pollution
through leaching of toxic metals examined. A national conference, Flyash Disposal and
Deposition: Beyond 2000 AD, organised at the Institute in February 1999, looked into
areas such as design of ash disposal facility, reclamation of ash ponds, structural filling of
low-lying areas by flyash and the environmental aspects of ash disposal.
The problems related to flyash are complex and huge, requiring a national effort and
commitment. The expertise available at different institutions has to be fully harnessed to
develop technologies for large scale eco-friendly utilization of flyash.
Rajiv Sinha
IIT Kanpur
e.mail: rsinha@iitk.ac.in
Environmental Issues
Flyash
Flyash is categorised as high volume low effect
waste under Hazardous Wastes ( Management,
Handling & Transboundary movement ) Rules ,
2008
Chemically , flyash mainly consists of oxides of
silica, aluminium, Iron and calcium., besides
trace of elements like arsenic, beryllium, boron,
cadmium, chromium, chromium VI, cobalt, lead,
manganese, mercury, molybdenum etc.
Directions /Notification
Vide notification No.S.O.763(E), [14/9/1999]
Background
Ash disposal in thermal power plants, a highly
environmentally sensitive issue.
India is currently producing in excess of 100 million tonnes
of Coal Ash.
Currently, Fly ash and Bottom-ash are being mixed together
and transported hydraulically to ash ponds.
The end uses of Bottom-ash and Fly ash are different, as
their properties are widely different.
Bottom Ash
Crushed bottom ash is evacuated from the hoppers using jet pumps
and disposed off in form of a slurry.
Bottom ash is a very coarse material and is easy to handle.
Fly Ash
Fly ash is evacuated from various locations either hydraulically or
pneumatically.
In the pneumatic method, ash is transported to a buffer silo from
where it can be given out for utilization.
In the hydraulic method, ash is transported to a common sump.
Centrifugal slurry pumps are used to transport the ash slurry to ash
pond.
In most of the thermal power plants, the concentration of ash in the
slurry is very low and is of the order of 10 – 15% by weight.
This method is known as low concentration slurry disposal. (LCSD)
Typically same disposal system is used both for bottom ash as well
as fly ash.
In one of the thermal power plants (NCPS, DADRI) ash is handled
in completely dry form and disposed in the form of ash mound.
However, this requires special equipment's.
TRADITIONAL TECHNOLOGY
To dispose off large amount of ash efficiently
(i) HYDRO-SLUICING:
Bottom Ash :-
The standard wet systems for bottom ash
conveying can generally be divided
into two categories:
water impounded bottom ash hopper hopper
Pressure Conveying
System
Pressure systems offer high-capacity fly ash transport over long
conveying distances. Pressure
vessels required at each collection hopper are furnished with
rugged valving with hardened
seats and discs, internal aeration to provide positive ash flow,
and air flow control from the clean
side of the vessel to provide uniform, controlled ash flow to the
conveying line. Operating at
pressures up to 35 PSIG, pressure systems can satisfy
conveying capacities over 100 TPH.
consumption.
Lower line sizes.
site.
Disposal System (HCSD). The advantages of HCSD
Systems are:
In Lean phase slurry system, the concentration is
contamination.
Much less area of ash pond is needed.
Ash Utilization
Used as replacement of Silica in
cement industries.
Its share in cement is about 30% only.
Only few cement companies in this
region, carry fly ash from
silo at present.
Farming on cultivable lands.
construction materials.
Land filling i.e. levelling land pitfalls for
urbanization, colony
development and increasing cultivation
hectares.
Road construction.