B

A REV

20.09.10 16.09.10 DATE

Revised as per ABIR Comments Preliminary Issue DESCRIPTION REVISION INDEX

CKS CKS PRPD

MG MG CHKD

SS SS APRD ECEPL

BHAVANAPADU THERMAL POWER PROJECT STAGE ± I : 2x660MW, ANDHRAPRADESH, INDIA
DOCUMENT TITLE :

FEASIBILITY REPORT FOR BOTTOM ASH HANDLING SYSTEM
OWNER: OWNER¶S ENGINEER :

EAST COAST ENERGY PRIVATE LIMITED
HYDERABAD ± INDIA BOP CONTRACTOR:

ENERGY INFRATECH PRIVATE LIMITED
THERMAL POWER DIVISION, HYDERABAD- INDIA BOP CONSULTANT:

ABIR INFRASTRUCTURE PRIVATE LTD
THERMAL POWER DIVISION, HYDERABAD- INDIA

IDEA - PB CONSORTIUM
CHENNAI / BANGALORE - INDIA

DOC.NO

AIPL ± 5310 ± M ± 1602± 5016

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1

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10

Rev

B

BHAVANAPADU THERMAL POWER PROJECT STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

TABLE OF CONTENTS 1.0 2.0 3.0 INTRODUCTION PROJECT BACKGROUND SYSTEM DESCRIPTION 3.1 3.2 3.3 3.4 3.5 4.0 General Jet Pump System Scrapper Chain Conveying System Source of Water Cost Implications 4 4 4 4 4 5 7 9 9

Recommendation

APPENDIX Appendix 1 Comparison of SCC System with Contract Requirements

LIST OF DRAWINGS AIPL-5310-M-0102-5103 AIPL-5310-M-0102-5113 AIPL-5310-M-0302-6033 AIPL-5310-G-0101-0001 Flow Scheme ± Bottom Ash Handling System (Jet Pump System) Flow Scheme ± Bottom Ash Handling System (SCC System) Layout of SCC General Layout Plan (Tentative Routing of Bottom Ash Conveyor)

FEASIBILITY REPORT FOR BOTTOM ASH HANDLING SYSTEM DOC.NO. AIPL-5310-M-1602-5016

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BHAVANAPADU THERMAL POWER PROJECT STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

LIST OF ABBREVIATIONS BA BoP DEC ECEPL SCC : Bottom Ash : Balance of Plant : DONGFANG Electric Corporation Ltd. : East Coast Energy Pvt. Ltd. : Scrapper Chain Conveyor

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BHAVANAPADU THERMAL POWER PROJECT STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

1.0

INTRODUCTION The purpose of this report is to check the feasibility of utilizing Scrapper Chain Conveyor (SCC) system for bottom ash removal in lieu of Jet Pump system. The Contract specification calls for jet pump system for bottom ash removal and ash handling system DBR was accordingly submitted. However, in a meeting between the Owner and ABIR on 4th Sep. 2009, the Owner suggested Scrapper Chain Conveyor (SCC) system for bottom ash removal. This report examines the feasibility of incorporating an SCC system for the project.

2.0

PROJECT BACKGROUND East Coast Energy Pvt. Ltd. (ECEPL) (Owner), proposes to install a 4x660 MW, Super Critical Thermal Power Plant based on a blend of imported coal and indigenous coal at Bhavanapadu, Srikakulam District of Andhra Pradesh, India about 175km away from Visakhapatnam sea port. This project is proposed to be implemented in two Phases i.e. Stage I ± 2x660MW and Stage II - 2x660MW. The Owner appointed NEC CONSORTIUM (ABIR & NAVAYUGA), as the EPC contractor for Balance of Plant and Civil Works for Stage I of the proposed power project. ABIR appointed IDEA-PB Consortium for carrying out the Engineering Consultancy and Project Management Services for Mechanical, Electrical and C&I work for the Balance of Plant.

3.0
3.1

SYSTEM DESCRIPTION General The following two types of Wet Bottom Ash Handling Systems are widely utilized in thermal power plants for bottom ash removal:-

y y

Jet Pump System Scrapper Chain Conveying System

3.2

Jet Pump System The jet pump system consists of water impounded hopper (two µV¶ legs or W-type), from where bottom ash passes through large gates (hydraulic Feed Gate) on to dual roll clinker grinders that grind clinkers to an appropriate size (maximum 25mm). The grinders then feed the ash to a hydraulic ejector (jet pump) which transfer the resultant ash-water slurry to an , ash slurry sump located in the bottom ash slurry pump house. Make water and impulse -up water are supplied by Low Pressure (LP) and High Pressure (HP) water pumps. Operation of the jet pump requires high pressure impulse w ater that is supplied by the HP water pump. The bottom ash handling system flow schematic (using jet pump system) is attached as Dwg. No. AIPL-5310-M-0102-5103.
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BHAVANAPADU THERMAL POWER PROJECT STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

3.3

Scrapper Chain Conveying System The SCC System receives hot ash, slag and clinkers falling from the boiler, through a transition chute to the water-filled trough. The transition chute provides an airtight seal between the boiler and the scrapper chain conveyor. Ash is continuously conveyed up the conveyor incline for dewatering. The bottom ash discharged onto the scrapper chain conveyor will be fed to clinker grinders where it is crushed to (-) 25mm size. The crushed bottom ash will be conveyed to the bottom ash silo by belt conveyors. A bottom ash silo having eight (8) hours storage capacity along with provision for water decantation is proposed for the each unit. Bottom ash collected in silo will be disposed to ash dyke by means of the belt conveyor and under emergency circumstances ash will be loaded on to truck for off-site disposal. The bottom ash handling system flow schematic (using SCC system) is attached as Dwg. No. AIPL-5310-M-0102-5113. Recirculation system: Over flow water from trough of scrapper chain conveyor and seal trough over flow will be transferred to clarifier for supplying clear water to the Bottom ash system. This water will also be cooled in the recirculation system. Make up water(desalinated quality) will be added in the trough of scrapper chain conveyor. Cooling arrangement for the SCC overflow water:Generally three options are available to cool the SCC overflow water :FRP Cooling tower Plate type heat exchanger Settling & surge tank

y y y

Normally settling & surge tank is required to clarify the contaminated ash water before itis cooled by the cooling tower or the heat exchanger. In the case of cooling tower additional auxiliary power will be required for operating the pumps and fans andmake-up water will also be required to compensate for the blow down /evaporation losses. In the case of heat exchanger option secondary cooling water from the sea water will be required. In order to minimize water consumption, it is proposed to install a larger settling tank & surge tank, so that retention time will be more and cooling will be achieved by evaporation. Layout and Routing of the belt conveyor Belt conveyors are proposed to dispose the bottom ash from scrapper chain conveyor to bottom ash silo. In order to accommodate the bottom ash belt conveyor, IA/SA compressor house (No. 45) and Acid/Alkali Unloading Area & Neutralizaion Pit (No. 46) are shifted towards east side.

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BHAVANAPADU THERMAL POWER PROJECT STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

The routing of the belt conveyor is shown in the enclosed drawing, Dwg. No. AIPL-5310-M0302-6033.

The routing of the belt conveyor is tentative, which will require confirmation by DEC for any potential interference with the boiler equipment. Bottom ash silo is proposed to be located at the location where hydrobin are envisaged, please refer to General Layout Plan, Dwg. No. AIPL -5310-G-0101-0001 enclosed in this report. Pros and cons of the Jet Pump system compared to SCC system are as follows; Pros Cons

Simple layout, occupies less space in BA Higher power consumption area Widely installed in Indian power plants More number of equipment and structures required Higher installation cost Water consumption high To accommodate large volume of ash holdup, part of BA system with jet pump need to be located below ground.

Pros and cons of the SCC system compared to Jet Pump system are as follows; Pros Less water consumption (about 10% less) Cons Maintenance prone, hence standby SCC is required

Less power consumption (about 15 to 20% Complex layout due to use of belt conveyors less) and belt feeders in the boiler area Due to continuous operation, capacity of water recirculation system less. Installation cost may be less SCC located on the ground level and mounted on the rails

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BHAVANAPADU THERMAL POWER PROJECT STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

3.4

Source of Water The below tables summarizes the source of water required for handling ash.

Source of Water for AHS with Jet Pump No. Description 1. 2. AHS Instrument Air Compressor cooling AHS Conveying Air Compressor cooling 3. AHS Vacuum Pump Source DMCW or Desalinated CW DMCW or Desalinated CW Desalinated water once through Desalinated water will be used to cool/seal vacuum pump coolers, supplied from seal water pump. The discharge will be let into the Ash water sump and used in the AHS system. Supplied by HP Water Pumps Supplied by LP Water Pumps Supplied by Seal water pumps Seawater can be also used for HCSD slurry preparation. Sea water application will increase the cost of HCSD system by approximately 2 to 3 times. Remarks

4. 5.

Source of water for Jet pumps BA Hopper filling, BA Hopper Cooling and Seal Trough Make up Seal Water for Clinker Grinder, Sludge Pumps, BA Slurry Pumps For HCSD slurry preparation

Desalinated water Desalinated water

6.

Desalinated water

7.

Desalinated water or Seawater

FEASIBILITY REPORT FOR BOTTOM ASH HANDLING SYSTEM DOC.NO. AIPL-5310-M-1602-5016

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BHAVANAPADU THERMAL POWER PROJECT STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

No. Description 8. Fly ash Conditioning

Source Service water

Remarks To be tapped off from service water network

Source of Water for AHS with Scrapper Chain Conveyor No. Description 1. 2. 3. AHS Instrument Air Compressor cooling AHS Conveying Air Compressor cooling AHS Vacuum Pump Source DMCW or Desalinated CW DMCW or Desalinated CW Desalinated water once through Desalinated water will be used to cool/seal vacuum pump coolers, supplied from seal water pump. The discharge will be let into the Ash water sump and used in the AHS system. Remarks

4. 5. 6. 7

Economizer hopper flushing apparatus Make-up for seal trough and Scrapper Chain Conveyor Seal Water for Clinker Grinder For HCSD slurry preparation

Desalinated water Desalinated water Desalinated water Desalinated water or Seawater LP Pumps Supplied by Seal water pumps Seawater can be also used for HCSD slurry preparation. Sea water application will increase the cost of HCSD system by approximately 2 to 3 times. To be tapped off from service water
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8.

Fly ash Conditioning

Service water

FEASIBILITY REPORT FOR BOTTOM ASH HANDLING SYSTEM DOC.NO. AIPL-5310-M-1602-5016

BHAVANAPADU THERMAL POWER PROJECT STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

No. Description

Source

Remarks network

It shall be noted that, the water requirement for SCC system will be about 10% less than the Jet pump system. 3.5 Cost Implications Preliminary discussion with the prospective vendors reveals that SCC systemcould be less expensive compared to the jet pump system in terms of capital cost.

4.0

Recommendation Both Jet pump with hydro bin system and SCC described above are technically acceptable and both could be adopted depending upon the cost effectiveness.Also desalinated water requirement for scrapper conveyor system could be less compared to hydro bin system. Since SCC is prone to maintenance, a standby SCC is to be envisaged.The feasibility of scrapper conveying system will also depend to a large extent in the ability to route the belt conveyor between the boiler & the bottom ash silo. Pre liminary assessment reveals that the routing can be accomplished as per enclosed drawings. In view of the above, bottom ash handling system with scrap per conveyor system is recommended.

FEASIBILITY REPORT FOR BOTTOM ASH HANDLING SYSTEM DOC.NO. AIPL-5310-M-1602-5016

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BHAVANAPADU HER A P WER PR JEC S A E- I : 2x660 W, ANDHRAPRADESH, INDIA

A C m a is

e

ix 1 it C t act Req i eme ts

f SCC System

C m a is Sl.N . C t act eq i eme t Jet P m System

it C P

t act Req i eme ts se system SCC System Rema ks ake up water (Desalinated water) requirement likely to be less (by about 10%) Jet pumps, ash slurry pumps, hydro bin system is not required Bottom ash disposal will be semi wet HP water is not required

1 2 3 4 5 6

Water i pounded hopper Jet pump Clinker grinder Ash slurry pump Hydro bin system Power consumption

Dry bottom ash hopper Scrapper chain conveyor Clinker grinder Belt conveyor Bottom ash silo Power consumption of SCC system will be approximately 15 to 20% less

Power consumption will also be less

EASIBI I Y REP R RB ASH HAND IN D C.N . AIP -5310- -1602-5016

SYS E

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