THERMAL

POWER PLANT
OFFSITE
KRISHNAMOHAN
MARPINA
MANAGER - OPERATION
Sunday, March 14, 2021 1
Circulating Water System
 Cooling Water requirement
• Bulk requirement of water is used in thermal plants for
the purpose of cooling the steam in condensers.
• The requirement of water for this purpose is of the
order of 1.5-to2.0 cubic foot per second/MW of
installation.
• Where sufficient water is available once through system
is used.
• Where water supply is not consistent, closed loop
cooling system with cooling tower is used.
Circulating water scheme
• A circulating water pump house
• Intake channel
• Trash rack
• A chlorination plant
• Traveling water screen
• Connecting pipe line to condensed
• Outlet channel
• A cooling tower
Circulating water scheme
• We shall discuss the open loop system first.
Function of each component
• A circulating water pump house
• It houses the main CW pumps. Vertical submergible pump with operating
pressure around 1 Kg/ cm2.
• The pump house resides on the fore bay.
• The fore bay is flooded through intake system.
 Intake
 It is RCC open trench from where Raw water is taken through
canal/reservoir.
 The intake level is normally 10-15 ft. above from flood level of
the water source and 12 m in depth.

Trash Rack
•Trash rack to avoid entering wood, tree branches, animal, plastic,
floating object.
• provides uniform flow/suction to the CW pump
Traveling Water Screen
•leaves
It catches small pieces of coal, sand, gravel, wood, plastic, herbs,
which can go into the impeller and may choke/damage the
pump.
Once through system
 Chemical dosing done for disabling micro organism
development inside the tube.
•through
Condenser is fitted with 4 way valve to enable reverse flow
condenser when required.
• An air purging line fitted with condenser for initial charging
•through
Hot water coming out from condenser is allowed to pass
long outlet channel to get cool down before
meeting the main stream of water.
•Performance of condenser mainly depends on Inlet temp.
to the condenser, Condenser tube fouling, Air ingress in
condenser etc.
 Types of CWCT systems
Open Loop system:
Water is abundant…
Reduction in the APC..

Steam from Turbine

Cold Water
Condenser
Pump
Hot water

River Flow
CW scheme…

Reservoir/ River Canal Intake

Trash rack
Cooling tower

TWS
CT pumps

Hot Pond CW pumps

Condenser
PMI Revision 00
Hot Pond:

•Hot Water from the condenser discharged to hot pond

and provide source for the CT pump.

CT Pump

•It takes suction from the Hot pond and discharged

the water to the riser tubes of Cooling towers
Cooling Tower - Introduction

• A cooling tower is an air and water management device,

which consists of fan stacks, fans, drift eliminators, fill
and water/air distribution systems.
• It uses principle of evaporation of water in unsaturated
air.
Cooling Tower - Introduction
• Cooling tower is the most important equipment for closed cycle water
recirculation system.
• The efficiency of cooling tower has direct effect on condenser vacuum
and in turn, the heat rate of the station.
• 1oC rise in cold water temperature in a 200MW unit corresponds to
5mm vacuum loss leading to 7.5 Kcal/kwh loss in heat rate and in
500MW, 5.74 Kcal/kwh loss in heat rate..
Types of cooling Tower
• Wet type
• Dry type
• Wet type cooling towers are two type
• [Link] draft
• [Link] draft
• Mechanical draft may be devided in to two type
• [Link] draft
• [Link] draft
• Both of these can be counter flow type or cross flow type.
NATURAL DRAFT C.T.
• It produces air flow through utilisation of stack or chimney
[Link] diff. causing air flow is given by p=(douter-dinner)H.g
• The fill is located in the lower portion of shell with upper 85 to 90% of
shell empty which is used to create chimney effect.
• They are more suitable in the area of high relative humidity ratio and
low temp.
• They may be of cross flow or counter flow.
PMI Revision 00
MECHANICAL DRAFT C.T.
• Forced draft
• Advantage:-fan is subjected to less severe condition
• Disadvantage:-recirculation more
• Induced draft
• Advantage:-min recirculation
• Disadvantage:-fan is subjected to warm humid condition.
 MECHANICAL DRAFT C.T.
• Counter flow :-fill is arranged over entire tower [Link] is
typically film type.
• Advantage:-more thermal efficiecy,smallest tower,lower
capital cost, lower pumping head
• Disad:-increased pressure drop requires more horse
power of fan.
• Cross flow:-fill is arranged at the outer perimeter.
• Advantage:-large air inlet area hence pressure drop is
less.
• Disad:-high pumping head due to more height of fill.
PMI Revision 00
PMI Revision 00
 Types of Cooling Towers

Sunday, March 14, 2021 PMI Revision 00 21

 A BIRD’s EYE VIEW OF NDCTs OF DADRI-Coal (4 X 210 MW)
Sunday, March 14, 2021 PMI Revision 00 22
ARRANGEMENT OF C.T.
• [Link] type:-each cell indentical,more long area required, low
capital cost,for plant upto 250mw.
• [Link] type:-less recirculation,more capital cost,for plant more than
250mw.

Sunday, March 14, 2021 23

 Cooling Tower Thermal Design
Parameters are used to develop the tower design :

• Water flow rate

• Cooling range
• Design Heat load
• Design Wet-bulb temperature.
• Recirculation and interference
• DBT and relative humidity
Sunday, March 14, 2021 24
DESIGN HEAT LOAD
• Condenser and c.t. are designed on the basis of MCR load point.

Sunday, March 14, 2021 25

 Design Wet-bulb Temperature

• The impact the design wet-bulb temperature has on the size and
power requirements of a cooling tower is critical to optimizing
the cooling tower economics.
• In the majority of applications, the design duty of an evaporative
cooling tower is based upon an acceptable/required cold water
return temperature
• If investment and operational costs were not a concern, the ideal
design wet-bulb temperature would be equal to, or higher than,
the highest local wet-bulb temperature recorded.
• In this way, the returned water temperature would never be
higher than the acceptable/required cold water temperature.
• Design W.B.T.=DESIGN AMBIENT D.B.T.+RECIRCULATION
ALLOWANCE.

Sunday, March 14, 2021 26

Component Design : Fills
• The component most likely to provide improvement in tower
performance is the fill packing.
• The earliest and most common designs utilized splash type fills
• Film type counter flow designs using relatively low cost PVC materials.
• The new film type designs provide energy savings both in fan power
and pump head through the high surface areas per cubic feet of fill.

Sunday, March 14, 2021 27

 TYPES OF FILLS

• Splash type consisting of splash

Bars used for crossflow and
Counterflow.

• Film type consisting of thin film of

Sheets used mostly for counterflow

Sunday, March 14, 2021 28

 SPLASH FILLS
In splash fill, the hot water strikes the bar and
breaksup into many smaller drops.

Sunday, March 14, 2021 29

 FILM FILLS
Film fill consists of flat or formed sheets to provide
a surface upon which water and air come in
contact for heat exchange.

Sunday, March 14, 2021 PMI Revision 00 30

 Drift Eliminators
• A cooling tower drift eliminator is a low pressure, momentum
filter.
• Components are arranged to force the air leaving the fill
section to make a series of directional changes.
• Water droplets, which cannot negotiate these turns, impinge
on the surface of the eliminator, from which they are collected
and drained back into the wet side of the tower.
• The designer's goal is to provide the maximum drift
elimination at reasonable cost and minimum pressure loss.
• The design o drift eliminators has undergone tremendous
improvement in the last decade.
• New eliminator configurations accomplish this improvement
while actually reducing eliminator pressure losses

Sunday, March 14, 2021 31

 Drift Eliminators
• Cellular eliminators are typically constructed of PVC
sheets vacuum formed into very precise, compound
shapes, with an integral honeycomb strength. The
compound shape allows significant improvements in drift
eliminations and the use of cellular structure appreciably
reduces the pressure losses through the eliminator when
compared to either the wood lath or wave form
eliminators.
• The net free are of well-designed, modern cellular
eliminators is in excess of 95%.

Sunday, March 14, 2021 32

Sunday, March 14, 2021 PMI Revision 00 33
 Air-Water Distribution System Design
1) Water Distribution:

• Assured performance is a function of nozzle design, nozzle installation pattern, nozzle distance,
and the structural cleanliness of the spray chamber.

• To provide the primary function of precise water distribution, the nozzle must be designed with
other considerations in mind:

• The location of counter flow nozzles and the potential for poor quality circulating water
demands that the nozzle system be designed to minimize fouling.

• The nozzle must be capable of providing uniform distribution over a wide range of flows,
without significant loss in nozzle performance.

• The nozzle must be capable of efficient operation while consuming a minimum of expensive
pump energy.

Sunday, March 14, 2021 34

 Air-Water Distribution System Design
2) Air Distribution: Three variables control the distribution of air to the
fill in a counter flow configuration.

• The first is the air inlet geometry.

• Pressure Ratio : The pressure ratio reflects the ratio of resistance to

available entering air energy. The higher the ratio, the better entering
air will be spread out before entering the fill. The lower the pressure
ratio, the less uniform, and less stable the distribution of air flow
becomes. The degradation of air flow uniformity is readily apparent,
particularly at the inlet.
(Pressure Ratio = Static Pressure / Velocity Pressure at Air Inlet)

• The third is the fan coverage over the eliminators

Sunday, March 14, 2021 35
Fan Design
• Each fan has only one design point which is established by
a specific air flow, total pressure, air density, and fan
speed.
• The factors that must be known when replacing a fan on
an existing installation are:

1. Fan diameter.
2. Installed motor horsepower.
3. Gear reduction ratio of gear reducer.
4. Shaft size or gear reducer model.
5. Some estimate of elevation above sea level of installation.
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 Cooling Tower Performance

Sunday, March 14, 2021 37

Cooling Tower Effectiveness = Range/(Range+Approach)
Coolin g Tower Performa nce

Cooling Tower Capacity = mass flow rateXspecific Heat x Temperature Difference

Evaporation Loss in cub mtr/Hr = 0.00085x1.8xcirculation ratexTemperature Diff.

Cycle of Concentration = Dissolve solid in circulating water/Dissolve solid in make

up water

Blow Down = Evaporation Loss/(C.O.C.-1)

COMPRESSED AIR SYSTEM
 What is Compressed Air System
• It consists of compressor used to generate high
pressure air as per requirement of a TPS.
• The compressor used in power plant is a two staged
reciprocating type.
• Two separate compressed air system namely
Instrument air system and Plant air system are in use.
• Suitable dryer is provided for making the delivered air
free from moisture for specific application purpose.

Sunday, March 14, 2021 40

 Necessity of Compressed Air

• Operating Electro pneumatic controllers, pneumatic

valves, Oil burner movement, Burner tilt mechanism,
pneumatic motors and devices etc. in main plant

• Operating MGR & CHP equipments

• Pneumatic transportation of ash.

• Cleaning purpose.

Sunday, March 14, 2021 41

 Instrument Air Compressor – basic structure

• Instrument air compressors are of the double acting

horizontal cross head type of two opposed cylinder.
The compressors are driven by electric motor through
V belts
• The suction air filter is at the middle of the cylinder so
that air can enter at both ends of the piston.

Sunday, March 14, 2021 42

 Instrument Air Compressor – basic structure

• After compression the air passes through the

delivery valves to the Inter-cooler where the air is
considerably cooled and enters the H.P. cylinder.

• The entrapped air in HP side is compressed in a

similar manner as in L.P. Cylinder to the required
pressure and enters the header connected to the H.P.
cylinders through the delivery valves and then finally
to the air receiver.

Sunday, March 14, 2021 43

 Reciprocating Compressor
Sunday, March 14, 2021 44
 Air-Drying Unit

• Air contains moisture which tends to condense, and

causes trouble in operation of various devices by
compressed air.
• Air drying unit consists of dual absorption towers
with embedded heaters for reactivation.
• The absorption towers are adequately filled with
specially selected silica gel and activated alumina.
• While one tower is drying the air, the other tower is
under reactivation.

Sunday, March 14, 2021 45

 Service-Air Compressor

• Station air compressor is generally a slow speed

horizontal double acting double stage type and is
arranged for belt drive

• From the high pressure cylinder compressed air is led

through water cooled " after cooler" which is provided
with inlet and outlet water connection and a drain.

Sunday, March 14, 2021 46

 Compressor outlet & interconnection

• A moisture separator with a drain trap and a filter are

provided to remove moisture and dust particles from
the compressed air.
• There is one interconnection between service air and
instrument air headers just at the inlet of air drying
units.
• This connection has been provided as an emergency
provision to meet the requirement of instrument air in
case of non-availability of instrument Air Compressor.

Sunday, March 14, 2021 47

Sunday, March 14, 2021 48
 Problem encountered with compressed air system

• System leakage.
• Loading – unloading cycle.
• Ambient temperature.
• Moisture in outlet. (in efficiency in dryer)

Sunday, March 14, 2021 49

FUEL OIL SYSTEM
Purpose of Fuel Oil
• Initial firing of the Boilers

• Flame stabilization

• Low load operation

Sunday, March 14, 2021 51

Types Of Fuel Oil

• Light diesel oil (LDO)

• High speed diesel oil (HSD)
• Heavy Furnace oil (HFO)
• Low sulphur heavy stock (LSHS)

Sunday, March 14, 2021 52

Use of different types

• LDO & HSD normally used in

• Auxiliary boiler
• Ignitor for certain boiler design.

• HFO generally used for power boiler

Sunday, March 14, 2021 53

 TYPICAL HFO SPECIFICATIONS

• Standard: IS 1593 / 1971

Grades LV-MV-HV
• Flash point: 660C (minimum)
• Viscosity (Max.): 80-120-370 CST at
500C
• Gross heating value: 10270 Kcal/kg
• Total Sulphur (Max.): 3.5-4-4.5%by weight

Sunday, March 14, 2021 54

 Presentation Outline
• FO unloading system
• FO storage
• FO pressuring pump house
• Safety procedure in FO handling

Sunday, March 14, 2021 55

 FO unloading system
• Heavy oil is received at the site in railway tankers of 20
tonne capacity each
• An unloading header with number of receiving points
for number of wagons unloading is provided.
• The connections between loading header and tankers
are through rubber flexible hosepipes.
• Railway tankers are equipped with steam heating coils.

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 Strainers

Transfer P/P

Sunday, March 14, 2021 57

 Return oil
From Unit
FILLING HDR
Suction HDR
Return Hdr

I/L
HEATER
O/L
Steam
R/C
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 OIL
TANK

OIL
TANK

Recirculation P/P

Suction Header Return Header

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 Return Steam Steam to Atmosphere
From Heater

Flash
Tank

Water to Sump Pit

Sump Pump
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 DRAIN
HDR
Drain
Tank
Oil
Drain Oil p/p Tank

Sunday, March 14, 2021 61

 Oil Guns
HOTV CV

HORV

Sunday, March 14, 2021 62

Water Treatment Plant
 Why water treatment?
• Raw water contains many dissolved minerals and organic
materials.
• At high temperature certain minerals left scaling on the tube
metal of the boiler and cause permanent damage.
• Some dissolved minerals leads to corrosion of tube metals.
Some leads to foaming
• At high pressure and temperature an element, silica can be
carried away with steam causing damage to turbine low
pressure stage.
• A Thermal Power Station needs water of varying quality for
different process and hence the requirement.
• The performance and life expectancy of the station greatly
depends on water chemistry compliance.

Sunday, March 14, 2021 64

Type of water treatment

• the type of demineralization process chosen for a power

station depends on three main factors :
• The quality of the raw water.
• The degree of deionisation i.e. treated water quality
• Selectivity of resins.

Sunday, March 14, 2021 65

Different water qualities in use at NTPC-Stations

Condenser cooling…..Raw water/ Clarified & post-

chlorinated water.
BA flushing – Raw water.
Boiler feed water…..Conditioned DM water.
ESP / Channel flushing…..Raw/ Clarified water.
Other aux. cooling…..Clarified water.
H2 generation plant…..DM water.
Drinking water…..Filtered & post-chlorinated water.
DM plant operation…..Filtered water.
Sunday, March 14, 2021 66
 Steps of treatment process
• Aeration of raw water
• Adding chemicals for bacteria removal
• Adding chemicals for sedimentation of suspended
particles
• Flocculation
• Filtration
• Ion Exchange process
• water treatment process is generally made up of two
sections :
• Pretreatment section
• Demineralisation section
Sunday, March 14, 2021 67
 What is pre treatment process?
• Pretreatment plant removes the suspended solids
• The coarse components, such as sand, silt etc, can be removed
from the water by simple sedimentation
• the non-separable solids (colloids) will not settle in any
reasonable time and must be floculated to produce the large
particles which are settle able.
• Flocculation is obtained by gentle and prolonged mixing which
converts the submicroscopic coagulated particle into discrete,
visible & suspended particles.
• This operation is done by flash mixer in the clarifloculator.
• Proper pre treatment reduce loading on anion and cation
exchanger.

Sunday, March 14, 2021 68

 Raw water to Clarified water
Aerator
Raw water bay

RW make up pumps

Clarified Clariflocculator Cl2 dosing

water Pershall
flume
Lime dosing

Alum dosing

Flash
Sunday, March 14, 2021
mixer 69
 A view of Clari-flocculator

Flocculation zone

Clarification zone

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 Motion of water in a Clari-flocculator

Clarification zone Flocculation zone

Sunday, March 14, 2021 71

 Clarified water to Filtered water
GF Bed
Clarified water Sand filters

FW DW
sump sump

Clari-flocculator
Cl2 Post-chlorination

DW
Cl2 House FW pumps
pumps

Filtered water

To Township for
DM water for
DM PLANT drinking water
Plant purpose
Sunday, March 14, 2021 72
Turbidity & Free Cl2 check
 Demineralization
plant

Sunday, March 14, 2021 73

 FWDemineralization
water Plant

ACF WAC SAC

Degasser

WBA SBA MB

CST

Sunday, March 14, 2021 74

 Activated carbon Filter (ACF)
• Activated carbon acts on principle of adsorption which is a surface active
phenomenon
• It removes residual turbidity (<2 NTU) of water to its 1/10 level.
• It removes organic molecules to control colour and odour.
• It removes free residual chlorine present in filtered water(0.5 ppm Nil)

Sunday, March 14, 2021 75

 Ion exchange resin & its functional group

• An ion exchange resin consists of a cross-linked polymer matrix

(poly-styrene cross linked with 5-8% di-vinyl benzene for
srtuctural stability) to which charged functional groups are
attached.
• Common functional groups are : -SO3-H+ (SAC), -COO-H+
(WAC), -NR4+OH- (SBA) and –NR2 (WBA).

Sunday, March 14, 2021 76

 Exchange Reactions

• CATION RESIN:

• 2R-H + Na2CO3 2R-Na+H2CO3

• ANION RESIN:

• 2R-OH + H2SO4 2R-SO4+2H2O

Sunday, March 14, 2021 77

 Working of WAC ion exchange resins

• WAC resin is capable to exchange cations of alkalinity

producing salts only ie, for carbonate hardness removal
purpose.
• 2 R-COOH + Ca(HCO3)2  (RCOO)2Ca2+ 2 H2CO3
• WAC resin can exchange ions only in neutral to alkaline pH
range.
• WAC results efficient TDS reduction in high carbonate hardness
water.
• Efficient regeneration takes place even with very dilute acid
solution.

Sunday, March 14, 2021 78

 Working of SAC ion exchange resins

• SAC resin works over wide pH range & is capable to exchange

any type of cations present in salts as sulphonic acid group is
strongly acidic.
• 2 R-SO3-H+ + CaCl2  (RSO3)2Ca2+ 2 (H+ + Cl- )

Sunday, March 14, 2021 79

 Working of Degasser

• Water from the ex-cation contains carbonic acid which is very

weak acid and difficult to be removed by strongly basic anion
resin and causing hindrance to remove silicate ions from the bed.
• The ex-cation water is trickled in fine streams from top of a tall
tower packed with rasching rings, and compressed air is passed
from the bottom
• Carbonic acid break into CO^ and water. carbon dioxide escapes
into the atmosphere. Water is pumped back to anion exchanger
bed

Sunday, March 14, 2021 80

 Working of WBA resins

• WBA resin works over acidic pH range only & is capable to trap
any strong type acid molecules present in cation effluent,
through protonation of secondary / tertiary amine centre, as
the amine group is weakly basic in nature.
• ▓-NR2 + HCl  ▓-NR2H+Cl-
• WBA can be regenerated easily with very dilute alkali (NaOH)
solution

Sunday, March 14, 2021 81

 Working of SBA ion exchange resins

• SBA resin works over wide pH range & is capable to exchange

any type of anions present in water as quarternary ammonium
group is strongly basic.
• 2 ▓-NR3+OH- + SiO32-  (▓-NR3+)2SiO32- + 2 OH-

Sunday, March 14, 2021 82

 Working of Mixed bed

• ex-anion water is fed to the mixed bed exchanger containing both

cationic resin and anionic resin.
• This bed not only takes care of sodium slip from cation but also
silica slip from anion exchanger very effectively
• The final output from the mixed bed is an extira-ordinarily pure
water having less than 0.2/Mho conductivity, H 7.0 and silica
content less than 0.02 ppm.

Sunday, March 14, 2021 83

Regeneration of ion exchanger

• During water treatment any deviation from the specified quality in

the output means that the resins in mixed bed became exhausted and
need regeneration.
• regeneration of the mixed bed first calls for suitable back washing and
settling, so that the two types of resins are separated from each
other.

Sunday, March 14, 2021 84

 Regeneration of resin bed

•ACF is regenerated by backwashing the bed with

air-water.

•WAC and SAC are regenerated by counter

current regeneration with 4% Hydrochloric Acid
with a down flow of DM water.

Sunday, March 14, 2021 85

 •WBA and SBA are regenerated by counter current
regeneration with 4% caustic with a down flow of DM
water.

•Resins of MB is first separated by air scouring.

•Individual resins are regenerated by acid and alkali

respectively.

Sunday, March 14, 2021 86

Regeneration of ion exchanger

• After regeneration, the effluent comes out from the system is treated
in a neutralizing pit for discharging through normal drain.

Sunday, March 14, 2021 87

Ash Handling System
 WHAT IS ASH?
Ash is the residue remaining after the coal has been
incinerated to constant weight under standard conditions.
Ash is oxidised form of the mineral matters present in

coal.
Typical ash composition : SiO , Al O , Fe O , CaO,
2 2 3 2 3
MgO etc.
Coal with more SiO & Al O , Ash MP > 1400ºC
2 2 3
Coal with more Fe O , CaO & MgO, Ash MP < 1100ºC
2 3

Sunday, March 14, 2021 89

 WHY ASH HANDLING?

Ash content of Indian coal used in power station is

about 30 to 40 %.
A typical 2000 MW station produce around 9000T to

12000T of ash per day.

This huge amount of ash needs to be disposed off

continuously.
Necessary care to be taken for preventing pollution

Ash Handling system takes care the above requirement

Sunday, March 14, 2021 90

 WHAT HAPPENS TO THE ASH
PRODUCED?
20 % Of the ash falls at the bottom of the furnace known
as Bottom Ash (BA).
80 % of the ash carried away with flue gas known as FA.
BA can form slag and clinker depending on the temp.

of the combustion zone and environment inside.

reducing environment (Less O2) reduces ash MP.
BA is disposed off through BA disposal system.
FA is collected through ESP and disposed through FA

disposal system.

Sunday, March 14, 2021 91

 Overburden Surge Pile

Coal Seam Pulverize (-150)

Electrostatic Precipitator Boiler

Flue Gas Flue Gas
Fly Ash
Fly Ash Bottom Ash

Bottom
Fly Ash
Ash
Smoke
Stack

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 Ash volumes and properties
Furnace ESP
(1300 - 1500°C)

Economizer Electrostatic Stack

Precipitator
Air
preheater
Pulverized APH
Coal

Stage A: 80 %
Stage B: 17 %
Stage C: 3 %
Coal Bottom Ash Eco Ash APH Ash Fly ash
100 % 10-20 % 1% 1% 80-90 % Ash
Fineness
Sunday, March 14, 2021 93
 BA Handling System
BA can be collected at furnace bottom as Wet or Dry form.
Wet bottom ash system consists of i)Trough seal, ii)BA

gate, iii)Hopper, iv)Scrapper Conveyer, v)Clinker grinder,

vi)BA trench, vii)BA tank, viii)BA pump, ix)BA pond.
Dry BA consists of i)Trough seal, ii)BA gate, iii)Hopper,

iv)Scrapper Conveyer, v)Clinker grinder, vi)Silo.

Trough seal : A channel around the furnace bottom

filled with water where the furnace bottom end is

immersed in water. This is to prevent air ingression in the
boiler during operation.

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 BA Handling System
BA Gate: Each hopper has separate gate to isolate Scrapper
conveyor from running furnace for any repairing at scrapper.
Scrapper Conveyer : Consists of number of scrapper bars
fasten at both the ends with two chain which can run on
chain pulley and driven by scrapper conveyor motor. The
whole conveyor is submerged in water for wet BA system.
Bottom ash after falling on scrapper is scrapped away by the
running conveyor to one end of the conveyor to clinker
grinder.
Clinker grinder : Any big size ash clinker is crushed to
enable to be carried away by water jet through BA trench.
BA trench : Through water jet ash slurry is carried away to
BA tank
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Sunday, March 14, 2021 PMI Revision 00 96
Sunday, March 14, 2021 PMI Revision 00 97
 BA Handling System
BA pump : Ash slurry handling pump. It carries ash to the BA pond.
Depending on the distance of BA pond two or more BA pumps
connected in series.
BA pond : Finally ash is discharged to ash pond. It is a large area
surrounded by embankment. Ash mixed with water is allowed to settle
for considerable time. Water from top surface is allowed to go out from
the pond through a designed escape route. Quality of water discharge is
always monitor for turbidity and heavy metal. Piezo meter is used for
monitoring the slope stability of the embankment.
BA Supporting water pumps
LP BA pump : Supply water to trough seal, scrapper conveyor sump,
BA sump and LP jets.
HP BA pump : HP jets in BA trench and line cleaning.

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 Dry BA Handling System

Dry BA collection system after clinker grinder collect ash

to silo through a transport mechanism for further transport
through road system.

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Sunday, March 14, 2021 PMI Revision 00 100
 FA Handling System
FA is collected from Air heater hopper, Eco hopper and
ESP hopper.
Either through flushing apparatus or hydrobactur system.
In Flushing apparatus system ash is allowed to fall in
flushing apparatus under gravitation.
Water jet in flushing apparatus carries away the ash to FA
trench
High pressure jets further carries it to FA sump.
Series pumping carries the ash slurry to FA pond.

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Sunday, March 14, 2021 PMI Revision 00 102
 Dry FA Handling System

Hydrobackter is a vacuum device to collect ash from the

hopper.
Water jet ejectors used for creating vacuum.
Dry ash thus collected to silo through belt conveyor.
Dry ash is disposed through road transport to a dry ash
disposal system. Part of it sold for commercial purpose

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Sunday, March 14, 2021 PMI Revision 00 104
 ASH UTILISATION
Major usage of ash
•Fly ash bricks / blocks
•Cellular concrete products
•Light weight aggregates
•Concrete and mortar
•In manufacture of cement
•In manufacture of asbestos products
•Road construction
•Embankment/back fills/land development
•In agriculture
•Mine filling
•Manufacture of fertiliser

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 Other usage
•Manufacture of distemper
•Floor and wall tiles
•Refractory bricks
•Manufacture of ceramics
•Use with Ferro cement
•Recovery of metals
•Use in grouting
•Manufacture of alum
•Domestic cleaning powder
•In synthetic wood

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 THANK YOU

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