BURNING OF COAL IN A THERMAL POWER STATION

• Heat of coal generates steam in the Boiler which is fed to the steam
Turbine coupled with the Generator for ‘ GENERATION OF
ELECTRIC POWER’.

• It leaves behind huge quantities of residue called as ASH.

• FURNACE BOTTOM ASH
TO
• ECONOMISER COARSE ASH CHIMNEY
• FLY ASH

BUNKER ECO ESP+APH

HOPPERS HOPPERS

BOILER
MILLING SYSTEM

BOTTOM ASH COARSE ASH

FLY ASH
POWER GENERATION IN A THERMAL POWER STATION
IS DIRECTLY AFFECTED BY:

• The coal supply

• Ash Evacuation from the Boiler / Hoppers

•The Milling plant performance / Availability

•Main plant & auxiliary equipments performance/

Availability
CLASSIFICATION OF ASH HANDLING SYSTEM

 A) Operation duty
• Operating Continuously
• Operating Intermittently
 B) Method of Handling
• Wet Disposal System
• Dry Disposal System

 C) Means of Handling
• Pipe Lines
• Belt Conveyors
• Trucks / Mobile Equipments
 TO REDUCE LAND & WATER REQUIREMENT

TO MINIMISE UNDERGROUND WATER & SURROUNDING

WATERWAYS POLLUTION

 TO FACILITATE UTILISATION OF ASH IN BULK QUANTITIES

The fly ash is evacuated from fly ash hoppers & transported to ash
Storage Silos in two steps

> From the ESP & APH Hoppers to Buffer Hoppers throu
‘ VACUUM SYSTEM’.

> From Buffer Hoppers to ash storage Silos thro ‘PRESSURE

SYSTEM’.
 A1 A8

FLY ASH ESP HOPPERS TOTAL ESP HOPPERS/PASS =28 NOs.

PASS-A

•EACH PASS HAVING 4 VAC LINES

•EACH VAC LINE HAVING 7 HOPPERS
APH HOPPERS •APH HOPPERS ARE CONNECTED TO
PASS B AND C

VACUUM PUMPS
1A/2A
A7 A14

BUFFER HOPPERS 1A/2A

TACs 1,2,3

FA LINES 1,2 TO ASH SILOs

 VAC P/P
BAG FILTERS

BHVIV
FROM ESP HOPPERS

DASV SCVEV
PCUDG
Pr.COLLECTOR PCVEV SCUDG
SEC. COLLECTOR

PCPEV
PCLDG SCLDG SCPEV
TO ESP DUCT

BUFFER HOPPER
3-WAY V/V 3- WAY V/V

ALTUG ALTUG

AIR LOCK TANKS

FROM TAC LINES FROM TAC LINES

TAC LINE # 1 ALTLG ALTLG

TAC LINE # 2
 REAL TIME SEQUENTIAL OPERATION

ASH COLLECTION
(ESP HOPPERS TO BUFFER HOPPER VIA PR/SEC COLLECTORS)
T
I
M
TIME (SEC) PCVEV PCPEV SCVEV SCPEV UDG LDG

0-60 OPEN CLOSE CLOSE OPEN OPEN CLOSE

65-125 CLOSE OPEN OPEN CLOSE CLOSE OPEN

 OPERATION MODE

1. AUTO
MHV SELECTION MHV OPENING AND MHV CLOSING- ALL
OPERATIONS ARE PERFORMED IN AUTO DEPENDING ON
LINE VAC

2. MANUAL
MHV SELECTION IS WITH THE OPERATOR’S CHOICE

MHV SELECTION OPENING & CLOSING

LINE VAC 115 MMWC – SELECTED MHV CLOSING &
NEXT MHV SELECTION
LINE VAC 250 MMWC – SELECTED MHV OPENING
 S/V
TO ESP DUCT

BUFFER HOPPER
3-WAY V/V 3- WAY V/V

ALTUG ALTUG

AIR LOCK TANKS

FROM TAC LINES FROM TAC LINES

TAC LINE # 1 ALTLG ALTLG

TAC LINE # 2
 REAL TIME SEQUENTIAL OPERATION

REMOVAL OF ASH
(BUFFER TANK TO TAC LINES VIA AIR LOCK TANK)

TIME (SEC) 3-WAY Pr EQ. V/V ALTUG ALTLG

0-45 OPEN OPEN CLOSE

50-95 CLOSE CLOSE OPEN

 FLY ASH EVACUATION – PROCESS (Contd.)

EACH UNIT HAS 4 BUFFER HOPPERS & TWO ASH TRANSPORT LINES.

 ASH IS TRANSFERRED FROM VAC SYSTEM TO PRESSURE

SYSTEMWITH THE HELP OF PLCCONTROLLED UPPER GATE, LOWER.
GATE & PRESSURE EQUALISING VALVES

 EACH BUFFER HOPPER IS PROVIDED WITH PULSE JET CLEANED

BAG FILTERS TO SEPARATE ASH FROM CONVEYING AIR.
 FLY ASH EVACUATION - PROCESS

 FA HOPPERS ARE DIVIDED INTO GROUPS.

 FA IS REMOVED FROM GROUPS IE ONE HOPPER FROM EACH GROUP

SIMULTANEOUSLY IE ONE HOPPER FROM EACH GROUP AT A TIME.
THRO’ PLC SYSTEM

 VARYING LINE VACUUM IS USED TO CONTROL THE SYSTEM OPERATION

 WHEN HOPPERS BECOME EMPTY VAC. FALLS AND THEN MHV CLOSES,
ANOTHER HOPPER IS SUBSEQUENTLY SELECTED.
 A NO. OF PROTECTION / INTERLOCKS ARE PROVIDED FOR SYSTEM OPERATION.

 3 SILOS FOR 2 UNITS OF 500 MW

 SEG V/Vs LOCATED ON EACH SILO IN EACH FLY ASH TRANSPORT LINE ARE

USED TO CONTROL SILO SELECTION.

 THE SYSTEM HAS PROVISION FOR STORAGE OF SEGREGATED ASH FROM ESP

HOPPER INDESIRED SILO FOR PURPOSE OF MEETING DIFFERENT REQMTS

FOR ASH SALE/UTILISATION.

SILO IS ALSO PROVIDED WITH BAG FILTERS, VENT FANS, HYDROMIX DUST

CONDITIONERSROTARY FEEDERS, AERATION BLOWERS ETC.

TAC LINES TAC LINES VENT FAN

ASH STORAGE SILO

( CAPPACITY- 500 MT)

HMDC

ROTARY FEEDERS

TO OPEN TRUCKS
TO CLOSED TRUCKS
 FROM ESP HOPPERS
VB WSV VB

WSV
FROM VAC P/P
FROM FAHP VIVs WHWV

FROM FAHP
WHWV
WETTING HEAD

COLLECTOR TANK

ASH SLURY PIT

ASH SLURY P/PS

 BOTTOM ASH / COARSE ASH EVACUATION

 BOTTOM ASH EVACUATION SYSTEM:

BOTTOM ASH -WATER IMPOUNDED BA HOPPER-BOTTOM ASH GATE--CLINKER GRINDER—

-HYDROEJECTOR-ASH SLURY LINES--ASH SLURY PIT

> EACH BAH HAS TWO SECTION.

> EACH BAH HAS TWO OUTLETS.

> EACH OUTLET IS HAVING ONE BA GATE,ONE CLINKER GRINDER & ONE HYDROEJECTOR

> EACH UNIT IS HAVING TWO ASH SLURY LINES, BOTH OPERATING SIMULTANEOUSLY.

.> TOTAL 02 ASH SLURY PIT FOR TWO UNITS.

> BAH OVERFLOW-OVERFLOW TANK-OVERFLOW P/PS-SETTLING TANKS

> ECO HOPPER  FLU. APPT  ECO SLURY TANK  ECO SLURY P/PS  ASH SLURY PIT
 STAGE # 1 ASH DISPOSAL SYSTEM
• EACH ESP HAVING 56 NOS OF HOPPERS
• THERE ARE 3 NOS OF ASH SLURRY PUMP HOUSES
• ONE PUMP HOUSE IS COMMON FOR TWO UNITS
• EACH PUMP HOUSE HAVING 3 SERIES OF ASH SLURRY PUMPS
• EACH PUMP HOUSE IS HAVING 3 NOS OF ASH DISPOSAL LINES
• ANY P/P CAN BE SELECTED FOR ANY ASH SLURRY LINE
ASH SLURRY PIT

GATE

ESP
HOPPER LOW LIFT P/P

ISOLATING GATE

HIGH LIFT P/P

HP / LP
WATER GATE
SLURRY TO
ASH SLURRY PIT
ASH SLURRY LINES
FLUSHING APPARATUS
TO ASH POND