Bottom Ash and Grate

System
BY: AHSAN ALAM (UNIT CONTROLLER-MCR)
Introduction
 This system is designed for the removal of Boiler bottom
ash from the boiler and is for continuous operation.
 Under normal operation, ash will fall continuously from
the bottom of the boiler on the ash conveyor.
 Ash is discharged from the ash conveyor into crusher.
 The crusher can reduce the particle size and then into the
chain bucket conveyor that convey the material to an ash
storage silo.
Equipment involved

 Three Hydraulic Units:

 Grate Hydraulic Oil Unit.
 Ash Conveyor Belt tightening Hydraulic Oil Unit.
 Shut-off Gates Hydraulic Oil Unit.
 Two Conveyors:
 Dry Ash Conveyor/Extractor
 Chain Bucket Conveyor
 Six Rotary Feeders
 Six Grate Dampers
 Six Grate Carriages
 Four Hydraulic Shut-off gates
Ash Flow

Grate Grate Dry Ash

Rotary
Carriages (6) Dampers Conveyor/
Feeders (6)
(6) Extractor

Chain-
Ash Silo /
Bucket Crusher
Ash Bin
Conveyor
DCS Diagram
Start Sequence

Ash and Slag Handling System should be started before firing the Boiler. Following sequence
has to be adopted for that:
 Start Ash Conveyor/Extractor Belt tightening Hydraulic Oil system from Local.
 Start Grate Hydraulic Oil Pump
 Start Shut-off Gates Hydraulic Oil pump.
 Start Chain Bucket Conveyor.
 Start Crusher
 Start Dry Ash Conveyor/Extractor.
 Start all 6 Rotary Feeders.
 Open all 6 Grate Dampers
 Hydraulic Shut-off gates will only be opened when there is sufficient Ash accumulated
above them. It will be seen by the Cameras.
Burnout Grate System

Function:
 The furnace ash of the lignite fired boiler contains coarser particles
that also contain unburned material.
 –The burnout grate system has to reduce the share of unburned
combustibles. This increases the efficiency of the lignite boiler.
 –In addition, the ash (slag) is cooled before it is discharged into the
dry ash conveyor.
Description of the
burnout grate system
 –The grate system is located in the boiler slot at the bottom end of the boiler
hopper.
 –There are two longitudinal arranged grates facing each other. A slag hopper is
located between the grates.
 –The two grates transport the furnace ash to the center. There the ash is
discharged into the slag hopper and falls into the dry ash conveyor.
Burnout grate system
Diagram
Burnout grate system
Diagram
Functionality of the
Burnout grate
 The ash fuel mixture falls from the boiler furnace to the grate. The mixture is
burned on top of the grate surface and transported to the slag hopper.
 The hot combustion air is fed underneath the grate surface to the 2x 3 air zones of
the grates. The distribution of the combustion air can be adjusted via manual
dampers according to the combustion requirements. The dampers are located in
the air ducts.
 The grate surface consists mainly of casted grate bars with air slots for the
passage of the combustion air.
Functionality of the
Burnout grate
 Speed of the grate (number of cylinder strokes per minute) can be
adjusted through DCS, according to the need.
 The grate speed affects the ash--fuel--layer covering the grate bars.
 The layer should not be less than 0.2 m, as otherwise the grate
surface will be overheated by radiation, which leads to increased
wear of the grate bars.
 A slow operation reduces the mechanical wear of the moving parts
of the grate. The height of the layer must not exceed 1.5 m.
Grate Dampers

6 Grate dampers are provided at Boiler Bottom.

 According to the logic provided, they can only be
opened if the respective rotary feeder is in service.
 They will close automatically if the respective
rotary feed motor stops.
Rotary Feeders

 6 Rotary Feeders are provided i.e. one after each Grate Damper.
 Each impeller of the rotary feeder has 9 blades.
 The task of the rotary valves is to enable the ash to pass the ash
hoppers and at the same time not to let the combustion air
escape.
 Rotary Feeders work to supply ash from boiler bottom to the
Dry Ash Conveyor/Extractor.
 According to the logic, Rotary Feeders stop automatically once
Dry Ash Conveyor/ Extractor Stops.
Dry Ash Conveyor
/ Extractor
 It supply ash from boiler Bottom to the Crusher.

 If crusher is not available, ash can also be thrown away

through an emergency drain present at the downstream of the
Dry Ash Conveyor / Extractor.

 Dry Ash Conveyor / Extractor Start Permissive:

 Hydraulic tension Device normal.
 Crusher in service.
Crusher

 Two crushers are provided at site. One remains in service

while other is standby.
 Ittakes ash from the Dry Ash Conveyor /Extractor, crush it
and sends it to the chain bucket.
 According to the logic provided in DCS, Crusher will not
take start command unless Chain Bucket Conveyor is in
service. And it will instantly when Chain Bucket Conveyor
stops.
Chain Bucket Conveyor

 It supplies Ash from the Crusher to the Ash Bin/Ash Silo.

 According to the logic provided in DCS, Chain Bucket Conveyor cannot be

stopped until Crusher has been put off.

 Chain Bucket Conveyor motor will trip on following Protections:

 Ash Bin/Ash Silo Level > High.
 Chain Bucket Conveyor chain-Break alarm.
Hydraulic Shut Off Gates

 Four Hydraulic Shut Off Gates are provided (A1, A2, B1

and B2).

 These gates remain closed in normal operation.

 When excess amount of ash is collected (which can be

seen through camera) these gates can be opened for Ash
removal.
Thank You