Circumix Dense Slurry Technology

CIRCUMIX MIXER
IN DENSE SLURRY SYSTEM

OF
GEA EGI Co. Ltd.

an environment friendly solution for coal fired power plants 2009
Thermal Engineering / GEA EGI Contracting/Engineering Co. Ltd.
Thermal Engineering / GEA EGI Co. Ltd.
GENERAL DEFINITIONS OF DSS TECHNOLOGY DSS stands for Dense Slurry System Slurry is a mixture of water and residue of coal fired boilers Slag or bottom ash or bed ash is the rough-grained part of residue
from boiler furnace
Ash or fly ash is the fine-grained residue collected by electrostatic

precipitators (ESP) or bag filters from the flue gas
Dense reflects the density of slurry with a ratio around 1:1 (1 kg solid
material:1 kg water)
Thin reflects the density of the slurry with a ratio around 1:10. (1 kg
solid material:10 kg water). Thin slurry is produced in the conventional residue discharge systems
Mixer is the key component of dense slurry preparation CIRCUMIX is the given name of EGIs patented mixer equipment
GENERAL DEFINITIONS OF DSS TECHNOLOGY

DSS technology means complete environment friendly slag and ash disposal technology of EGI based on comprehensive technology know-how
Dense slurry of CIRCUMIX mixer means

viscous non-Newtonian fluid (Bingham plastic fluid) as water/solid material mixture to keep solid particles in suspension in mixer and in the connecting hydraulic transport system, even if rough-grained bottom ash is mixed together with fly ash;
water/solid material mixture near to the stoichiometrical ratio needed to be bounded and to be solidified with slight excess water to fill up interparticle voids promoting
transformations of ash mineral phases
Intensive slurry homogenization and crystal nucleus generation by collisions on blades of rotating circulation pumps in the mixer aggregate.
GENERAL DEFINITIONS OF DSS TECHNOLOGY
Solid body mechanics Continuum Mechanics
Elasticity Plasticity NonReology Newtonian fluids Newtonian fluids
Fluid mechanics
HISTORY OF TECHNOLOGY DEVELOPMENT The first dense slurry system delivered by EGI was the ash discharge
system of Pcs Power Plant in 1991;
The dense slurry mixer operated on batch mode. There were two
mixers operated parallel. First a mixer was filled up by a scaled amount of makeup water, fly ash and dewatered bottom ash. A rotating blade agitator was operated continuously in the mixer. After a pre-set mixing time the slurry was discharged from the mixer, and during discharge the next mixer was filled up and agitated. EGI faced serious operational problems with bottom ash. Finally Client decided to handle the bottom ash by trucks;
EGI has decided to develop his own mixer type that is capable of
running continuously, to handle rough-grained bottom ash particles (later on to mix in also FGD gypsum slurry) without mechanical rotating blades.
The result of the development is the patented CIRCUMIX mixer.

5
DESCRIPTION OF PATENTED CIRCUMIX MIXER Main features of CIRCUMIX mixer

The CIRCUMIX mixer has two main parts: pre-mixer head and mixing tank
Agitation by slurry circulation pumps (pre-mixer and mixing tank) and
hydrodynamic internal mixing for intensive slurry homogenization, for applying appropriate amount of mixing work per unit mass of dense slurry;
Bottom ash can be mixed into as there are no dead zones inside for settling; FGD gypsum can be mixed into the dense ash slurry; Exhaust air venting system connected to mixing tank helps degassing of
slurry and keeping the slurry homogeneous (incompressible);
Cleaner equipment are applied to keep clean dry-wet interfaces;
CIRCUMIX MIXER SCHEME

Fly ash
Pre-mixer Head circulation
Pre-mixer Head
FGD gypsum slurry
Makeup water Exhaust air venting Deflector
Thickened BA slurry Tank circulation
Mixing Tank
Dense slurry discharge
PATENT OF CIRCUMIX MIXER Patent header of CIRCUMIX mixer equipment
PATENT OF CLEANING APPARATUS Hydromechanical Mixing Apparatus
DENSE SLURRY MIXER EQUIPMENT LINE Size and capacity development of CIRCUMIX mixer projects
The size and capacity variation of CIRCUMIX mixer references

MTRA POWER PLANT Co. Ltd. VISONTA PLANT NEYVELI LIGNITE CORP. Tendering Phase 3 Qslurry =100 m/h JEA PP 2001. Q slurry =120 m/h
3
1999. Q slurry =240 m/h

3
10
DENSE SLURRY MIXER ARRANGEMENT
Mixer Exhaust Venting System
Fly Ash Dosing Silo
Pre-mixer Head Circulation Pump
Mixer Tank Circulation Pump
11
MAIN MILESTONES OF CIRCUMIX DEVELOPMENT Testing of dense slurry sample properties made by laboratory scale
and by EGIs semi-industrial mobile mixer with residues from several coal fired power plants;
Support the appropriate test procedures applied at laboratories of

environmental authorities considering the specialties of dense slurry disposal field (effect of aging, way of sampling, etc.);
Collecting qualifications based on tests mentioned above for potential

Clients without and with FGD gypsum;
Studies at three different universities and other specialists for

rheological, sedimentation, transportation and solidification properties of dense slurries;
12
LABORATORY TESTS AND STUDIES Ash particle size distribution measurements; Ash particle density measurements; Ash chemical composition measurements; Ash mineral phases measurements mainly for evaluating CaO forms;
Rheological tests of dense slurry at different solids concentration by

pipe viscometer;
Stress analysis of test cubes
13
LABORATORY TESTS AND STUDIES FOR DSS APPLICATIONS

Eesti PP / Narva Power Plants Particle size distribution of ash samples of PCB and CFB
100 90 80 70
Undersize, wt%
60 50 40 30 20 10 0 10 100 Particle size, micro-meter 1000 Furnace bottom ash Coarse fly ash Fine fly ash PCB ash CFB ash
Technical University of Miskolc

14
LABORATORY TESTS AND STUDIES FOR DSS APPLICATIONS

Oxides composition of generated total ash of CFB unit #8 of Eesti PP
CFB ash Ignition loss (810 C) 10.25% Cl2 0.18% SO3 5.68% TiO2 0.10% K2O 3.38% Na2O 0.13% Fe2O3 4.21% CaO 30.93%
Al2O3 7.44%
MgO 5.17%
Technical University of Veszprm

15
SiO2 32.51%
COMPUTER FLOW DYNAMIC DSS MIXER MODEL Computer flow dynamic model and physical model was developed for
developing CIRCUMIX technology to study effect of mixer size, slurry
recirculation and for aiding appropriate design of other mixer details);
Preliminary
modeling
were
required
to
select
optimal
grid
arrangement, the best fitting turbulence model, etc.
Physical model was built to compare measured and calculated

velocity profiles.
16
DSS MIXER MODEL AND COMPUTER FLOW DYNAMIC
Budapest University of Technology and Economics

17
COMPUTER FLOW DYNAMIC DSS MIXER MODEL
Extract from presentation abstract for Multiphase Flows Workshop 26-28 May 2009, Dresden-Rossendorf Numerical simulation and measurements of the free surface flow in a hydrodynamic mixer Cs. Hs(1), Gy. Pal(1), G. Walter(2) Corresponding author: Cs. Hs, csaba.hos@hds.bme.hu (1) Department of Hydrodynamic Systems Budapest University of Technology and Economics (2) GEA EGI Contracting / Engineering Co. Ltd.
18
COMPUTER FLOW DYNAMIC DSS MIXER MODEL

This part of the presentation deals with the numerical simulation of a mixer consisting of a cyclon-like cylinder in which the free-surface swirling water flow is driven by two tangential water jets above the water level. The challenge in this problem was to properly capture the velocity distribution and the free water surface. 3D unsteady simulations were performed with SST and SSG turbulence models in a geometry containing 800k cells. A test rig was built in which -beside the visual access to the whole fluid domain velocity measurements were performed using turbine flow meters. The circumferential velocity component was measured along several radial and axial lines and compared to the simulation results showing reasonable agreement.
19
COMPREHENSIVE DENSE SLURRY SYSTEM
Dry Bottom Ash Collection / Treatment
Bottom Storage Bin
Dry Fly Ash Collection
Fly Ash Storage Silo
Dense Slurry CIRCUMIX Mixer
Dense Slurry Transport
Makeup Water Treatment
Makeup Water Surge Tank
Dense Slurry Deposition
20
DENSE SLURRY SYSTEM

BA slurry handling EGI DSS technology includes bottom ash slurry thickeners and clean
water return back to ash flushing at operating boilers;
Oversize particles of bottom ash slurry are separated and collected in

waste container;
Thickened bottom ash slurry is pumped into operating dense slurry

mixer(s);
FGD gypsum slurry handling CIRCUMIX mixers can accept FGD gypsum slurry flow from gypsum
slurry reservoir;
FGD gypsum slurry flow is monitored and the final dense slurry quality is
protected from unacceptably high gypsum content;
21
DENSE SLURRY SYSTEM

I&C
The control system is part of the technology know-how of EGI; Equipment have their on PLC controls and on top level a DCS system
controls the whole ash handling technology;
The ash discharge system is operated by issuing automatic operational

sequences from the operator station of the ash handling plant;
Closed and open loop controls helps automatic system operation; Alarms and protections are for avoiding forced outages; Management system helps scheduling maintenance;
22
BOTTOM ASH SLURRY THICKENER
23
ECOLOGYCAL FEATURES OF DSS TECHNOLOGY The dense slurry is deposited generally onto a plain ash field area.
The ash field is divided into smaller size slurry cassettes one for
operation and the other for stand by.
The cassette is surrounded by dike made from own material

excavated from deposited dense slurry.
On the top of the dike are the dense slurry distribution pipes, and at
even positions dense slurry discharge pipe can be connected.
24
ECOLOGYCAL FEATURES OF DSS TECHNOLOGY Water requirement is low. Zero waste water plant is achievable by
mixing in plant waste waters, including water treatment plant and
flue gas desulphurization
No return water system from ash disposal area should be operated
After mineral transformation of settled dense ash slurry, ash stone is

developed icharacterized by
low water leakage to surface and ground water systems
low dissolution of ash components

embedded hazardous components acceptable strength and stability
25
ECOLOGYCAL FEATURES OF DSS TECHNOLOGY The developed, settled and aged ash layers are mechanically stable,
there is no dusting by wind, and the rain leakage through the ash has
environmentally acceptable quality.
The ash field height can be increased layer by layer. The compressive
strength of the deposited ash allows to built high ash storage fields.
The side surfaces are covered by thin earth layer, and by some
plantations the field can easily be recultivated.
26
BASIC ASH TRANSFORMATIONS
Slaking, calcium and sulfate ion generation:

CaO + H2O Ca(OH)2 CaSO4 + H2O Ca++ + SO4-FAST FAST
Ettringit formation:
Ca++ + OH- + SO4-- + Al2O3 + H2O 3CaOAl2O3 3CaSO4 31-32H2O Calcium silicate hydrates formation: Ca++ + OH- + SiO2 + H2O CSH MINOR REACTION INITIALLY FAST
27
ASH STONE PROPERTIES
Compressive strength and leakage data for 90 days ash stone formed from dense ash slurry of a high CaO content ash (according to DIN standards):
Sample W/S kg/kg I-3-F I-2-K-11 II-1-F II-3-F II-2-K-7 II-2-K-1 1:1 1:1 0.8:1 0.8:1 0.8:1 0.8:1
Strength kN/m2 4182 1936 13043 8571 4670 5586
Leakage m/s <E-12 <E-12 <E-12 2.2E-11 3.7E-06 (30 days old)
28
CULTIVATION OF DISPOSAL AREA

Dense ash slurry disposal area (typical)
DISCHARGE SUPPORT
DISTANCE SLURRY LINE STEEP SLOPE
OPTIONAL FOIL COVERAGE EXISTING DAM PLANNED BOUNDARY PLANNED SEPARATOR DAM WEST SIDE ASH FIELD NO 1 WATER DRAIN WATER COLLECTING WELLS MONITORING STATION EAST SIDE
EXCESS WATER DITCH
29
DENSE SLURRY LANDFILL DISCHARGE
30
DENSE SLURRY SYSTEM, LANDFILL AREA
31
MARKET OF DSS TECHNOLOGY
EGI DSS technology means complex environmentally sound solution

for Clients:
by replacement of obsolete thin ash slurry systems at existing

power plants. Retrofitting of existing bottom ash and fly ash
collection systems (if it is required by environmental agencies);
by fitting an environmentally acceptable ash disposal technology at

new plants.
32
REFERENCE PLANTS - ROMANIA

HCSD DSS Plant Capacity Purchase Order No. with complete postal Address Location Year Bottom Ash TPH Total Ash TPH
Fly Ash TPH
SC Colterm SA Timisoara Sud Power Plant, Romania
Episcop Joseph Lonovici, 4 Timisoara 300092, Romania Episcop Joseph Lonovici, 4 Timisoara 300092, Romania
2000
20
20
SC Colterm SA Timisoara Sud Power Plant Ext., Romania
2007
17
20
Romelectro, Romania Rovinari Power Plant 6X330 MWe, Romania Romelectro, Romania Craiova-II Power Plant 2X150 MWe, Romania
020371, Bucureti, Sector 2 Bulevardul Lacul Tei, Nr. 1-3

020371, Bucureti, Sector 2 Bulevardul Lacul Tei, Nr. 1-3 020371, Bucureti, Sector 2 Bulevardul Lacul Tei, Nr. 1-3
2009
4x30
4x127 FA +4x33 gypsum

4x51 FA +4x17.3 gypsum 4x55.2 FA +4x20 gypsum
4x190
2009
4x9.2
4x77.5
Romelectro, Romania Isalnita Power Plant 2X315 MWe
2009
4x7
4x82.2
33
REFERENCE PLANTS - ROMANIA Listed Romanian projects No. 1 and 2 are completed and are
operating. The first installation originally was designed as pilot plant for Romanian plants to test dense slurry handling system properties in semi industrial scale.
After the pilot plant was operated for years without problem, the Client
had decided to extend the dense slurry system capacity for the full plant.
Projects No. 3, 4 and 5 are running projects. All EGI equipment are at
site, but the EPC Contractor is in delay because of different reasons (financial, etc.). Commissioning of these projects are expected in the near future.
34
REFERENCE PLANTS - ROMANIA A new Romanian project is the ash handling system delivery for
Turceni Power Plant. This ash handling system will be similar to Rovinari case, but the installed total ash discharge capacity will be twice. EGI has good chance to participate (tender was submitted on 30 July, 2009.)
Recently a New Romanian tender has been issued for Paroseni

Power Plant. (Tender was submitted on 20 August, 2009.)
35
ROVINARI POWER PLANT - ROMANIA Next slides demonstrate first the assembly schedule of Rovinari PP
Dense slurry mixers for a unit.
Next a photo shows mixer tank before dispatch And finally three selected operator graphic diagrams are shown.
36
POWER PLANT - ROMANIA AshROVINARI silo
37
GEA EGI Power & Process Technology
POWER PLANT - ROMANIA AshROVINARI silo

CIRCUMIX mixers
38
GEA EGI Power & Process Technology
design phase AshDetailed silo

CIRCUMIX mixers Head and tank recirculation pumps
39
st October, 2008. Budapest, 21Power GEA EGI & Process Technology
Ash silo CIRCUMIX mixers Head and tank recirculation pumps Platforms
40
Ash silo CIRCUMIX mixers Head and tank recirculation pumps Platforms Rotary ash feeders
41
Ash silo CIRCUMIX mixers Head and tank recirculation pumps Platforms Rotary ash feeders Head recirculation pipelines
42
Ash silo CIRCUMIX mixers Head and tank recirculation pumps Platforms Rotary ash feeders Head recirculation pipelines Tank recirculation pipelines
43
Ash silo CIRCUMIX mixers Head and tank recirculation pumps Platforms Rotary ash feeders Head recirculation pipelines Tank recirculation pipelines Make up water
44
Ash silo CIRCUMIX mixers Head and tank recirculation pumps Platforms Rotary ash feeders Head recirculation pipelines Tank recirculation pipelines Make up water Flushing water
45
46
Exhaust air filters
47
Exhaust air filters Exhaust air pipelines
48
Exhaust air filters Exhaust air pipelines
Gypsum slurry pipelines
ABRASIVE RESISTANT INTERNAL LINING
49
PRE-ERECTION IN HUNGARY
50
PREPARATION FOR TRANSPORTATION
51
DENSE SLURRY DCS SOFTWARE CIRCUMIX MIXER
52
DENSE SLURRY DCS SOFTWARE - THICKENERS
53
DENSE SLURRY DCS SOFTWARE LONG DISTANCE TRANSPORTATION
54
REFERENCE PLANTS - JEA

JEA Jacksonville Northside Generating Station / USA/ 2x300 MWe CFB
circulating fluidized bed boiler based on petroleum coke (90 %) and coal (10 %) fuel. The boiler is the largest CFB boiler on the world. 2x62,5 tons/h of fly ash + 2x62,5 tons/h of bed ash mixing units (high CaSO4 fly ash / high CaO bed ash)
CIRCUMIX continuous mixing technology Bed ash and fly ash slurry handling Slurry distance transport 2 sets of piston diaphragm type slurry pump (GEHO) 1,7 km slurry transport distance
Commissioned: 2002
55
JEA 120 TPH DENSE ASH SLURRY MIXER, BED ASH MIXER HEAD AND TANK
56
JEA 120 T/H DENSE SLURRY MIXER, LANDFILL AREA
Walking on the surface of 24 hours ash stone
57
PROJECT HANDLING TECHNICAL

Tendering phase
Physical and chemical analysis of residues Test cubes preparation by mobile mixer Computer flow dynamic model Design data by calculation software
Design phase

58
Standardized modules 3D model preparation Pipe stress analysis Own software application in DCS system Full scale software test by simulation in EGI
PROJECT HANDLING TECHNICAL

Manufacturing phase
Continuous quality assurance and expediting Pre-erection at workshop in Hungary Geometrical verification by laser scanner Well-documented package transportation
Erection and commissioning phase
Supervision by EGIs experts deeply involved in the projects from

the beginning
59

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CIRCUMIX MIXER

IN DENSE SLURRY SYSTEM

GEA EGI Co. Ltd.

Thermal Engineering / GEA EGI Co. Ltd.

Ash or fly ash is the fine-grained residue collected by electrostatic

Thermal Engineering / GEA EGI Co. Ltd.

GENERAL DEFINITIONS OF DSS TECHNOLOGY

Dense slurry of CIRCUMIX mixer means

transformations of ash mineral phases

Thermal Engineering / GEA EGI Co. Ltd.

GENERAL DEFINITIONS OF DSS TECHNOLOGY

Solid body mechanics Continuum Mechanics

Elasticity Plasticity NonReology Newtonian fluids Newtonian fluids

Thermal Engineering / GEA EGI Co. Ltd.

The result of the development is the patented CIRCUMIX mixer.

Thermal Engineering / GEA EGI Co. Ltd.

DESCRIPTION OF PATENTED CIRCUMIX MIXER Main features of CIRCUMIX mixer

Cleaner equipment are applied to keep clean dry-wet interfaces;

Thermal Engineering / GEA EGI Co. Ltd.

CIRCUMIX MIXER SCHEME

Makeup water Exhaust air venting Deflector

Thickened BA slurry Tank circulation

Thermal Engineering / GEA EGI Co. Ltd.

PATENT OF CIRCUMIX MIXER Patent header of CIRCUMIX mixer equipment

Thermal Engineering / GEA EGI Co. Ltd.

PATENT OF CLEANING APPARATUS Hydromechanical Mixing Apparatus

Thermal Engineering / GEA EGI Co. Ltd.

The size and capacity variation of CIRCUMIX mixer references

1999. Q slurry =240 m/h

Thermal Engineering / GEA EGI Co. Ltd.

DENSE SLURRY MIXER ARRANGEMENT

Mixer Exhaust Venting System

Fly Ash Dosing Silo

Pre-mixer Head Circulation Pump

Mixer Tank Circulation Pump

Thermal Engineering / GEA EGI Co. Ltd.

Support the appropriate test procedures applied at laboratories of

Collecting qualifications based on tests mentioned above for potential

Studies at three different universities and other specialists for

Thermal Engineering / GEA EGI Co. Ltd.

Rheological tests of dense slurry at different solids concentration by

Stress analysis of test cubes

Thermal Engineering / GEA EGI Co. Ltd.

LABORATORY TESTS AND STUDIES FOR DSS APPLICATIONS

Technical University of Miskolc

Thermal Engineering / GEA EGI Co. Ltd.

LABORATORY TESTS AND STUDIES FOR DSS APPLICATIONS

Technical University of Veszprm

Thermal Engineering / GEA EGI Co. Ltd.

arrangement, the best fitting turbulence model, etc.

Physical model was built to compare measured and calculated

Thermal Engineering / GEA EGI Co. Ltd.

DSS MIXER MODEL AND COMPUTER FLOW DYNAMIC

Budapest University of Technology and Economics

Thermal Engineering / GEA EGI Co. Ltd.

COMPUTER FLOW DYNAMIC DSS MIXER MODEL

Thermal Engineering / GEA EGI Co. Ltd.

COMPUTER FLOW DYNAMIC DSS MIXER MODEL

Thermal Engineering / GEA EGI Co. Ltd.

COMPREHENSIVE DENSE SLURRY SYSTEM

Dry Bottom Ash Collection / Treatment

Bottom Storage Bin

Dry Fly Ash Collection