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Tons
Bottom Ash
Tons
Fly Ash
Tons
11000 4400
660
3740
INDIAN COAL
Generally high ash content.
Larger amounts of ash to be handled.
Inconsistent Quality.
CHALLENGES OF ASH HANDLING
Indian coal presents high ash content generally which tends to be inconsistent.
Design of the system has to adequately cover anticipated variations and be
capable of handling the worst scenario.
System has to be environmentally friendly.
System has to be reliable with least maintenance problems.
System has to be energy efficient.
In areas where such as disused gravel or clay pits or low lying land
are available for ash and dust disposal and are up to a distance of about
two miles from the power station both furnace bottom ash and dust
mixed with water can often be pumped to the point of disposal, and this
method can be the cheapest of all. For greater distances, up to about six
miles, only the dust is pumped; the furnace bottom ash is removed from
the power station site in vehicle.
There are two main reasons for not pumping the furnace bottom
ash over long distances: first, because it requires to be transported at a
higher velocity than dust, and secondly, its abrasive qualities can cause
excessive wear on the pipeline.
TYPES OF ASH :
Evacuation system
PRESENT TREND OF
FLY ASH
EVACUATION IN
MODERN THERMAL
POWER PLANTS
COMPATIBILITY
The Dense Phase Pneumatic Conveying
system is flexible enough and compatible
with all size and type of boilers
Whether Boiler is from 3 MW to 600 MW,
Water tube or Fire tube,
CFB, PFB, Stoker fired,
Coal, Coke, Lignite, Rice Husk, etc.
H.P. JETTERING
LINE
OVERFLOW
LINE
WEIR
BOX
FEED
GATE
S
B
FROM HP PUMP
FROM SURGE TANK
ECENTRIC
CRUSHER
L.P. WATER
MAKE UP
L.P. RETURN
LINE
1A
DEWATERING BIN
OVERFLOW
TRANSFER
TANK
EMERGENCY
OVERFLOW
TO PLANT
DRAIN
1B
CENTRAL
DECANTER
LOWER
DECANTER
STRAINERS
FOR WATER
SUCTION
1C
OVERFLOW
TRANSFER
PUMP
LP MAKE UP
WATER
DECANT
WATER
TRANSFER
TANK
LOAD IN TRUCK
MAKEUP
OVERFLOW
LINE
TO
DRAIN
SETTLING
TANK
RECIRCULATION
LINE
LP PUMPS
SURGE
TANK
1A
1B
1C
DECANT WATER
TRANSFER PUMPS
TO
PLANT
DRAIN
1A
SLUDGE
PUMPS
1B
TO
DEWATERING
BIN.
1A
1A
SLUDGE
PUMPS
1A
1B
1B
HP
PUMPS
1B
ESP : ELECTROSTATIC
PRECIPITATOR
ELECTROSTATIC
PRECIPITATOR (ESP) IS THE
INDUSTRIAL EQUIPMENT
THAT REMOVES THE DUST
PARTICLE AND SMOKE
THROUGH THE EFFECTIVE
FILTRATION PROCESS
Contd.
COMPONENTS USED IN
ELECTROSTATIC
Emitting electrodes
Collecting plates
440V 50HZ 3 AC supply
High voltage transformer
Rectifier
Insulators
ESP Hooper
DERM
CERM
Hopper
Technical specifications
Aspect Ratio
specific
collection area (SCA) is defined as the
ratio of collection surface area to the
gas flow rate into the collector. It is an
important determinant of collection
efficiency
Charge Ratio The duty cycle or the
charge ratio is defined as the ratio of
the number of ON cycle to the sum of
the ON and OFF cycle The charge ratio
can be varied in the range 1:1 to 1:159,
which is necessitated to tackle the high
resistivity of fly ash encountered in
precipitators in India
BACK CORONA
COLLECTION EFFICIENCY
The weight of dust collected per unit
time divided by the weight of dust
entering the precipitator during the same
unit time expressed in percentage. The
computation is as follows:
Efficiency =(ESP inlet Kg/Hr) (Dust out
let Kg/Hr) X 100 / (Dust in let Kg/Hr)
Contd.
The collection efficiency () of a precipitator is
given by an empirical formula.
(WkSCA)1/2 = 1 e
where Wk has the dimension of velocity and
is known as migration velocity
SCA is specific collecting electrode area. =
Total projected collecting area
Gas flow rate
Contd.
Casing
Hoppers
Gas distributor screen
Collecting system
Emitting system
Rapping mechanism for collecting system
Rapping mechanism for emitting system
Insulator housing
Casing
HOPPER
The hoppers are of pyramidal type. The valley
angle of the hoppers (angle between hopper
corner and horizontal) is never less than 55o and
often more to ensure easy dust down to the feed
out flange.
All hoppers have gas baffles.
The upper portion of the two adjacent
hoppers have a reinforced bridge to support the
hoppers across the precipitator width.
To ensure free flow of ash into disposal
system lower portions of the hoppers are
provided with electrical heaters with
thermostatic control.
COLLECTING SYSTEM
EMITTING SYSTEM
The emitting framework is thoroughly braced
and forms a rigid box-like structure. The frame
is assembled adjusted and welded to its final
position inside the casing.The emitting
electrodes are spiralized from semi-hard
stainless steel wire. The spiral electrodes are
sent to the erection site as closely wound
coils with one hook mounted at each end. At
the erection, the coils are stretched and
attached by means of a special stretching
device between top and bottom holders in
each stage of the framework
The flue gas from a coal fired thermal power station contains fine particles
of ash with size varying from 80 microns to less than 5 microns.
Ammonia injected into flue gas in the presence of sulfur trioxide and flue
gas moisture reacts to form ammonia compounds, principally ammonium
sulfate and bisulfate compounds. These particles nucleate on sub micron
particulate in the gas stream and help to agglomerate and increase ash
particle size. The ammonia also reacts with acidic ash to facilitate
absorption of sulfur trioxide. The resulting ammonium bisulfate is a sticky
compound and is believed to help agglomerate the ash and improve the
ash cohesivity. Another observed effect is an increase in the flow of ions,
electrons and charged particulate in the interelectrode space, or space
charge. The lower ash resistivity enables the ash to more readily release its
charge to the collecting plate, reducing the electrostatic holding force. The
reduced holding force allows more ash to re-entrain into the gas stream
when the collecting plates are rapped. The improvement in ash cohesivity
from dual conditioning reduces rapper re-entrainment by agglomerating
ash on the collecting plates. The lower resistivity particulate readily reentrains into the gas stream.