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Advanced Dry Bottom Ash Technology

Enhancing Pulverised Coal Fired


Generation.

Qingdao Daneng
Content

Brief Introduction - Qingdao Daneng- Who are we?

Dry Bottom Ash Technology

Case study – GNPower - Mariveles Units 1 & 2 Retrofit


Project

Questions and further discussion

Qingdao Daneng Advanced Dry Bottom Ash Technology


Content

Brief Introduction - Qingdao Daneng- Who are we?

Dry Bottom Ash Technology

Case study – GNPower - Mariveles Units 1 & 2 Retrofit


Project

Questions and further discussion

Qingdao Daneng Advanced Dry Bottom Ash Technology


Who are we?
Qingdao Daneng Environmental Protection
• Established:2009
Equipment Incorporated Company • Registered Capital: 11 million
USD
• Turnover: 150 million USD
• Staff: 900
• Combined experience: More
than 800 power plant projects
• Production: 120,000 m2

Qingdao Daneng Advanced Dry Bottom Ash Technology


Technologies and Products
Qingdao Daneng Technologies and Product Lines Wet ESP
•Flue Gas
Aerosol and
Flue Gas Cooler Reheater,
Boiler High-Eff. Demister particle,
Energy saving, eliminates
Optimisation. Dust Emission: Emission :
Improved ESP Dust “visible plume”
<5mg/Nm3 <5mg/Nm3
SCR Temperature Collection
Control

•Wet BA Handling System(SSC)-PC Boiler


•Dry BA Handling System -(PC Boiler)
•Traditional Steel Belt Type WET FGD
•Daneng Patented DUNOCON Fly Ash Pneumatic Waste Water
•Bottom Ash Cooler(NEW) -CFB boiler Conveying and Dosing Zero-Emission Heat Accumulator
•Traditional Rotary Ash Cooler
•Daneng Patented 2 Stage-Cooling No.1 Ash Handling System and Flue Gas Products Supplier
Production Facilities

Qingdao Daneng Advanced Dry Bottom Ash Technology


Quality Control & Quality Assurance

Qingdao Daneng Advanced Dry Bottom Ash Technology


Project Management

• Delivering “Quality, On-time, and Value for money”


Products, Solutions and Services for the global market.”

Project
Manager

Project
Project Project Planning/ After Sales
Quality
Procurement Engineering Controlling Engineer
Engineer

• Highly committed and experienced Project


Management team
• International team with global experience
and after sales
• International standard quality control

• Project Schedules, effectively controlled,


logic driven and fully integrated.

Qingdao Daneng Advanced Dry Bottom Ash Technology • Detailed progress reporting and analysis.
Major Customers and Cooperation

Qingdao Daneng Advanced Dry Bottom Ash Technology


Content

Brief Introduction - Qingdao Daneng- Who are we?

Dry Bottom Ash Technology

Case study – GNPower - Mariveles Units 1 & 2 Retrofit


Project

Questions and further discussion

Qingdao Daneng Advanced Dry Bottom Ash Technology


PCC Boiler Technology and the Formation of
Bottom Ash.
• Over 90% Coal Generation is PCC
• Typically 300MWe to 1000MWe
• Efficiency 36 – 43%

• Residual Ash in coal forms Fly Ash


(~85%) and Bottom ash (~15%)

Qingdao Daneng Advanced Dry Bottom Ash Technology


Traditional – Wet Type Bottom Ash Systems

Qingdao Daneng Advanced Dry Bottom Ash Technology


Dry Bottom Ash Working Principle
•Technology first developed in Europe in mid 1980’s.
•Utilises negative pressure in the furnace to draw tramp cooling air from
the boiler building into the conveyor.
•Increased boiler efficiency from heat is recovered from the ash.
•No water system required.

Combustion Chamber - Ambient Cooling Air


4mbar Air Volume ~80%
Radiant Heat
Ash 800-900°C
Air 340-410°C

Ash
Discharge
Temperature
90 – 110°C

Ambient Cooling Air


Air Volume ~20%
Total Cooling Air: approx. 1% of the Combustion Air
Qingdao Daneng Advanced Dry Bottom Ash Technology
Benefits Considered – Dry vs Wet

Environmental Increased efficiency

• Elimination of water usage and • Reduction of thermal energy losses


treatment and unburned carbon
• Easier compliance with environmental • Increased boiler efficiency
protection regulations
• Reduction in CO2 Emissions
• Fully enclosed system

Cost reduction Increased revenue

• Reduced maintenance costs (-60 to 80%)


• Improved boiler efficiency (+0.1 to 0.5%)
• Reduced power consumption (-15 to 90%)
• Saleable ash quality
• Reduction of water treatment and ash
handling costs

Qingdao Daneng Advanced Dry Bottom Ash Technology


Dry Bottom Ash Technology
1st Generation-Steel Belt (Mesh) Type

Qingdao Daneng Advanced Dry Bottom Ash Technology


Dry Bottom Ash Technology
1st Generation-Traditional Steel Belt Type

• Limited Capacity and Incline Angle


• Requires additional fine ash conveyor
• Direct dust wear between carrying idlers,
drive drum and mesh belt – slippage and
misalignment
• Can be damaged by large lumps.
• Very difficult mesh repair
• Lower cooling efficiency and combustion
efficiency
Qingdao Daneng Advanced Dry Bottom Ash Technology
2nd Generation - DUNOCON
Design Priorities
• Increased availability
• Increased ash capacity and angle
• Enhanced ash cooling and air control
• Resistant to impact from large lumps
• Easily maintained and reduced spare
parts
• Simple fines removal
- using -
• Proven reliable components
• Positive drive and tensioning

Qingdao Daneng Advanced Dry Bottom Ash Technology


Dry Bottom Ash Technology
2nd Generation- DUNOCON

Qingdao Daneng Advanced Dry Bottom Ash Technology


Mechanical Seal

• This device provides a robust air tight seal between the boiler
outlet and ash hopper or conveyor.
• Mechanically attached to a plate welded to the boiler tubes.
• An integrated heat shield provides added protection to the flexible
•Fixing plate thermal insulation layer
element.
固定板及保温层
非金属伸缩节 挡灰板
• nonmetal expansion •Ash damper
joint
Dry Bottom Ash Hopper

• Can be supplied to provide additional storage and transition


between boiler outlet and the DUNOCON conveyor.
• Robust asymmetrical design to absorb impact from agglomerated
slag.
• Lined with refractory concrete or thermal insulation.
Hydraulic door & Pre-crusher

Qingdao Daneng Advanced Dry Bottom Ash Technology


DUNOCON - Features

Charpy Shaft Auxiliary


Support Roller Support Plate

Ash Receipt Section Structure

Qingdao Daneng Advanced Dry Bottom Ash Technology


Unique Air Intake System

Qingdao Daneng Advanced Dry Bottom Ash Technology


DUNOCON Scale Bucket Conveyor
Tensioner & Self-Cleaning Device

• Tensioner
‐ Hydraulic Driven Type

• Self-Cleaning Device
‐ Scratch the fine residual ash at the bottom section to the
tail section and further rotate onto the conveying section,

Qingdao Daneng Advanced Dry Bottom Ash Technology


DUNOCON – Added Safety

• Far infrared thermometer detects combustion or large lump


requiring emergency cooling.
• PLC control system initiates additional cooling via water sprays
located close to the transition section.
• Water injection is carefully controlled to ensure the problem is
remedied whilst keeping the process dry.
Single Roller Crusher
• Crush High-temp. Ash (Normally
100~300℃)
• Composition:
‐ Tooth Roller Assembly
‐ Shaft Sealing Assembly
‐ Casing
‐ Driving System.
• Features:
‐ Simple Structure
‐ Strong Biting Ability
‐ Convenient Maintenance
‐ Slag Blockage Reversing
‐ Automatic Stoppage Functions.
• 3 Drive Types:
‐ Chain, Direct (Motor &Reducer),
Shaft-mounted

Qingdao Daneng Advanced Dry Bottom Ash Technology


Applicable Patents
• 1. Scale Plate Type Conveying Belt
• 2. Dual Direction Flight and Link
Chain Flexible Connecting Device
• 3. Precise Forging Chain Scale
Bucket Type Dry Bottom Ash
Conveyor
• 4. Sectionalized Scale Bucket Type
Dry Bottom Ash Conveyor
• 5. Multistage Air Cooling Dry Bottom
Ash Handling Device
• 6. Self-Cleaning Type Scale Bucket
Type Dry Bottom Ash Conveyor
• 7. Dry Single Roller Crusher
• 8. Crusher Tooth Roller
• 9. Frictional Dragging Sprocket for
Bucket Elevator
• 10. Gravitational Discharging Type
Bucket Elevator.

Qingdao Daneng Advanced Dry Bottom Ash Technology


DANENG – The world‘s most experienced dry
bottom ash conveyor supplier

• Over 80 projects (> 166 Units) supplied.


• Significant references on 300 MW, 600 MW
and 1000 MW boiler units.
• 11 projects (17 Units) converting existing wet
systems to Dry Bottom Ash.

Qingdao Daneng Advanced Dry Bottom Ash Technology


Typical Application

Qingdao Daneng Advanced Dry Bottom Ash Technology


Typical Reference- 2×1000MW

•Banji 2×1000MW Project, Length: 65m

Qingdao Daneng Advanced Dry Bottom Ash Technology


Content

Brief Introduction - Qingdao Daneng- Who are we?

Dry Bottom Ash Technology

Case study – GNPower - Mariveles Units 1 & 2 Retrofit


Project

Questions and further discussion

Qingdao Daneng Advanced Dry Bottom Ash Technology


GNPower Mariveles Units 1 & 2
•Located Luzon, Philippines.
•Equity holders TPI, AC Energy
Holdings, Inc. and Power Partners
Ltd. Co.
•Originally 2 x 300 MW subcritical
boilers.
•EPC Supplier – CNEEC.
•Brought Online – April 2013
•Subsequently output increased to
2 x 342 MW.

Qingdao Daneng Advanced Dry Bottom Ash Technology


Previous Bottom Ash Handling System
Traditional Submerged Scraper Chain Conveyor

•Boiler

•Transition
Chute

Qingdao Daneng Advanced Dry Bottom Ash Technology Submerged Scraper Conveyor (SSC)
Previous System – Reported Issues

• Under powered drive, could not extract with ash stored in


the conveyor.
• Chain misalignment, tension issues and failures.
• Damage to components when large slag falls from boiler.
• Chain jumping off idler sprockets.
• Poor Chain and component lifetime.
• No isolation from boiler so cannot safely conduct on-line
maintenance.
• Fines carry over into water system, which requires
additional systems and maintenance.
• The result
‐ Loss of boiler availability - @ circa $500,000 per day
‐ Excessive operating and maintenance costs.

Qingdao Daneng Advanced Dry Bottom Ash Technology


Mariveles Unit 1 & 2 –
DUNOCON vs Wet Typical Energy Comparison

Application Details
Boiler Size 342 MWe
Plant Efficiency 37.31 %
Required Heat Input 916.71 MWt
Calorific Value of Fuel 15715 kJ/kg
Required Coal Feed Rate 210 tph
Coal Price 48.74 $/t
Normal Conveying Rate 0.984 tph
Design Conveying Rate 10 tph

Qingdao Daneng Advanced Dry Bottom Ash Technology


Mariveles Unit 1 & 2 –
DUNOCON vs Wet Typical Energy Comparison
DUNOCON SSC
Improvement in Boiler 
0.1 0
Thermal Efficiency %
Coal Saving Due to Increase 
0.56 0
in Efficiency tph

Power Consumption (values given for normal conveying rate)

Drives (installed power) 30 200 kW

Drives (normal power) 3 100 kW

Crusher Power 15 0 kW
Required Coal Feed Rate for 
Required Energy 0.011 0.061 tph
Saving in Coal Feed Rate for 
Required Power Input of 
conveying system 0.05 tph
Total Saving in terms of coal 
feed rate 0.612 tph
Total cost saving due to 
energy 29.82 $/hr

715.68 $/day @ full load
Qingdao Daneng Advanced Dry Bottom Ash Technology
Equivalent to $261,000 and 4900 Tonnes CO2 per year
Proposed Solution

Qingdao Daneng Advanced Dry Bottom Ash Technology


Proposed Solution

Qingdao Daneng Advanced Dry Bottom Ash Technology


Proposed Solution – Key Features

• Installation to be carried out in a planned outage.


• Retain current Bottom Ash Hopper, Boiler Seal and Some
Support Structures.
• Replace existing SSC with free standing advanced
DUNOCON dry ash conveyor complete with boiler
isolation / pre – crushing system
• Existing foundations to be utilised.
• Replace silo body to incorporate new dry ash truck
loading system whilst retaining original storage volume.
• Bottom Ash Silo to incorporate secondary crusher and
vibrating discharge
• Utilise existing silo support structure
• New Stand alone PLC control system.

Qingdao Daneng Advanced Dry Bottom Ash Technology


Timeline

• 15th May 2017 - Initial Site Visit.


• 30th June 2017 – Further Site Visit & Clarification
Meeting.
• 13th July 2017 – Contract award for Unit 1 (Delivery Dec
18) & Unit 2 (Delivery Dec 17) Dry Bottom Ash System.
• 20th & 21st July – Kick Off Meeting at Site.
• 28th September - Unit 1 delivery brought forward to 16th
Feb 2018.
• 20th October 2017 – Contract award for optional E&C
System and Site Service.
• December 2017 – Both Units delivered to site.
• March 2018 – Unit 2 successfully installed and
commissioned.
• January 2019 (tbc) – Unit 1 installation planned.
Qingdao Daneng Advanced Dry Bottom Ash Technology
Installation Programme
•Originally installation and commissioning was planned to be
completed in 23 days!

Qingdao Daneng Advanced Dry Bottom Ash Technology


New Silo Shell and Discharge Equipment

Qingdao Daneng Advanced Dry Bottom Ash Technology


Existing BA Hopper, remedial works to dipper
plate and modifications to boiler seal concept

Qingdao Daneng Advanced Dry Bottom Ash Technology


DUNOCON Installation

Qingdao Daneng Advanced Dry Bottom Ash Technology


Acceptance Report & Satisfaction Survey

Qingdao Daneng Advanced Dry Bottom Ash Technology


A Great Team Effort!

Qingdao Daneng Advanced Dry Bottom Ash Technology


Thank You to all at GNPower
and for your attention this afternoon!
Any Questions?
www.daneng.cc