15 September

2014
1
Ash Handling
System
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2014
2
WHAT IS ASH?
Ash is the residue remaining after the coal has been
incinerated to constant weight under standard conditions.
Ash is oxidised form of the mineral matters present in
coal.
Typical ash composition : SiO
2
, Al
2
O
3
, Fe
2
O
3
, CaO,
MgO etc.
Coal with more SiO
2
& Al
2
O
3
, Ash MP > 1400C
Coal with more Fe
2
O
3
, CaO & MgO, Ash MP < 1100C
3
WHY ASH HANDLING?
Ash content of Indian coal used in power station is about 30 to 40 %.
A typical 2000 MW station produce around 9000T to 12000T of ash per day.
This huge amount of ash needs to be disposed off continuously.
Necessary care to be taken for preventing pollution
Ash Handling system takes care the above requirement
Typical Ash Data
210 MW 500 MW 660 MW
TOTAL ASH 75 180 240
BOTTOM ASH 11.25 28 36
ECONOMISER ASH 2.25 6 7
AIR PREHEATER
ASH
1.5 4 5
ESP ASH 60 144 192
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2014
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WHAT HAPPENS TO THE ASH
PRODUCED?
20 % Of the ash falls at the bottom of the furnace known
as Bottom Ash (BA).
80 % of the ash carried away with flue gas known as Fly
Ash.
BA can form slag and clinker depending on the temp.
of the combustion zone and environment inside.
reducing environment (Less O
2
) reduces ash MP.
BA is disposed off through BA disposal system.
FA is collected through ESP and disposed through FA
disposal system.
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2014
5
Coal Seam
Surge Pile
Pulverize (-150)
Overburden
Fly Ash
Flue Gas
Electrostatic Precipitator
Flue Gas
Boiler
Fly Ash
Bottom Ash
Smoke
Stack
Fly Ash
Bottom
Ash
Schematics of Ash Generation
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2014
6
Ash volumes and properties
ESP
Pulverize
d
Coal
Furnace
(1300 - 1500C)
Electrostatic
Precipitator
S
t
a
g
e

A
:

8
0

%

S
t
a
g
e

B
:

1
7

%

80-90 %
S
t
a
g
e

C
:


3

%

Fly ash
Air
preheater
APH
Economizer
Eco Ash APH Ash
1 % 1 %
Stack
Fineness
Bottom Ash
Coal
10-20 % 100 %
Ash
7
Bottom Ash Handling
System
Wet Type
Continuous
Scrapper
Conveyor
Screw
Conveyor
Intermittent
Jet Pump /
Ejector
Dry type
Pneumatic Conveyor
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2014
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BA Handling System
BA can be collected at furnace bottom as Wet or Dry form.
Wet bottom ash system consists of i)Trough seal, ii)BA
gate, iii)Hopper, iv)Scrapper Conveyer, v)Clinker grinder,
vi)BA trench, vii)BA tank, viii)BA pump, ix)BA pond.
Dry BA consists of i)Trough seal, ii)BA gate, iii)Hopper,
iv)Scrapper Conveyer, v)Clinker grinder, vi)Silo.
Trough seal : A channel around the furnace bottom
filled with water where the furnace bottom end is
immersed in water. This is to prevent air ingression in the
boiler during operation.

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2014
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BA Handling System
BA Gate: Each hopper has separate gate to isolate Scrapper conveyor
from running furnace for any repairing at scrapper.
Scrapper Conveyer : Consists of number of scrapper bars fasten at
both the ends with two chain which can run on chain pulley and driven
by scrapper conveyor motor. The whole conveyor is submerged in
water for wet BA system. Bottom ash after falling on scrapper is
scrapped away by the running conveyor to one end of the conveyor to
clinker grinder.
SCRAPER-CHAIN CONVEYOR
ONE REFRACTORY-LINED TRANSITION HOPPER WITH ISOLATION GATES FOR EMERGENCY
STORAGE OF ASH FOR 3 TO 4 HOURS

2 X 100% ( ONE WORKING + ONE STANDBY) , OR 2 X 50% (TWO WORKING + TWO STANDBY)
DEPENDING ON SUPPLIERS CAPABILITY

WATER SUPPLIED CONTINUOUSLY
FOR SPRAY-QUENCHING OF ASH IN TRANSITION HOPPER
FOR COOLING OF ASH IN TROUGH. OVERFLOW WATER FROM TROUGH RECYCLED IN ASH
HANDLING PLANT AFTER SETTLING OUT CARRY OVER ASH

DEWATERED ASH FALLING FROM SSC SLUICED THROUGH TRENCH TO LOCAL BOTTOM ASH
SLURRY SUMP BOTTOM ASH

SLURRY PUMPED OUT BY HEAVY DUTY CENTRIFUGAL PUMPS TO MAIN SLURRY DISPOSAL
PUMPHOUSE











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2014
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Wet Bottom Ash System with Scrapper Conveyor
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2014
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2014
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BA Handling System
Clinker grinder : Any big size ash clinker is crushed to enable to be
carried away by water jet through BA trench.
BA trench : Through water jet ash slurry is carried away
to BA tank
SCREW CONVEYOR
ONE TRANSITION HOPPER PER UNIT

WATER SPRAYED ON BOTTOM ASH FALLING THROUGH
HOPPER FOR QUENCHING

ASH FALLS INTO TROUGH BELOW HOPPER

ONE SCREW CONVEYOR ,INCLINED UPWARDS,
PROVIDED IN TROUGH TO REMOVE THE ASH
CONTINUOUSLY
DEWATERED ASH SLUICED VIA TRENCH TO SLURRY
DISPOSAL PUMPHOUSE


15
WATER IMPOUNDED HOPPER WITH JET PUMPS

HOPPER EVACUATED ONCE IN 4 HOURS OR 8 HOURS
USING JET PUMPS SUPPLIED WITH HIGH PRESSURE
WATER FROM DEDICATED PUMPS. ASH SLUICED VIA
PIPELINES TO MAIN SLURRY PUMPHOUSE.





LOWER CAPITAL COST
EASIER MAINTENANCE- FEWER MOVING PARTS
HOPPER DISCHARGE GATES LEAKAGE PRONE
HIGHER WATER AND POWER CONSUMPTION OVERALL OF ASH
PLANT DUE TO UNEVEN WATER AND SLURRY FLOWS
WIDELY EMPLOYED
PROS AND CONS
16
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2014
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Dry BA Handling System

Dry BA collection system after clinker grinder collect ash
to silo through a transport mechanism for further transport
through road system.
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2014
PMI Revision 00
18
ECONOMISER ASH HANDLING SYSTEMS
WET TYPE

- FLUSHING BOX
- FEEDER EJECTOR

DRY TYPE
VACUUM TYPE PNEUMATIC CONVEYING
PRESSURE TYPE PNEUMATIC CONVEYING

ECO ASH SYSTEMS
FLUSHING BOX BASED SYSTEMS
CONTINUOUS ASH REMOVAL
CAN BE COMBINED WITH CONTINUOUS -TYPE BOTTOM ASH
REMOVAL SYSTEMS( SSC , SCREW CONVEYOR) TO OPTIMISE
WATER AND POWER CONSUMPTION AND LAYOUT
PREFERRED , AS HOT ASH IS CONTINUOUSLY COOLED AND
REMOVED

FEEDER EJECTOR BASED SYSTEMS
INTERMITTENT ASH REMOVAL
CAN BE COMBINED WITH INTERMITTENT TYPE BOTTOM ASH
REMOVAL SYSTEMS (WIH) TO OPTIMISE WATER AND POWER
CONSUMPTION AND LAYOUT




AIR PREHEATER ASH REMOVAL
SYSTEMS
SIMILAR TO ECONOMISER ASH REMOVAL SYSTEMS

RELATIVELY EASIER DUE TO LOWER ASH
TEMPERATURE( 150-200 DEG. C)

MAY BE COMBINED WITH ESP DRY ASH REMOVAL
SYSTEM
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2014
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Dry FA Handling System

Hydrobackter is a vacuum device to collect ash from the
hopper.
Water jet ejectors used for creating vacuum.
Dry ash thus collected to silo through belt conveyor.
Dry ash is disposed through road transport to a dry ash
disposal system. Part of it sold for commercial purpose
ESP ASH REMOVAL SYSTEMS
ESP Ash
Removal
Wet
Continuous Intermittent
Dry
Dry
Extraction
from Silo
Pressure
Type
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2014
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FA Handling System
FA is collected from Air heater hopper, Eco hopper and
ESP hopper.
Either through flushing apparatus or hydrobactur system.
In Flushing apparatus system ash is allowed to fall in
flushing apparatus under gravitation.
Water jet in flushing apparatus carries away the ash to FA
trench
High pressure jets further carries it to FA sump.
Series pumping carries the ash slurry to FA pond.
ESP ASH REMOVAL SYSTEMS
CONTINUOUS TYPE
- FLUSHING BOX AND TRENCH SLUICE (WET
SYSTEM)
- PNEUMATIC TYPE (DRY SYSTEM)

INTERMITTENT TYPE
- FEEDER EJECTOR AND TRENCH SLUICE (WET
SYSTEM)

ESP ASH REMOVAL SYSTEMS
(AS PER STATUTORY REQUIREMENTS)

DRY ASH EXTRACTION FROM ESP

PROVISION OF ASH SILOS FOR SALE OF ASH
ESP ASH EXTRACTION
SYSTEMS
DRY CONVEYING FROM ESP HOPPERS , AND

FURTHER REMOVAL EITHER BY WET SYSTEM AS
SLURRY FOR ONWARD DISPOSAL TO ASH POND OR BY
DRY SYSTEM TO STORAGE SILO FOR SALE

PNEUMATIC SYSTEMS

- VACUUM TYPE
- PRESSURE TYPE



ESP ASH REMOVAL SYSTEMS
VACUUM TYPE SYSTEMS

- SUITED FOR REMOVING MATERIAL FROM MANY
COLLECTION POINTS AND DISCHARGE TO ONE
POINT(ESP)
- MATERIAL CONVEYED AS A SUSPENSION IN THE PIPE
AT HIGH VELOCITIES

- VACUUM PRODUCED USING

- LIQUID-RING VACUUM PUMP, IF ASH IS TO BE CONVERTED
TO SLURRY FOR DISPOSAL

- LOBE-TYPE AS VACUUM PUMPS IF ASH IS TO BE HANDLED
DRY



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2014
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VACUUM TYPE SYSTEMS - PROS AND CONS
SIMPLE LAYOUT DOES NOT REQUIRE MUCH HEADROOM BELOW
ESP

SIMPLE IN OPERATION

NO LEAKAGE OF ASH

EASY TO MAINTAIN

HIGH WEAR AND TEAR ,ESPECIALLY AT VALVES AND BENDS

RESTRICTION ON CONVEYING RATE/DISTANCE MAX. 60 TPH/150 M
.




PRESSURE SYSTEMS


LOW
PRESSURE
MEDIUM
PRESSURE
HIGH
PRESSURE
MATERIAL
TRANSPORT MODE
SUSPENSION PARTLY IN
SUSPENSION,
PARTLY AS
MOVING BED
SLUG (DUNE OR
PLUGS FILLING
WHOLE PIPE
SECTION)
TYPICAL
CONVEYING AIR
PRESSURE (BAR)
1-1.5 1.5-3 >3
TYPICAL AIR/ASH
RATIO BY WT.
10-15 20-30 >50
TYPICAL
CONVEYING
VELOCITIES(M/S)
20-25 10-15 5-8
TYPICAL AIR
SOURCE
BLOWER/COM
-PRESSOR
SINGLE-STAGE
SCREW
COMPRESSOR
TWO-STAGE
SCREW
COMPRESSOR
ESP ASH HANDLING
SINGLE STAGE CONVEYING TO SILO BY

VACUUM SYSTEM IF TONNAGE IS WITHIN 60 TPH
AND/OR DISTANCE IS WITHIN 150 M
OTHERWISE, PRESSURE SYSTEM FOR DISTANCE
WITHIN 400M FROM ESP

TWO-STAGE CONVEYING SYSTEM FOR DISTANCE MORE
THAN 400M

VACUUM EXTRACTION+PRESSURE TRANSPORTATION
PRESSURE EXTRACTION+PRESSURE
TRANSPORTATION

ASH SLURRY DISPOSAL
BOTTOM ASH AND FLY ASH DISPOSED OFF AS COMBINED
SLURRY

ASH PUMPED AS LEAN SLURRY
MAX. 25% FOR BA/BA+FA
MAX. 30% FOR FA ONLY

HORIZONTAL, CENTRIFUGAL ,SLURRY DUTY PUMPS USED
PUMPS COUPLED IN SERIES TO ACHIEVE DESIRED TOTAL HEAD
TYPICALLY FOUR PUMPS PER SERIES TO PUMP UPTO 10KM

TOTAL NO. OF DISPOSAL SERIES IS NO. OF UNITS +2

GARLANDING OF ASH POND FOR EFFECTIVE FILLING AND
CONSTRUCTION AND OPERATIONAL FLEXIBILITY


35
Ash Pipe line System
ASH WATER SYSTEM
RAW WATER,CW BLOWDOWN, RECYCLED WATER FROM
ASH POND USED FOR ASH SLUICING

CLARIFIED WATER FOR SEALING/COOLING

HORIZONTAL, CENTRIFUGAL PUMPS WIDELY USED
LESSER COST
EASIER TO INSPECT AND MAINTAIN

ASH POND WATER RECYCLED TO SAVE ON WATER
CONSUMPTION AND FROM ENVIRONMENT ANGLE


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2014
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BA Handling System
BA pump : Ash slurry handling pump. It carries ash to the BA pond.
Depending on the distance of BA pond two or more BA pumps
connected in series.
BA pond : Finally ash is discharged to ash pond. It is a large area
surrounded by embankment. Ash mixed with water is allowed to settle
for considerable time. Water from top surface is allowed to go out from
the pond through a designed escape route. Quality of water discharge is
always monitor for turbidity and heavy metal. Piezo meter is used for
monitoring the slope stability of the embankment.
BA Supporting water pumps
LP BA pump : Supply water to trough seal, scrapper conveyor sump,
BA sump and LP jets.
HP BA pump : HP jets in BA trench and line cleaning.
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Typical Ash Dyke Design
40
Typical Ash Dyke Design
41
Ash Pond in Google Map
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Initially in an endeavor to utilize around 100 MMT of ash
generated in the country Ministry of Environment and Forest
(MoEF) came up with a notification (S.O. 763(E) Dt.
14.9.1999)(Annexue-5) which allows the ash users (e.g.-
Cement companies, Asbestos manufacturing companies,
brick manufacturers etc.) to take ash "Free of cost" from
power generating companies till Sep-2009.
During the period of ten years, ash utilization has increased
from 12% to 40% and is growing at fast rate. Ash user
companies especially Cement, and Asbestos sheet
manufacturing companies used this opportunity and
exploited pozzolanic properties of ash by using ash as a raw
material in the manufacturing of their products.
In line with the practices followed in western countries, like
USA and Europe, in April -2007 Ministry of Environment and
Forest (MoEF) came up with a draft notification which allow
sale of Ash
Ash Utilization Govt Initiatives
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2014
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ASH UTILISATION
Major usage of ash
Fly ash bricks / blocks
Cellular concrete products
Light weight aggregates
Concrete and mortar
In manufacture of cement
In manufacture of asbestos products
Road construction
Embankment/back fills/land development
Controlled low strength material (CLSM)
In agriculture
Mine filling
Manufacture of fertilizer
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Other usage
Manufacture of distemper
Floor and wall tiles
Refractory bricks
Manufacture of ceramics
Use with Ferro cement
Recovery of metals
Use in grouting
Manufacture of alum
Extraction of Cenospheres
Domestic cleaning powder
In synthetic wood

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Direct Disposal