DRY ASH EVACUATION

&
HCSD SYSTEM

SANJAY GUPTA
 WHAT IS ASH?
 Heat liberated by combustion of coal generates steam in the Boiler
which is fed to the Steam Turbine coupled with the Generator for
“GENERATION OF ELECTRIC POWER”.

 Combustion of Coal leaves behind huge quantities of residue called ASH.

 Ash is basically oxides of Silicon, Aluminium, Iron, Ca and Mg etc.

 Proposed Coal – Fixed Carbon : 31 %, VM : 26%, Moisture: 8% and ASH: 35%

 Specific Coal Consumption for generation of 1 kWh is around 0.80 kg.
 Total Coal requirement of NACO CPP is around 16500 T per day.

 Presently our coal has ash content of about 40-45 %.

 Ash generation per day is around 6600-7450 T.

 Out of total ash - about 20 % is Bottom ash and 80 % is Fly ash.

 TYPES OF FLY ASH EVACUATION

 There are basically two types of Fly Ash Evacuation Systems.

1) Wet Ash Evacuation and Conveying using Flushing Box and Water
(Unit # 1 to # 6 ESP)

2) Pneumatic Ash Evacuation and Conveying using Vessel and Air

Vacuum System (PULL) and Pressure System (PUSH)

a) Lean Phase Vacuum System ( X : Air/Ash : m3 : 85/15)

b) Lean Phase Pressure System (Unit # 7 ESP- Air/Ash : m3 : 85/15)
c) Dense Phase Pressure System (Unit # 8, 9 & 10 ESP-Air/Ash:m3: 65/35)
ASH EVACUATION IN WET FORM ESP #1 to #6
 In wet system ash is mixed with water to form slurry which
is then send to ASPH through ESP trench.
Ash Evacuation in Unit # 1 to #6 ESP
ESP Hoppers (Fly Ash Collection)
RV Feeder (1st to 3rd Field)
Fall due to Gravity (4th to 6th or 7th Field)
Flushing Box (Ash+Water=Slurry)
ESP Trench (Slurry)
Ash Slurry Pump House.

Disadvantages
Huge and continuous supply of water is required
Large storage area is required
Ash can not be utilized properly.
PNEUMATIC or DRY ASH EVACUATION Unit # 7 to # 10

 Pneumatic System is an effective method of dry ash Evacuation

and Conveying through pipes by means of air as a conveying
medium.
 Pneumatic Pressurized Conveying System is adopted in ESP # 7 to # 10.

Ash Evacuation and Conveying in Unit # 7 to # 10 ESP.

ESP Hoppers (Fly Ash Collection)

Hopper Vessel (Ash filling and fluidized by air)
Ash Conveying Pipe (Ash + Air = Stream)
Silo–1 & 2 for Unit #7,
Silo–3 & 4 for Unit # 8 and
Silo-- 5 & 6 for Unit #9 & 10.
FLY ASH EVACUATION SCHEME- UNIT # 7 ESP

CONVEYING PIPE-1

CONVEYING PIPE-2

CONVEYING PIPE-3

SILO-1 SILO-2

CONVEYING PIPE-4
FLY ASH CONVEYING 1st & 2nd FIELD- UNIT # 7 ESP

SILO-1 SILO-2

MASTER SLAVE-1 SLAVE-2 SLAVE-3

PROBE BASED CONVEYING ( X ), TIMER BASED CONVEYING ( YES )

FLY ASH CONVEYING 1st & 2nd FIELD- UNIT # 7 ESP

ASH
FLOW
HP
WATER
VALVE

HYDRO EJECTOR

VESSEL FILLING – Inlet Valve and Vent Valve will OPEN simultaneously.

VESSEL EVACUATION – Inlet and Vent Valve will CLOSE, Conveying

Valve and Pressure Valve (Slave-3, 2, 1 and then Master) will open and
ash conveying will take place either 1st or 2nd Field through conveying
pipe to Pre Selected SILO.
FLY ASH CONVEYING 3rd to 6th FIELD- UNIT # 7 ESP

PROBE BASED CONVEYING ( X ), TIMER BASED CONVEYING ( YES )

FLY ASH CONVEYING 3rd to 6th FIELD- UNIT # 7 ESP

VESSEL FILLING – Inlet Valve of all four Vessel will OPEN simultaneously to fill Ash.

VESSEL EVACUATION – Inlet Valve will CLOSE, Conveying Valve will open and ash
conveying will take place either 3 or 4 and/0r either 5 or 6 Field through conveying
pipe to Pre Selected SILO.
 HCSD SYSTEM
(HIGH CONCENTRATION
SLURRY DISPOSAL SYSTEM)
 Slurry Disposal System in NALCO CPP
There are mainly two types of Ash Disposal System.
Lean Concentration Slurry Disposal (LCSD) System:
ASPH – 1 to 5

 The lean slurry ash from the ASPH sump is pumped longer distance to the ash
pond with the help of Centrifugal Pumps that are used in series.
 To recover the water, ash water recovery system is also used.
 The Lean slurry ash disposal system operates at 10% to 15% of ash by wt.

High Concentration Slurry Disposal (HCSD) System:

Fly Ash of Unit # 7 to # 10

 The HCSD Ash Slurry from Silo is pumped longer distance to the ash pond with the
help of Reciprocating Pumps (piston-Diaphragm pump).
 The HCSD System operates on a higher concentration & for ash slurry it is about
50-60% of ash by weight.
Comparison of LCSD System and HCSD System
LCSD System (Disadvantages)
 Huge quantity of water is required
 High Power consumption as we pump 85-90 % water and then recover it
 Higher costs for large ash pond construction and maintenance
 Water recovery system is required
 Potential threat of ash pond collapse
 Stored Ash can not be used effectively.

HCSD System (Advantages)

 Minimal water consumption, when compared with lean slurry system
 Low cost, Faster, Efficient and Eco Friendly system
 Nearly dry disposal system, as ash quantity is 50 –55 % by weight
 Requires less disposal area due to dry stacking
 No water recovery system is required
 Ash can be used in Bricks and Cement industries and for land filling.
 HCSD - GEHO PUMP
 MAKE – WEIR MINERALS (NETHERLAND)
 BRAND NAME – GEHO
 TYPE - TZPM 1200
GEHO PUMP is a Crank Shaft Driven, High Pressure,
Triple piston and Single Acting pump.

SPECIFICATION
FLOW RATE (m3/hr) 16 to 160
SPEED (SPM) 5.4 to 54.4
DISCHARGE PRESSURE (K Pa) 16000
POWER (k W) 748.5
HCSD - GEHO PUMP WORKING
 HCSD SYSTEM - MAIN EQUIPMENTS

 Fly Ash Silo- 1 (5) and Silo – 2 (6) : To Store Fly ash (Normal Level < 11.0 m)

 Flushing Water Pump: to supply water required in HCSD System (3 in numbers)

 Seal Water Pump: supply water to Seal CHARGE PUMP bearings (2 in numbers)

 Agitator Retention Tank (ART): to store ash slurry (2 in numbers -Level 3.0 to 3.5 m)
 Ash Mixer: to mix ash and water to form slurry and enters in ART (1 / ART)
 Agitator: to agitate/mix slurry to maintain constant concentration in ART (1/ART)

 Charge Pump: takes slurry from ART and discharge it to GEHO pump (Four)
 GEHO Pump: takes slurry from Charge pump and send it to ash pond (Three)

 Bag Filter: prevent escape of ash to atmosphere

 Vent Fan: to remove air and help in ash flow

 Blower: supply hot air to Silo and Surge Hopper to fluidize ash (3 in numbers)
 Hose Pump –to carry out slurry concentration measurement (1 / ART)
HCSD- SCHEME
 HCSD START AND RUN PROCEDURE -1
 Decide Slurry discharge line to Ash Pond (Line - 1 or Line - 2)
 Press PRESTART button of the GEHO PUMP you want to RUN (LOP and
Prop Liquid p/p will start)
 Open slurry discharge line v/v of GEHO PUMP towards the selected line
 Run SILO Fluidizing Blower & Heater if OFF
 Open AIR SLIDE plate valve after the SURGE HOPPER & Run the VENT
FAN
 Run FLUSHING WATER PUMP with its recirculation v/v open and close it
after developing sufficient pressure
 Start the SEAL WATER PUMP or charge seal water header from flushing
water line
 Check that going to be run CHARGE PUMP is lined up from ART up to
the GEHO PUMP suction
 Open the flushing water v/v of the CHARGE PUMP which is to be started
 Open the seal water v/v of the CHARGE PUMP (Check PS is ok)
 Start the CHARGE PUMP with flushing water v/v open and flush the
system thoroughly for about 5 min
 HCSD START AND RUN PROCEDURE - 2
 Charge SERVICE AIR to the GEHO PUMP Suction Line Accumulator
 START AGITATOR when ART level >2.2 m (Normal Level is 3.0 to 3.5 m)
 START ASH MIXER after charging flushing water to it.
 Make the VFD of GEHO PUMP “ON”
 STOP SERVICE AIR supply to the GEHO PUMP Suction Line Accumulator
 OPEN CARGE PUMP SUCTION V/V from ART and close flushing v/v
 Give START command to the GEHO PUMP from REMOTE
 Set GEHO PUMP speed to 5 SPM, when it draws No Load current
(around 150 A)
 Vent all the three Diaphragm Chambers from LOCAL
 Raise the speed of GEHO PUMP by 2 SPM at a time but don’t exceed
beyond 50 SPM
 SET BIN WEIGHT low and high values
 CHECK SURGE HOPPER (BATCHING V/V) inlet DOME V/V is operating
 Ensure ash flow by seeing decrease / increase in BIN WEIGHT
 Maintain Slurry CONCENTRATION (Provided in FAS-1 and FAS-2)
through the operation
 A-B-C-D APPROACH FOR HCSD OPERATION

There are FOUR important parameters that need to be

watched carefully throughout HCSD System operation.

 A – ART LEVEL (Maintain ART Level : 3.0 m to 3.5 m)

 B – BIN WEIGHT (SET Bin Weight “LOW” and “HIGH” as required)

 C – CONCENTRATION (Keep Slurry Concentration: 50 to 55%)

 D - DISCHARGE PRESSURE (Keep Discharge Pre less than 40 bar)

FACE PLATES of FAS – GEHO – BIN Wt & FW P/P
 STOP PROCEDURE OF HCSD SYSTEM - 1
 Stop opening of BATCHING V/V
(CLOSE it after putting in MANUAL mode)
 SET BIN WEIGHT – LOW and HIGH values to ZERO

 LIMIT the GEHO PUMP speed to maximum 50 SPM

 Close AIR SLIDE plate v/v, when BIN WEIGHT stabilizes near “0” value
 After about 10 min STOP the VENT FAN and ASH MIXER
 Maintain ART level and watch Slurry Concentration continuously

 When Concentration < 10 %, run the system for 15 min more

 Gradually reduce the GEHP PUMP stroke to ZERO and STOP it
 Press PRESTART button to start LOP and PROP LIQUID OIL pumps
 STOP the AGITATOR
 STOP PROCEDURE OF HCSD SYSTEM - 2

 Flush the CHARGE PUMP with flushing water v/v for about 5 min
 STOP the CHARGE PUMP and CLOSE its suction & seal water v/v

 OPEN the flushing water header recirculation v/v

 STOP Flushing Water Pump and Seal Water Pump

 Take the selection of all FLUSHING WATER PUMPS & Seal Water
Pumps to MANUAL & MAINTENANCE MODE

 STOP GEHO PUMP its LOP and PROP LIQUID PUMP will stop
 Make the VFD OFF
 DAILY CHECKING IN HCSD PUMP HOUSE
GEHP PUMP AREA

 Lubricating, Propelling & Gear box sump “OIL LEVEL” is normal

 Lubricating & Propelling liquid “OIL FLOW” is OK ( 10 - LED)
 Propelling Liquid Accumulator pressure is > 9.0 bar
(Normal Pre is 8 to 13 bar)
 Discharge Dampener Pressure LOW and HIGH are 15 and 35 bar
respectively
 Suction Accumulator pressure gauge is hunting in small range
 Gear box cooling water flow out through running pump is normal
 Abnormal Sound if any from main PUMP / Motor / Oil pumps /
Discharge line etc
 Ash / Slurry/ Water/ Oil leakage if any.
 DAILY CHECKING IN HCSD PUMP HOUSE
AUXILLIARY SYSTEM AREA

 Oil Level in Flushing water pump, Fluidizing blower is normal

 Oil Level in Ash Mixer, Agitator, Hose Pump is normal

 All Manual v/v of Fluidizing Air system is in charged condition

 Abnormal Sound if any from running drives

 Ash/ Slurry/ Water/ Oil leakages if any.

GEHO PUMP PARAMETERS & TRIP SETTING
PARAMETER SET VALUE RESULT
GEHO P/P OPERATING PR ( k Pa ) 16800 HIGH ALARM

GEHO P/P OPERATING PR ( k Pa ) 17600 GEHO PUMP will TRIP

PROPELLING LIQUID PR ( k pa ) 700 GEHO stroke will go to ZERO

INSTRUMENT AIR PR ( k Pa ) 450 LOW ALARM

INSTRUMENT AIR PR ( k Pa ) 400 GEHO PUMP will TRIP

SUCTION PRESSURE ( k Pa ) 200 GEHO stroke will go to ZERO

LUBRICATING OIL FLOW (LED-10) LED 7 (RED) LOW ALARM

LUBRICATING OIL FLOW(LED-10) LED 5 (RED) GEHO PUMP will TRIP

PROPELLING LIQUID OIL FLOW (LED-10) LED 7 (RED) LOW ALARM

PROPELLING LIQUID OIL FLOW (LED-10) LED 5 (RED) GEHO PUMP will TRIP
THANK YOU