A PRESENTATION ON PRODUCTIVITY

IMPROVEMENT IN ASH HANDLING PLANT

ADHUNIK POWER & NATURAL RESOURCES LIMITED, PADAMPUR,
JAMSHEDPUR
(2X270 MW)

BY-
GYANENDRA KUMAR
AGM (AHP)
What is Ash ?
Ash is the residue remaining after the coal is
incinerated.
In other words when anything organic burns,
it becomes carbon and when the carbon has
burnt it becomes ash.
The composition of ash including following:
SiO
2,
Al
2
O
3
, Fe
2
O
3
, CaO, MgO

INDIAN COAL
Generally high ash content
Larger amounts of ash to be handled ( 30 to
46 % of coal)
Inconsistent Quality.
CHALLENGES OF ASH HANDLING
In Thermal Power Plants coal is generally used as fuel
and hence the ash is produced as the byproduct of
Combustion. Ash generated in power plant is about 30-
46% of total coal consumption and hence the system is
required to handle Ash for its proper utilization or
disposal.
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.
TRADITIONAL TECHNOLOGY
To dispose off large amount of ash efficiently
(i) HYDRO-SLUICING:
Water impounded bottom ash hoppers with jet pump systems followed by
lean phase slurry pump system up to ash dyke.

Dry type Bottom Ash Hopper with submerged scraper chain conveyor
system followed by lean phase slurry pumps system up to ash dyke.

(ii) PNEUMATIC HANDLING:
Negative pressure type
Lean Phase
Dense Phase



SYSTEM INTRODUCTION

6
MAXIMUM COAL CONSUMPTION 204 TPH
PERCENTAGE OF ASH 46%
TOTAL ASH GENERATION (WORST
COAL)
93 TPH
BOTTOM ASH (23%) 21.39 TPH
FLY ASH (77%) 71.61 TPH
BUFFER HOPPERS 3 NOS WITH 20T CAPACITY EACH
CONVEYING AIR COMPRESSOR 3 NOS (2W+1SB), 56 m/min, 2kg/cm
2
TYPE OF COMPRESSOR ROTARY SCREW TYPE
FLUIDIZING AIR BLOWER (ESP) 3 NOS (2W+1SB), 800m/hr, 6 MWC
SILOS 2 NOS, 2200T CAPACITY EACH,
BOTTOM ASH HOPPER 2 NOS, 225m EACH HOPPER, 180T
BUFFER
HOPPER
AIR
COMPRESSOR
FROM
ATMOSPHERE
D-PUMP
BAG
FILTER VACCUM
PUMP
Bottom Ash
Hopper
APH ES
P
Coal
Consumption
/Day/Unit =
4400T
Ash Generation
/Day/Unit ( 46%) =
2000T (Approx.)
Slurry System (460 T /Day /Unit)
Bottom Ash=23% of Total Ash APH + ESP =77% of Total
Ash
Flue Gases & Fine Ash
Economiser
Dry System (1540 T /Day /Unit)
ID
FAN
CHIMNE
Y
.
Ash Storage Silo: Capacity 2200 MT Each
Silo Vent
HMDC
ROTAR
Y
VANE
FEEDER
DRY ASH INTO
CLOSED
TANKERS
ELESCOPIC
CHUTE
VENT
CONDITIONED
ASH INTO OPEN
TRUCKS
FROM 2ND UNIT
DUMP VALVE
BAG
FILTER
SFB-
1
SFB
-2
HEATE
R
BAG
FILTER
FLY ASH
SILO
Silo Vent
FROM 1ST UNIT
FEED
SUM
P
TO ASH
SLURRY PUMP
HOUSE
ROTAR
Y
VANE
FEEDER
ROTAR
Y
VANE
FEEDER
SYSTEM INTRODUCTION
ash handling- 1-2
Maximum Coal Consumption-
204TPH
Percentage of Ash- 46%
Total Ash Generation-93 TPH
SYSTEM INTRODUCTION
ash handling- 2-2
8
D-
PUMP
BUFFER
HOPPER-
2
BAG
FILTE
R
D-
PUMP
D-
PUMP
BUFFER
HOPPER-
3
D-
PUMP
BAG
FILTE
R
D-
PUMP
D-
PUMP
D-
PUMP
BUFFER
HOPPER-
1
BAG
FILTE
R
D-
PUMP
AIR
COMPRESSOR
S
WATER
TRAPS
TO
SILO
D-
PUMP
VACUUM
PUMP
ASH INLET ASH INLET ASH INLET
ASH
CONVEYING
CONVEYING
AIR
FLUDIZIN
G AIR
(i) HYDRO-SLUICING
BOTTOM ASH HADNLING SYSTEM:
The bottom ash handling system will comprise the
following:
Bottom ash hopper complete with clinker grinder and all
accessories. Each boiler will be provided with a W type bottom ash hopper for
transport the bottom ash discharged to the ash slurry sump through clinker grinder One
clinker grinder will crush the clinker up to >= 25 mm Size.
Three high pressure water pump for two units, including one stand by, will be used for ash
conveying pipes with high-pressure booster nozzles and hydro ejectors.
The bottom Ash Slurry thus formed is conveyed to slurry sumps. Slurry sumps consist of 3
compartments with 51 m3 capacity each. The slurry then pumped through 3 set of pumps.










Bottom Ash
Hopper
Jet Pump
Ash Water
Tank
LP HP
Ash Slurry
Sump
Ash Slurry
Pump
To Ash
Dyke
TYPICAL BOTTOM ASH HANDLING DIAGRAM
(ii)PNEUMATIC HANDLING (NEGATIVE PRESSURE)

Negative pressure (vacuum) type operate essentially by Lean Phase fluidising
method. There is a material handling valve below each hopper to segregate the
hopper from transport line. The water operated mechanical vacuum pump
installed in ESP, exhaust air from the transport line and the resultant rise in
vacuum operates high vacuum switch. Solenoid valve is energized and material
handling and associated branch segregating valves are opened. Ash in the
hoppers is fed into the vacuum lines and is conveyed to a fabric filter which
separates the ash from the air. The ash is discharged into the storage buffer
hopper and air is drawn through the vacuum pump via a line filter and exhausted
to atmosphere. This system operates on the lean phase principle with a high air
to ash ratio and high conveying velocities
Vacuum pump has 5 set points:

VAC-P : 150170 mm of Hg
VAC-HH : 350-370mm of Hg
VAC-VH : 440-450mm of Hg
VAC-H : 300mm of Hg
VAC-L : 70-110mm of Hg


TYPICAL VACUUM ASH CONVEYING
DIAGRAM
Dense Phase Pneumatic Pressure
Conveying System
The Dense Phase Pneumatic Pressure Conveying
Systems uses low volume, medium pressure air stream
and relies on a continuously expanding volume of air
pushing cohesive slugs of material along the pipe.
separated by cushions of air. Average conveying
velocities are low between 2 to 5 m/sec. The material
air ratio is in the range of 20 -100.





TYPICAL PRESSURE CONVEYING
(DENSE PHASE) DIAGRAM
SAFETY & ENVIRONMENT
To provide general awareness and on site emergency plan to all
employees about Fly ash leakage and about Handling &Disposal
of Fly Ash.
Use Necessary PPEs Like Gas tight safety goggles, safety shoes & Nose
mask at SILO Areas& Collecting hopper areas.
Ensure proper sealing of collecting hoppers (Vacuum line) & and flange
joints tightness of ASH conveying line (High pressure conveying line) by
routine checks
Ensure proper healthiness of Discharge Chute & Dust Conditioner
Ensure proper operation of Conveying air compressors, Buffer hoppers,
D-pumps, Vacuum Pumps, and Fluidizing Blowers
Ensure proper safety guards are provided to vacuum pump &
compressors
Conduct awareness training program to people are directly involved in
ASH handling areas in case of any leakage & about emergency
preparedness
Spillage of Fly ash during maintenance activity of Hoppers need to be





SAFETY & ENVIRONMENT
Kept clean after completion of Job.
Ensure level of ASH silo & Balancing the Ash collection rate from ESP
and APH Hoppers to Ash Disposal rates.
Periodically check the following system healthiness:
Dry system through unloading spout.
Moist ash through ash conditioner.
Slurry through jet pump.
Bagging unit
In case of any leakage in the above system to be attended
immediately.
Check that all disposal lines are properly shut after unloading
Conduct Training program for workers directly involved in Fly ash
unloading systems & emergency preparedness on health hazard, Ash
leakage or spillage, optimum utilization of water in conditioners.






SAFETY & ENVIRONMENT

Display of safety slogan at Collecting Hopper areas & SILO area.
Conducting Flue Gas analysis at APH outlet & ESP inlet and outlet.
Conducting General awareness about on-site emergency plan in
case of Fly ash Leakage.
Ensure healthiness of Dust Conditioner, Slurry pump, and
Conveying air compressors.
Training on Safe Handling of equipments & Disposal fly ash to AHP
staff.





ADVANTAGES & UTILIZATION OF ASH
i) Saving of water a precious commodity.
ii) Building Sector for use in bricks, blocks, tiles, cement, concrete,
plaster, etc.
iii) Land reclamation, filling low lying areas, raising ground levels.
iv) Roads, embankments, ash dykes, road blocks, kerbstones, etc.
v) Mine filling.
vi) Industrial applications & high value areas.
vii) Roller compacted dams, pavements, roads etc.
viii) Special use for ash e.g., collecting cenospheres from floating
ash.


ADVANTAGES & UTILIZATION OF ASH
ix) Energy Efficient (High reliability) Long Plant Life.
x)Least maintenance
xi)Environment concern:
In a period, when environmental protection and awareness is
a major industrial and social concern, Dense Phase pneumatic
conveying, by totally enclosed handling system is
particularly amenable to the environment.
All conventional problems of spillage, dust, contamination and
storage are efficiently and successfully eradicated.
Plant housekeeping is greatly improved.