BHAVANAPADU THERMAL POWER PROJECT

STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

B 20.09.10 Revised as per ABIR Comments CKS MG SS

A 16.09.10 Preliminary Issue CKS MG SS

REV DATE DESCRIPTION PRPD CHKD APRD ECEPL

REVISION INDEX

BHAVANAPADU THERMAL POWER PROJECT

STAGE – I : 2x660MW, ANDHRAPRADESH, INDIA

DOCUMENT TITLE :

FEASIBILITY REPORT FOR BOTTOM ASH HANDLING SYSTEM

OWNER: OWNER’S ENGINEER:

EAST COAST ENERGY PRIVATE LIMITED ENERGY INFRATECH PRIVATE LIMITED

HYDERABAD – INDIA THERMAL POWER DIVISION, HYDERABAD - INDIA

BOP CONTRACTOR: BOP CONSULTANT:

ABIR INFRASTRUCTURE PRIVATE LTD IDEA - PB CONSORTIUM

THERMAL POWER DIVISION, HYDERABAD - INDIA CHENNAI / BANGALORE - INDIA

DOC.NO AIPL – 5310 – M – 1602– 5016 Page 1 of 11 Rev B

FEASIBILITY REPORT FOR BOTTOM ASH HANDLING SYSTEM Rev.: B

DOC.NO. AIPL-5310-M-1602-5016 Page 1 of 11
 BHAVANAPADU THERMAL POWER PROJECT
STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

TABLE OF CONTENTS
1.0 INTRODUCTION 4
2.0 PROJECT BACKGROUND 4
3.0 SYSTEM DESCRIPTION 4
3.1 General 4
3.2 Jet Pump System 4
3.3 Scrapper Chain Conveying System 5
3.4 Source of Water 7
3.5 Cost Implications 9
4.0 Recommendation 9

APPENDIX
Appendix 1 Comparison of SCC System with Contract Requirements

LIST OF DRAWINGS
AIPL-5310-M-0102-5103
AIPL-5310-M-0102-5113
AIPL-5310-M-0302-6033
AIPL-5310-G-0101-0001
Flow Scheme – Bottom Ash Handling System (Jet Pump System)
Flow Scheme – Bottom Ash Handling System (SCC System)
Layout of SCC
General Layout Plan (Tentative Routing of Bottom Ash Conveyor)

FEASIBILITY REPORT FOR BOTTOM ASH HANDLING SYSTEM Rev.: B

DOC.NO. AIPL-5310-M-1602-5016 Page 2 of 11
 BHAVANAPADU THERMAL POWER PROJECT
STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

LIST OF ABBREVIATIONS

BA : Bottom Ash

BoP : Balance of Plant

DEC : DONGFANG Electric Corporation Ltd.

ECEPL : East Coast Energy Pvt. Ltd.

SCC : Scrapper Chain Conveyor

FEASIBILITY REPORT FOR BOTTOM ASH HANDLING SYSTEM Rev.: B

DOC.NO. AIPL-5310-M-1602-5016 Page 3 of 11
 BHAVANAPADU THERMAL POWER PROJECT
STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

1.0 INTRODUCTION
The purpose of this report is to check the feasibility of utilizing Scrapper Chain Conveyor
(SCC) system for bottom ash removal in lieu of Jet Pump system.
The Contract specification calls for jet pump system for bottom ash removal and ash
handling system DBR was accordingly submitted. However, in a meeting between the
Owner and ABIR on 4th Sep. 2009, the Owner suggested Scrapper Chain Conveyor (SCC)
system for bottom ash removal. This report examines the feasibility of incorporating an SCC
system for the project.

2.0 PROJECT BACKGROUND

East Coast Energy Pvt. Ltd. (ECEPL) (Owner), proposes to install a 4x660 MW, Super
Critical Thermal Power Plant based on a blend of imported coal and indigenous coal at
Bhavanapadu, Srikakulam District of Andhra Pradesh, India about 175km away from
Visakhapatnam sea port. This project is proposed to be implemented in two Phases i.e.
Stage I – 2x660MW and Stage II - 2x660MW.

The Owner appointed NEC CONSORTIUM (ABIR & NAVAYUGA), as the EPC contractor for
Balance of Plant and Civil Works for Stage I of the proposed power project. ABIR appointed
IDEA-PB Consortium for carrying out the Engineering Consultancy and Project Management
Services for Mechanical, Electrical and C&I work for the Balance of Plant.

3.0 SYSTEM DESCRIPTION

3.1 General

The following two types of Wet Bottom Ash Handling Systems are widely utilized in thermal
power plants for bottom ash removal:-
 Jet Pump System
 Scrapper Chain Conveying System

3.2 Jet Pump System

The jet pump system consists of water impounded hopper (two ‘V’ legs or W-type), from
where bottom ash passes through large gates (hydraulic Feed Gate) on to dual roll clinker
grinders that grind clinkers to an appropriate size (maximum 25mm). The grinders then feed
the ash to a hydraulic ejector (jet pump), which transfer the resultant ash-water slurry to an
ash slurry sump located in the bottom ash slurry pump house. Make-up water and impulse
water are supplied by Low Pressure (LP) and High Pressure (HP) water pumps. Operation
of the jet pump requires high pressure impulse water that is supplied by the HP water pump.
The bottom ash handling system flow schematic (using jet pump system) is attached as
Dwg. No. AIPL-5310-M-0102-5103.

FEASIBILITY REPORT FOR BOTTOM ASH HANDLING SYSTEM Rev.: B

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 BHAVANAPADU THERMAL POWER PROJECT
STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

3.3 Scrapper Chain Conveying System

The SCC System receives hot ash, slag and clinkers falling from the boiler, through a
transition chute to the water-filled trough. The transition chute provides an air-tight seal
between the boiler and the scrapper chain conveyor. Ash is continuously conveyed up the
conveyor incline for dewatering.
The bottom ash discharged onto the scrapper chain conveyor will be fed to clinker grinders
where it is crushed to (-) 25mm size. The crushed bottom ash will be conveyed to the bottom
ash silo by belt conveyors. A bottom ash silo having eight (8) hours storage capacity along
with provision for water decantation is proposed for the each unit. Bottom ash collected in
silo will be disposed to ash dyke by means of the belt conveyor and under emergency
circumstances ash will be loaded on to truck for off-site disposal.

The bottom ash handling system flow schematic (using SCC system) is attached as Dwg.
No. AIPL-5310-M-0102-5113.

Recirculation system:
Over flow water from trough of scrapper chain conveyor and seal trough over flow will be
transferred to clarifier for supplying clear water to the Bottom ash system. This water will
also be cooled in the recirculation system. Make up water (desalinated quality) will be added
in the trough of scrapper chain conveyor.

Cooling arrangement for the SCC overflow water:-

Generally three options are available to cool the SCC overflow water:-
 FRP Cooling tower
 Plate type heat exchanger
 Settling & surge tank
Normally settling & surge tank is required to clarify the contaminated ash water before it is
cooled by the cooling tower or the heat exchanger. In the case of cooling tower additional
auxiliary power will be required for operating the pumps and fans and make-up water will
also be required to compensate for the blow down/evaporation losses. In the case of heat
exchanger option secondary cooling water from the sea water will be required. In order to
minimize water consumption, it is proposed to install a larger settling tank & surge tank, so
that retention time will be more and cooling will be achieved by evaporation.

Layout and Routing of the belt conveyor

Belt conveyors are proposed to dispose the bottom ash from scrapper chain conveyor to
bottom ash silo. In order to accommodate the bottom ash belt conveyor, IA/SA compressor
house (No. 45) and Acid/Alkali Unloading Area & Neutralizaion Pit (No. 46) are shifted
towards east side.

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 BHAVANAPADU THERMAL POWER PROJECT
STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

The routing of the belt conveyor is shown in the enclosed drawing, Dwg. No. AIPL-5310-M-
0302-6033.

The routing of the belt conveyor is tentative, which will require confirmation by DEC for any
potential interference with the boiler equipment.

Bottom ash silo is proposed to be located at the location where hydrobin are envisaged,
please refer to General Layout Plan, Dwg. No. AIPL-5310-G-0101-0001 enclosed in this
report.

Pros and cons of the Jet Pump system compared to SCC system are as follows;
Pros Cons
Simple layout, occupies less space in BA Higher power consumption
area
Widely installed in Indian power plants More number of equipment and structures
required
Higher installation cost
Water consumption high
To accommodate large volume of ash
holdup, part of BA system with jet pump
need to be located below ground.

Pros and cons of the SCC system compared to Jet Pump system are as follows;
Pros Cons
Less water consumption (about 10% less) Maintenance prone, hence standby SCC is
required
Less power consumption (about 15 to 20% Complex layout due to use of belt conveyors
less) and belt feeders in the boiler area
Due to continuous operation, capacity of
water recirculation system less.
Installation cost may be less
SCC located on the ground level and
mounted on the rails

FEASIBILITY REPORT FOR BOTTOM ASH HANDLING SYSTEM Rev.: B

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 BHAVANAPADU THERMAL POWER PROJECT
STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

3.4 Source of Water

The below tables summarizes the source of water required for handling ash.

Source of Water for AHS with Jet Pump

 
No Description Source Remarks
.
1. AHS Instrument Air Compressor DMCW or Desalinated
cooling CW
2. AHS Conveying Air Compressor DMCW or Desalinated
cooling CW

3. AHS Vacuum Pump Desalinated water once Desalinated water

through will be used to
cool/seal vacuum
pump coolers,
supplied from seal
water pump. The
discharge will be let
into the Ash water
sump and used in
the AHS system.
4. Source of water for Jet pumps Desalinated water Supplied by HP
Water Pumps
5. BA Hopper filling, BA Hopper Desalinated water Supplied by LP
Cooling and Seal Trough Make- Water Pumps
up
6. Seal Water for Clinker Grinder, Desalinated water Supplied by Seal
Sludge Pumps, BA Slurry water pumps
Pumps
7. For HCSD slurry preparation Desalinated water or Seawater can be
Seawater also used for HCSD
  slurry preparation.
Sea water
application will
increase the cost of
HCSD system by
approximately 2 to 3
times.

FEASIBILITY REPORT FOR BOTTOM ASH HANDLING SYSTEM Rev.: B

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 BHAVANAPADU THERMAL POWER PROJECT
STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

No Description Source Remarks

.
8. Fly ash Conditioning Service water To be tapped off
from service water
network

Source of Water for AHS with Scrapper Chain Conveyor

No Description Source Remarks
.
1. AHS Instrument Air Compressor DMCW or Desalinated
cooling CW
2. AHS Conveying Air Compressor DMCW or Desalinated
cooling CW
3. AHS Vacuum Pump Desalinated water once Desalinated water
through will be used to
cool/seal vacuum
pump coolers,
supplied from seal
water pump. The
discharge will be let
into the Ash water
sump and used in
the AHS system.
4. Economizer hopper flushing Desalinated water  
apparatus
5. Make-up for seal trough and Desalinated water  LP Pumps
Scrapper Chain Conveyor
6. Seal Water for Clinker Grinder Desalinated water Supplied by Seal
water pumps
7 For HCSD slurry preparation Desalinated water or Seawater can be
Seawater also used for HCSD
slurry preparation.
Sea water
application will
increase the cost of
HCSD system by
approximately 2 to 3
times.
8. Fly ash Conditioning Service water To be tapped off

FEASIBILITY REPORT FOR BOTTOM ASH HANDLING SYSTEM Rev.: B

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 BHAVANAPADU THERMAL POWER PROJECT
STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

No Description Source Remarks

.
from service water
network

It shall be noted that, the water requirement for SCC system will be about 10% less than the
Jet pump system.

3.5 Cost Implications

Preliminary discussion with the prospective vendors reveals that SCC system could be less
expensive compared to the jet pump system in terms of capital cost.

4.0 Recommendation
Both Jet pump with hydro bin system and SCC described above are technically acceptable
and both could be adopted depending upon the cost effectiveness. Also desalinated water
requirement for scrapper conveyor system could be less compared to hydro bin system.
Since SCC is prone to maintenance, a standby SCC is to be envisaged. The feasibility of
scrapper conveying system will also depend to a large extent in the ability to route the belt
conveyor between the boiler & the bottom ash silo. Preliminary assessment reveals that the
routing can be accomplished as per enclosed drawings.
In view of the above, bottom ash handling system with scrapper conveyor system is
recommended.

FEASIBILITY REPORT FOR BOTTOM ASH HANDLING SYSTEM Rev.: B

DOC.NO. AIPL-5310-M-1602-5016 Page 9 of 11
 BHAVANAPADU THERMAL POWER PROJECT
STAGE- I : 2x660 MW, ANDHRAPRADESH, INDIA

Appendix 1
Comparison of SCC System with Contract Requirements

Comparison with Contract Requirements

Sl.No. Contract requirement Proposed system Remarks
Jet Pump System SCC System
Make up water (Desalinated water)
1 Water impounded hopper Dry bottom ash hopper
requirement likely to be less (by about 10%)
Jet pumps, ash slurry pumps, hydro bin
2 Jet pump Scrapper chain conveyor
system is not required
3 Clinker grinder Clinker grinder Bottom ash disposal will be semi wet
4 Ash slurry pump Belt conveyor HP water is not required
5 Hydro bin system Bottom ash silo
Power consumption of SCC system will
6 Power consumption Power consumption will also be less
be approximately 15 to 20% less

FEASIBILITY REPORT FOR BOTTOM ASH HANDLING SYSTEM Rev.: A

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