ASH HANDLING

SYSTEM

What is ash?

Ash is the by product of coal combustion, created when coal is

burned in the boiler furnace to generate electrical energy.
Ash is the waste that is left after coal is burnt in boiler furnace.
Most ash generates from coal-fired electric power plants.
 Ash handling system

Ash

Bottom
Fly Ash
Ash

Dense
Wet Dry Lean
Phase
Handling Handling Conveyin
Conveyin
System System g
g
Coal is generally used as fuel and hence the ash is produced as the
by product of Combustion. Ash generated in power plant is about 30-
40% of total coal consumption and hence the system is required to
handle Ash for its proper utilization or disposal.

The ash generation from the Boiler is of two types .

Bottom ash
Fly ash
Bottom ash is approx. 20% and Fly Ash is approx.80% .
 Ash properties:-

Ash composition Sub- Lignite

Bituminous bituminous
Silica oxide-SiO2 20-60% 40-60% 15-45%

Aluminium -Al2O3 5-35% 20-30% 20-25%

Iron oxide- Fe2O3 10-40% 4-10% 4-15%

Calcium oxide- 1-12% 5-30% 15-40%

Magnesium oxide 0-15% 0-3% 0-5%

Coal Botto Economis APH Fly Ash

m Ash er Ash Ash Ash
100 % 10-20% 1% 1% 80- %
90%
Finenes
s
 Ash handling system flow
diagram-
Coal crushed in Pulverize form
CHP area coal - mill area

Coal stock

Electrostatic Precipitator Boiler

Flue Gas Flue Gas
Fly Ash Fly Ash
Bottom Ash

Bottom Ash
Fly Ash hopper
Chimney
 What is bottom ash?

Ash generated below furnace of the boiler is called bottom ash. The
bottom ash shall be collected in the water impounded bottom ash hopper.

Bottom ash handling system-

Bottom ash resulting from the combustion of coal in the boiler shall fall into the
over ground, refractory lined, water impounded, maintained level, double V-
Section type steel- fabricated bottom ash hopper having capacity to store about 8
hour bottom ash and economizer hopper will be continuously transferred to
bottom ash hopper in slurry form. The slurry formed shall be transported to slurry
pump through pipes.

The ash from the bottom ash hopper shall be fed to clinker grinder where it shall
be crushed to (-25 mm size).The jet pump below the clinker grinder shall convey
the crushed ash clinker using high pressure water to the ash slurry sump through
piping.
 Bottom ash handling system:
Clinker grinder system

The double roll clinker grinder shall be crushed ash clinker to

-25mm size .it is mounted below the discharge chute of the
bottom ash hopper. The clinker grinder capacity shall be min of 60
TPH .The clinker grinder shall be provided with sufficient drain
connection with valve.
 Clinker grinder specification

Clinker grinder Design details Unit

Clinker grinder Four (2nos working and 2nos standby )

Types of duty Heavy duty double roll
Capacity 60 TPH TPH
Material to be handled Bottom ash clinker
Maximum out put size -25 mm mm
Types of transmission Helical gear ,chain and sprocket
Grinder chamber Mild steel with 10 mm thk
 Wet Ash handling
system

Wet type systems have water impounded hopper and jet pumps for
intermittent removal.
The bottom ash fall into a Wet-type water impounded (water filled)
ash storage hopper .
The stored ash is removed by means of jet pumps and transported
in slurry pipe lines to the ash slurry sump for its further disposal.
 Slurry pump system:
 Bottom ash handling system
specification
Bottom ash hopper System specification Uni
t
Bottom ash hopper Two (2 no's)
Types of hopper Water impounded ,refractory lined ,w
type
No of out let opening Four (4)
Minimum thickness of 10mm
hopper
Jet pump Bellow bottom ash hopper
Discharge point Slurry sump
Type of lining Monolithic castable refractory (230mm )
Furnace temperature 1050 c
Material of construction Ni hard cast iron
wear resistant feed plate
 What is fly ash?
Fly Ash generated in the ESP which got carried out with the flue gas is
generally called Fly ash. The fly ash shall be collected at electrostatic
precipitator hopper(ESP) ,air pre heater hopper and stack hopper provided
along the flue gas path.

Fly ash handling system:

Fly ash handling system will be pneumatic system. The fly ash collected in
several sets of hoppers located in the flue gas path. ESP hopper and air
pre heater hopper will be evacuated pneumatically and shall be disposed
to ash pond through slurry pumps.

Air Pre Heater ash handling system

Ash generated from APH hoppers shall be evacuated by air conveying
system connected with the ESP hopper conveying system.
 Dry ash handling system

Fly ash is collected in ESP Hoppers. Fly ash from ESP hoppers extracted by
conveying air to Intermediate ash silo.
The first stage extraction of dry fly ash from under the various ESP / duct
hoppers to collect vessels located near the ESPs.
In the second stage ash shall be conveyed/transported from under these
hoppers to the storage silos. A conveying line shall be provided for extraction
of dry fly ash from ash silos.
 Electro static precipitator :
It is a device which captures the dust particles from the flue gas thereby
reducing emissions and dust from the chimney .

Electrodes at high voltage create a corona effect. Corona effect means ionized
atmosphere surrounding them. This charges the passing particles. Once charged
particles are subject to a transverse electrostatic force that pulls them toward the
collecting plates. Plates are periodically rapped (vibrated) to make the collected
particles fall down into the hoppers.
 working principle of ESP-

In high- voltage electrostatic field, affected by the electric field force, gas ionization
takes place. There are tremendous amount of electrons and ions existing in the
ionized gas. After the dust particles are combined with these electrons and ions, they
will be polarized, most of them are negatively polarized. Under the action of the field
force, negatively charged particles migrates towards the positive electrode and in
turn release electrons and attach to the positive electrode.

When the particles layers reaches a certain thickness on the plate, rapping system
will start to work and the particles will be dislodged from the collecting plate by
vibration and falling into the hopper. That ends the collection process.
 ESP COMPONENTS

All electrostatic precipitators, regardless of their particular designs

contain the following components:

Discharge electrodes
Collection electrodes
High voltage electrical systems
Rappers
Hoppers
Shell
 RAPPING MOTOR MECHANISM
 RAPPER MECHANISM -

Dust deposits are generally dislodged by mechanical impulses, or

vibrations, imparted to the electrodes .

Rapper system uses hammers mounted on a rotating shaft

As the shaft rotates, the hammers drop (by gravity) and strike anvils that
are attached to the collection plates.

The frequency of rapping can be changed by adjusting the speed of the

rotating shafts.
When the electrodes are rapped, the dust falls into hoppers.

Hoppers are usually designed with a 50 to 70 slope to allow dust to flow

freely
 RAPPING MECHANISM
 Fly ash handling system specification
Fly ash system Design data Unit
Capacity of conveying system 120 TPH each unit

Temperature of the material 140 c

handled
Bulk density of volumetric sizing 700kg/m3

Bulk density of power calculation 1200kg/m3

Fly ash valve Hopper isolation valve (knife gate)

Pressure system Slide plate/swing/dome type

location Below the ESP hopper & at the ash inlet transmitter vessel below

Conveying air compressors

Type Oil free screw type three (2-W and 1-S)

Fluid to be compressed air

Types of cooling Water

Cooling water requirement 75m3/hr

Quality of cooling water DM water

 Ash handling system details-

Description Details Unit

Bottom ash volume calculation 800kg/m3

Fly ash volume calculation 700kg/m3

Air temperature at different zone

Bottom ash 1040 c

Economiser ash 350 c

Air preheater 140 c

ESP ash 150 c

% of ash consider for design ash handling system

Bottom ash 0-9%

Economiser ash 0.5%

Air preheater 0.5%

 Ash pond
Utilisation of ash:

Cement additives.
Brick plants.
Road making
Saving of water
High reliability
Least maintenance
Environment concernAsh handling system is
useful for environment.
Plant housekeeping is improved
THANK
YOU