Professional Documents
Culture Documents
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Flue Gases & Fine Ash Coal Consumption /Day/Unit= Ash 3000T Generation /Day/Unit( 34% ) = 1000T (Approx.)
Economis er
APH
ESP
CAT APH + ESP =80% of Total Ash System (800 T /Day Dry /Unit)
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SYSTEM
AND
ITS
The concept of dry ash handling has been utilized for the first time in India at a NTPC Dadri. Conventional ash handling system, requires enormous land water and has associated problems of leaching effect, dust blow etc. Some major aspects with respect to dry ash handling system that make it more favorable in comparison to conventional method of wet disposal are: 1. LESS REQUIREMENT OF LAND: Approx. land required for ash mound area is 0.8 acres per MW of generation capacity for 30-35 years. At NTPC Dadri, total 375 acre land is acquired for ash mound which is designed for 25 years ash output of four 210 MW units i.e. only 0.45 acre land per MW of generation capacity for 25 years is required in dry ash handling system. 2. LESS WATER REQUIREMENT: In conventional method i.e. lean slurry disposal system of ash, is ash is mixed with water in approx. 1 : 10 ratio and the slurry formed is transported through the pipelines to remote ash bund area by means of ash slurry disposal pumps. At NTPC Dadri, dry ash is handled and water required for this system is only for providing the moisture to ash to control the fugitive dust during process. Approximate ash water ratio in this system is 10 : 1. 3. ELIMINATES UNDERGROUND WATER AND SURROUNDING WATER WAYS POLLUTION: At NTPC Dadri, before putting PFA, minimum 1.00 meter thick drainage blanket is laid over the ground with FBA. This layer allows water to flow freely to the perimeter ditch and protects the ground water from toxic leach ate contamination. 4. 5. FACILITATE LARGE SCALE UTILIZATION OF ASH. PROGRESSIVE RESTORATION OF ASH DISPOSAL SITE AS USEFUL LAND.
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CG
CG
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The coarse ash from economizer hoppers is also transferred to the hydrobin, via, flushing apparatus, coarse ash tank and pipe lines, for its further removal to the ash mound area. Alternative the de-watered hydrobin ash can also be unloaded to trucks through the reversible belt conveyor. PULVERIZED FLY ASH (PFA): Fly ash from air pre-heater collection chutes and electrostatic precipitators collection chutes is continuously removed to the buffer hoppers located near the ESP, by means of vacuum pumps. For buffer hoppers, dry ash is pneumatically conveyed, via pipe lines to the storage silos for its further removal to the ash mound area by means of belt conveyors. Alternate arrangement is provided to load the unconditioned dry ash from silo to closed trucks. Altogether five silos are provided for all the four units. Out of five silos one silo is common which receives fly ash from both the transport lines of all the four units and remaining each silo receives fly ash from both the transport lines of only two units. Thus fly ash from unit-1 can be transferred to silo-1, silo-2 and common silo. Segregating valves in each pressure transport line. Located at the fly ash storage silo, controls which of the three silos, the fly ash is to be deposited. Provision is also made in the system to collect separately the saleable and non saleable ash. When the fly ash reaches the silo it enters a target box and falls by gravity into the silo, while the conveying air passes through a vent filter mounted on the silo roof and is discharge to the atmosphere. A pressure relief door is mounted on the top of the silo to relieve any excess pressure from the silo. The vent filter, installed on the top of the silo, is continuously cleaned during system operation. Pulsating air is supplied to clean the fly ash from the exterior surface of the filter bags. The fly ash falls from the bag filter down into the silo. Each silo is provided with three hydromix dust conditioners, two operating and one standby, for the removal and conditioning of fly ash in a moist state. The conditioned fly ash is discharged to a running belt conveyor (to be supplied by others) located below the hydromix dust conditioners. Hydromix dust conditioner is supplied with fluidizing feeder and metering cut off gate. Water is sprayed through nozzles on the fly ash inside the hydromixer to condition the ash. Air slides. Arranged fan rows around the outlet adopter opening in the silo floor, aerate the dust in the silo and functions continuously irrespective of whether silo is used as storage of being loaded/unloaded. Apart from hydromix dust conditioners, each silo is provided with three more outlets for removal of fly ash as an alternative arrangement. Each
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outlet is having one manual isolation valve, one solenoid operated plate valve, one rotary feeder and one telescopic chute. Ash is unloaded through feeder in dry form on to a closed truck. The unloading of silo through rotary feeder is controlled only from local control station, whereas unloading of silo through hydromix dust conditioner can be controlled either from local control station or from conveyor control panel. Each silo having the capacity of 2500 MT where as hydrobin capacity is 650 MT.
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aeration air to assist in maintaining the fly ash in fluidized condition. The bag filters, installed on the top of the buffer hopper, is continuously cleaned during system operation through solenoid operated pulsating air system. Two air lock tanks are installed below each transfer hopper.Each air lock tank has an inlet or top gate and outlet or bottom gate to control fly ash flow from trans hopper to silo. Aeration above each gate assist to maintain the fly ash in fluidized condition. An equalizer valve controls the pressure in the air lock chamber. When top gate is open, the equalizer valve is connected with the transfer hopper to ensure the pressure in the air lock tank is equal to the transfer hopper. When the top gate closes, the equalizer valve shifts position, allowing air from the transport air compressor to pressurize the air lock tank and assist the flow of fly ash when bottom gate opens.] The plant has 5 fly ash storage Silos (3000 m 3 each) for four units. The Silos 1-2-3 for Units # 1 & 2 and Silos 3-4-5 for Units # 3 & 4. Silo 3 is common for all the four Units for saleable purpose. The system has provision for storage of segregated fine fly ash from ESP hoppers to Silo-3. Each Silo has three Hydro Mix Dust Conditioners (200 T /hr each) & three Rotary Feeders. In HMDCs Fly Ash is being conditioned (Ash : Air :: 80 : 20 ) & unloaded in conveyor belt and sent to Ash Mound. Through Rotary Feeders dry ash is unloaded in closed truck. BOTTOM ASH HANDLING SYSTEM: The Bottom Ash impounded into Bottom Ash Hopper (194 m 3) and fed into Clinker Grinder through Bottom Ash Hopper discharge Gate. After Clinker Grinder the slurry line is evacuated by Hydro ejector ( inlet Pressure 20 kg /cm 2 & outlet Pressure 4 kg /cm 2) and sent to Hydrobin (650 cu. M) through Slurry Line (1 km long). Each Unit has four Clinker Grinders including Gate Housing and two slurry lines, operated simultaneously. The plant has six Hydrobins for four Units. Three nos. for a group of two Units.
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The coarse ash from economizer is flashed by LP water and collected in Coarse Ash Tank. Further evacuated through hydro ejector & and sent to Hydrobin through Slurry Line. Bottom Ash Hopper evacuation done once in shift. Normal evacuation time by two hydro ejectors is 45 minutes. Evacuation of Coarse Ash Tank once in a shift by 20 minutes through one hydro ejector. In Hydrobin ash is being separated & collected and water overflows to Settling Tank (750 m 3), and further overflows to Surge Tank (1500 m 3). All the HP & LP pumps are taking suction from Surge Tank. LP water pumps (each 294 m 3 /hr at 6 kg /cm 2) feeding water for Bottom Ash Hopper filling/over flow, Economizer flashing to Coarse Ash Tank, Seal Trough make up. All the three water overflows to Over Flow Tank (24 m 3). From Over Flow Tank the water is being recycled to Settling Tank through Over Flow Pump (200 m 3 /hr) and Over Flow discharge line. Initially Hydrobin is filled with water. And afterwards ash settles down & water overflows to the Settling Tank. Gradually Ash level rises in the Hydrobin. Normally after six Bottom Ash Hopper deashing around 400 T of ash accumulated in the Hydrobin. Then the Hydrobin taken under decantation. Water drained through decanter plates to settling tank. It takes 8 to 10 hours & then unloaded to conveyor belts through Vibrofeeder and send to Ash Mound. 2. Transportation of conditioned Ash from Silos & Decanted Bottom Ash from Hydrobins to Ash Mound Through Conveyor belts and construction of Ash Mound in a systematic manner. Fly Ash collected in Silos & Bottom Ash decanted in Hydrobins transported to Ash Mound area by a series of belt conveyors system and ash is dumped in a systematic manner. Ash can be damped in three different areas in ash mound area depending upon the system availability and weather condition. Normally ash is damped in permanent ash mound area through Spreader-I & II.
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6 deg
ROTARY FEEDER
HEATER
TELESCOPIC CHUTE
SAB-2
SAB-1
HMDC
ASH MOUND
During rainy season or system non-availability, ash is being dumped in Temporary Stock Yard through Stacker from where it is reclaimed to the permanent Ash Mound through Reclaimer. In case of non-availability of permanent as well as temporary stock yard, ash is being dumped in Emergency Stock Pile from where it is reclaimed with the help of mobile equipments like dumpers & dozers.
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EXISTING OPERATIONAL PRACTICES TO UNLOAD DRY ASH FROM SILO TO ASH MOUND: First of all path is selected to unload fly ash / bottom ash. Conveyors are selected on control desk by selector switches. Selected conveyors are made healthy electrically from their modules. Operated belt sway, pull cord etc. Protection device switches are normalized. All the flap gates are positioned on selected conveyors manually or electrically at various junction houses (JH's). Individual location operator gives the clearance through p.a. system before start the conveyor belt. For HMDC's operation - conveyor belt, M.S. water pump and silo aeration blower, Instrument air compressor should be in running condition. System is started in backward sequence from machine SP-1 / SP-2 / Stacker / SC-2 as per selection of ash unloading area. Than C-33, C32, CD/CC, CA/CB, C-30/31, C-24/25, C-22/23, C-20/21 and Silo Conveyor C-01 to C-05 or Hydrobin Conveyor C-10 to C-15 are selected and started from ash mound control room. Machine conveyors are started from its local control panel. Conveyor belt system is used to unload dry / bottom ash from silo and hydrobins. System is designed to run in two shifts. Generally silo unloading is done in 1st Shift and hydrobin in 2nd Shift or as per requirement / availability of system. Average ash unloading is done 4000 T /day. System runs 7 - 8 hours per day to evacuate this quantity of ash. Belt loading capacity is 2000 T /hr.
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Each silo pressure is depending on per day coal consumption. Each silo takes different time to become empty. Silos are evacuated upto empty limit daily. system runs more hours. Due to this practice
Utility factor of this system is 32 and system running hours is 210 220 hours per month. On completion of silo / hydrobin unloading system is stopped from silo / hydrobin Conveyors and then other conveyors are also stopped in forward sequence.
ASH CAN BE DUMPED AT THREE DIFFERENT AREAS IN ASH MOUND DEPENDING UPON SYSTEM AVAILABILITY & WEATHER CONDITIONS: a) Normally ash is taken into permanent ash mound area with the help of boom spreader machine which receives ash from a tripper car lane the final shiftable field conveyor and deposits the ash to 15 meters height up to 60 meters from the center line of shiftable conveyor. b) During rainy season or system non-availability (like during horizontal shifting of field conveyor), ash is dumped in "temporary stock yard area" from where ash is transferred to permanent ash mound area through re-claimer machines. c) In case of non-availability of systems for permanent & temporary ash mound area, ash can be transported to emergency stockpile from where it is reclaimed with the help of mobile equipment. The extendable shiftable conveyors give maximum flexibility for ash mound construction to the full height over the entire area. Short, intermediate modules on pontoons are added or removed to change length. Head and tail units mounted on skids can be either towed by bulldozer sideways or lifted with a big crane to change the position of the conveyor. Modular section of belt conveyor structures of shiftable field conveyor are mounted on pontoons which can be easily towed by bulldozers sideways with the help of special shifting attachments during horizontal shifting of conveyor. Shifting attachment mounted bulldozers facilitate the shifting of conveyor in assembled condition to a new location.
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EQUIPMENTS OF AHP:
Equipments Transport Air Compressor Vacuum Pump Buffer Hopper Transport Air Line(300/350NB) Silo(2949m 3) Silo Aeration Blower Silo Vent Fan Hydro Mix Dust Conditioner Instrument Air Compressor Bottom Ash Hopper (194cuM) Coarse Ash Tank Clinker Grinder Hydro Ejector Over Flow Tank Over Flow Pump Hydrobin Settling Tank Surge Tank Sludge Pump HP Pumps LP Pumps MS Pumps Seal Water Pump Motor rating In kW 545 75 N/A N/A N/A 30 18.5 7.5 125 N/A N/A 7.5 Capacity 159/147 m 3 /min 46.5 m 3 /min 28 T up to high level 55 T max. (40T avg.) 2500 T 12 m 3 /min 200 m 3 /min 200 T/hr 14 m 3 /min 128 T 38 m 3 70 T/hr 45 54 m 3 245 m 3 /hr 650 m 3 750 m 3 1500 m 3 40 400 m 3 /hr 296 m 3 /hr 296 m 3 /hr 30 Pressure In kg/cm 2 2.29 -400 mmHg 0.5 - 1.5 atm 0.7+0.7=1. 4 atm N/A 7 kg/cm 2 N/A N/A Inlet Pr. 20 Outlet Pr. 4 2.8 Populatio n 2*4 4*4 4*4 2*4 5 2*2*5 2*5 3*5 3 1*4 1*4 4*4 6*4 1*4 2*4 6 2 2 2*4 6 6 3 2
11 320 75 75 45
3.5 20 7 10 21.6
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VACUUM PUMPS:
Number Make Type Inlet Volume Rpm Motor : : : : : : 16 no, 4 for each unit (2 working, 2 standby) Roots Division Dressers Industries Inc, USA Rotary Lobe Vacuum Blower 46.8 m3 /min at 16 mm of Hg 1057 75 kW / 415 V
BUFFER HOPPER:
Number Capacity Volume of air lock tank : : : 16 no, 4 for each unit (2 working, 2 standby) 35 m3 up to high level 1.41 m3 (2 no below each Buffer Hopper)
BAG FILTERS:
Number Material Size : : : 81 in each Buffer Hopper Nomex 150 mm Diameter & 2750 mm long (each)
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Capacity Diameter
: :
2949 m3 15 m
These blowers supply aeration air to silo by which dry ash slides towards inlet gate of Hydro Mix Dust Conditioners (HMDC).
ROTARY FEEDERS:
Number Motor : : 15 no, 3 for each silo 2.2 kW, 415 V
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Motor
Working pressure :
Mix spray water pumps are used for HMDC nozzles to condition the dry ash which passes through it. M.S. Pumps are also used for flushing of hydrobin decanters & slurry lines etc.
CLINKER GRINDERS:
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: : : : :
16 no, 4 for each unit (2 running, 2 standby) Double roll Indure 70 T / hr 7.5 kW / 415 V 7.52 : 1 960 rpm
OVERFLOW PUMP:
Number Make Capacity Dish. Pressure Motor : : : : : 8 no, 2 per unit (1 working, 1 standby) Indure Ltd., Sahibabad, U.P. 245 m3 /hr 2.8 kg /cm2 45 kW / 415 V
HYDROBINS:
Number Capacity Top Diameter : : : 6 no, 3 for unit 1 & 2 and 3 for unit 3 & 4 650 T 10.6 m 2*4 kW / 415 V / Opposite direction
Vibrofeeder Motor:
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SETTLING TANK:
Number Capacity Top Diameter : : : 2 no (one for unit 1&2 and one for unit 3&4) 750 m3 20.02 m
SURGE TANK:
Number Capacity Top Diameter : : : 2 no (one for unit 1&2 and one for unit 3&4) 1500 m3 23 m
SLUDGE PUMPS:
Number Seal Water Pr. Capacity Dish. Pressure Motor : : : : : 8 no, 2 for each Settling tank & Surge tank (1 working, 1 standby) 3.5 kg /cm2 50 m3 /hr 3.0 kg /cm2 11 kW/ 415 V
Number of Stages :
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Motor
75 KW
/ 415 V
Number of Stages :
Number of Stages :
LINE a) A.C.I. (3OO NB ) 50% b) CAST BASALT(350 NB) 50% LENGTH OF ESP Vac. LINE a) A.C.I. (2OO NB) b) A, C. I (250 NB) LENGTH OF APH Vac. LINE a) A.C.I. (2OO NB) b) A, C. I (250 NB) 50 meter 10 meter 80 meter 10 meter
km
km
km
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VIBRATORY ROLLER:
Vibratory roller is basically a compactor cum roller. This is used for compacting ash throughout the ash mound on place surface on top of mound and also on slopes. This is operated after leveling of ash on mound surface and after reaching to required level at final stage.
PAY LOADER:
Requirement of Pay Loader is not connected with ash mound construction. Pay Loader is used to lift and load ash in dumpers bucket for transportation of ash from ash mound to other low laying areas or to fill the rain cuts, pay loader is also used to remove the mud and silt taken out from ditches by other machines.
EXCAVATOR:
Requirement of Excavator has been felt for making peripheral ditch around ash mound & drains around ash mound. Ditch and drain cleaning was also a major problem and it was not possible to clean them manually. As before every rainy season ditch and drain cleaning was essential we preferred to purchase a excavator for this purpose. The additional work which has a major role is lifting & shifting of ash from ash mound area to other places, in the excavator plays a major role as filling of dumpers are easy with the help of excavator. Even though we
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have one pay loader but it was not sufficient to fill the dumpers. With help of excavator we have reduce idle time of dumpers.
MOTOR GRADER:
Motor Grader is a leveler / planner. It is having a small blade between its front and rear tyres. It is used for final leveling of ash on mound and slopes to get the final profile.
BOWSER:
As water spreaying is an essential task in ash mound construction and to reduce dust emission. Bowsers are procured for this purpose. Bowser are basically water spraying vehicle. Bowser is consists of 5 Kl. Capacity tank mounted on chasis, engine driven centrifugal pump is installed on the chasis with water meter, valves, hose recl. And spray nozzles. The operation of rear engine and nozzles etc. are controlled from drivers cabin. There bowser are also used for spraying of polymers on the ash mound finished surface to suppress dust. Polymer spray on surface on mound makes a thin film of polymer on mound surface which eliminates the dust emission even in storm.
PIPE LAYER:
Pipe Layer is specially designed equipment for shifting of field conveyor a special attachment was fabricated and fitted on bulldozer model D-155 for this purpose. This pulls field conveyor along its complete length in a step of 0.5 m at a time.
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ASH UTILIZATION:
OPC PPC (Portland Pozzolana Cement) Concrete Road Construction Embankments Land Development Structural Fills Lightweight Aggregates Lime-Fly Ash Bricks Clay-Fly Ash Bricks Insulating bricks Mineral Wool Cenospheres Colored Bricks
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