Baseline Document on Handling and Transportation of Fly Ash (without TF/TA)

Implemented by Indian Institute of Technology, Delhi Hauz Khas, New Delhi-110016

For Fly Ash Unit Department of Science and Technology New Delhi-110016

2013

TABLE OF CONTENTS
Chapter 1 Particulars Background 1.1 Scope of the Baseline Document 1.2 Deliverables 1.3 Methodology 1.4 Different facets of Handling and Transportation of Fly Ash 1.5 Some observations Details of Fly ash generations 2.1 Introduction 2.2 Ash Generation 2.3 Ash Collection Hoppers 2.4 Hydraulic Conveying 2.5 Pneumatic Conveying 2.6 Historical Perspective Wet Disposal of Coal Ash in the Thermal Power Plants 3.1 Background 3.2 Flow regimes and Classifications of Suspensions 3.3 Hydraulic design of ash disposal pipeline 3.4 Classification of Wet ash Disposal Systems 3.5 Study on Wet Disposal of Coal Ash at Medium Concentrations 3.6 Study on Wet Disposal of Coal Ash at High Concentrations 3.7 The typical cost of Wet Disposal System Pneumatic Conveying of Fly Ash 4.1 Mode of Conveying 4.2 Design Consideration 4.3 Present Systems for Power Station Ash Handling 4.4 Procedure for Design of Pneumatic Conveying Systems 4.5 Design for Fine Grade or ESP Fly Ash 4.6 Conveying Characteristics 4.7 Design Procedure Alternative Methods for Fly Ash Transportation to the Users 5.1 Use in Cement Grinding Units 5.2 Use of Trucks/Tankers 5.3 Export of Fly Ash 5.4 Small Quantity Users Important Issues on Handling and Transportation of Fly Ash 6.1 General 6.2 Operational Problems in existing systems 6.3 Issues/Technological Options to be considered for Future 6.4 Policy Issues to be considered 6.5 Suggestions Page No. 1 1 2 2 2 3 4 4 4 5 8 9 10 12 12 13 16 19 22 37 52 53 55 56 57 59 62 63 64 68 68 68 70 71 73 73 74 75 75 75

EXECUTIVE SUMMARY The project involves a compilation/review of the technologies used for transportation of ash both within the plant as well as away from it. The scope of the study includes all aspects of handling and transportation of coal ash like, in plant handling/storage, transportation to the users/disposal site, road and rail tankers, transfer by boats for export, closed tankers etc. In addition, the document also covers some aspects of the storage and handling systems at the user's site. Based on the review of the technology, it is proposed to recommend the type of activities that need to be taken up in future to handle and transport ash in a more environment friendly and energy efficient manner. Scope of the Baseline Document The various activities in the preparation of the Baseline Document are as follows: a) Analysis of the traditional methods of coal ash handling and transportation and identification of the draw backs. b) Identification of the changes that have taken place in recent years in this area. c) Identification of new technologies that have been developed in recent years and spell out how these can be incorporated into practice. d) Recommend the best methodology that needs to be followed in the thermal power plants in the area of coal ash management. e) Transportation of coal ash to user agencies from thermal power plants. f) Preparation of the baseline document which can serve as a catalyst to incorporate best available technologies and give a road map to be followed. The document will also include technology assessment and forecasting so that efforts needed to achieve the goal of full ash utilization can be identified. Deliverables The above scope covers the status of the technology for handling and transportation of fly ash at the thermal power plants, its transportation to the users site and handling at the users site. In case there are no avenues for its utilization, how the ash can be transported for safe disposal in the ash ponds or mounds. The primary objective is to ensure that the handling of the coal ash is undertaken in an environmentally friendly manner and with optimum energy. Methodology The work has been done through the following methods: a) Literature survey b) Study of existing practices being followed c) Study and analysis of the performance of new technologies wherever they have been implemented.

d) Visits to the major power plants to understand the difficulties faced and constraints in implementing new technologies. e) Develop models for implementing each technology and how it can be integrated into the rest of the system. f) Optimize transportation of coal ash from Thermal Power Plants to user agencies. g) Consultation with the other experts and user Industries. Different Facets of Handling and Transportation of Fly Ash: Collection of fly ash at thermal power stations from ESP, economizers, preheaters, bottom ash etc. Conveying and transportation of all these ashes within the power stations, their storage and supply to user points/ deposition points. Technologies for separate or mixed collection/transportation/deposition to maximize the beneficial use of fly ash and minimize the cost as well as the environmental impact; pneumatic conveying (lean phase and dense phase), slurry disposal (low concentration, medium concentration, high concentration with indigenous pumping systems, paste disposal with positive displacement pumps), etc. Transportation through belt, tube belt, rope ways, railways and others. Transportation of ash for various utilization modes like cement manufacture, Road and embankment construction, earth filling, stowing of mines, building component manufacture etc.

Some observations All thermal power stations now have a dry fly ash collection system to promote utilisation of ash. The location of the disposal silo at most plants has been moved to near the plant boundary. As a result, the conveying distance for the second stage of conveying has gone up to 2000 m. Most of the new units are of 660 MW or higher generation capacity and hence the quantum of fly ash to be handled is much more than in the past. The ash conveying systems capacity has, therefore, gone up to 100+ tonnes per conveying line. Many plants are now using medium concentration slurry systems while some have adopted high concentration slurry system. At several plants, cement grinding units have been set up in close vicinity. For the ash handling system, the consultants have specified strict guidelines for energy consumption and apply an additional loading on the price of those vendors quoting higher power consumption.