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THERMAL POWER GENERATION CAPACITY OF INDIA CAPACITY OF THERMAL POWER PLANTS IN INDIA AUG. 2008 - 77198 MW 2012 (ESTIMATED) -127768 MW ASH GENERATION - 130 Million Tons (approx)
- 800 ACRES
- 500 ACRES
- 25000 ACRES
ASH COMPOSITION
SILICA ( SiO2) ALUMINA ( Al2O3)61- 63 % 26 - 28%
IRON OXIDE( Fe2O3)TITANIA (TiO2) Phosphoric Anhydride(P2O5) Lime (CaO) Magnesia (MgO) Sulphuric Anhydride (SO3) Sodium Oxide (Na2O)
45%
1.75- 1.88 % 0.54-0.55 % 0.77- 1.52 % 0.46 1.12 % 0.05 0.06 % 0.08 %
0.32 1.22 %
1100 1400 DEG CENTIGRADE
PC FIRED BOILER
Air Preheater
Flyash To ESP
ESP
Electrostatic Precipitator
Stack
Stage B: 17 %
Stage A: 80 %
Bottom Ash
Fly ash
20 %
80 %
Fineness
Stage C: 3 %
Pulverized Coal
ASH PRODUCTION
BOTTOM ASH - BOILER FURNACE COARSE ASH (grits) - ECONOMISER - AIR PRE-HEATER FLY ASH (dust) - ELECTROSTATIC PRECIPITATORS - DUCT HOPPERS (IF APPLICABLE)
ASH DISTRIBUTION
LOCATION FURNACE BOTTOM % OF TOTAL ASH IN COAL FIRED 15-20
ECONOMISER HOPPERS
AIR PRE-HEATER HOPPERS
75-80
ASH QUANTITIES
ASH HANDLING SYSTEMS DESIGNED FOR HANDLING ASH FROM WORST COAL AT BOILER MCR CONDITION
TYPICAL WORST COAL FIRED GCV : 3000 kcal/kg Ash content : 40%
INTERMITTENT TYPES
WATER-IMPOUNDED HOPPER WITH JET PUMPS (R/FII/TK/SIM/NEW STATIONS) OPEN-HEARTH HOPPER WITH TRENCH SLUICE/JET PUMPS (RIHAND)
CONTINUOUS TYPES
SCRAPER-CHAIN CONVEYOR WITH TRENCH SLUICE/CENTRIFUGAL PUMPS (ALL OLD STATIONS) SCREW CONVEYOR WITH TRENCH SLUICE/CENTRIFUGAL PUMPS (V STG-I/KH STG-I)
HOPPER SIZED FOR 5-6 HOURS OR 8 HOURS CAPACITY ON DRY ASH BASIS DEPENDING ON ASH QUANTITY AND SPACE AVAILABLE BELOW BOILER FURNACE
TYPICALLY 180 CU.M. FOR 210 MW TYPICALLY 450 CU.M. FOR 500 MW
FOR COOLING THE REFRACTORY LINING FOR COOLING HOT BOTTOM ASH TO SHATTER CLINKERS
HOPPER EVACUATED ONCE IN 4 HOURS OR 8 HOURS USING JET PUMPS SUPPLIED WITH HIGH PRESSURE WATER FROM DEDICATED PUMPS. ASH SLUICED VIA PIPELINES TO MAIN SLURRY PUMPHOUSE.
SCRAPER-CHAIN CONVEYOR
ONE REFRACTORY-LINED TRANSITION HOPPER WITH ISOLATION GATES PER UNIT FOR EMERGENCY STORAGE OF ASH HOPPER SIZED FOR 3- 4 HOURS HOLDING CAPACITY
- TYPICALLY 150 CU.M. IN 210 MW - TYPICALLY 300 CU.M. IN 500 MW
WATER-FILLED TROUGH WITH SCRAPER BARS ATTACHED TO PAIR OF MOVING ENDLESS CHAINS FOR REMOVAL OF ASH CONTINUOUSLY
2 X 100% ( ONE WORKING + ONE STANDBY) , OR 2 X 50% (TWO WORKING + TWO STANDBY) DEPENDING ON SUPPLIERS CAPABILITY
SCRAPER CONVEYOR
SCC
WATER SUPPLIED CONTINUOUSLY
OVERFLOW WATER FROM TROUGH RECYCLED IN ASH HANDLING PLANT AFTER SETTLING OUT CARRYOVER ASH
OPEN-HEARTH
BOX -SHAPED REFRACTORY-LINED STORAGE HOPPER , DIVIDED INTO SEVERAL COMPARTMENTS WATER CONTINUOUSLY SPRAYED ON ASH FOR QUENCHING COMPARTMENTS EMPTIED SEQUENTIALLY ASH EVACUATION FROM HOPPER ON INTERMITTENT BASIS ( EG. ONCE A SHIFT)
OPEN-HEARTH
ASH FLUSHED FROM COMPARTMENTS USING HIGH PRESSURE WATER JETS AND THE SLURRY SLUICED VIA TRENCH TO DISPOSAL PUMPHOUSE ASH SLURRY CAN ALSO BE REMOVED USING JET PUMPS/CENTRIFUGAL PUMPS LOCATED BELOW FLOOR LEVEL
SCREW CONVEYOR
ONE TRANSITION HOPPER PER UNIT WATER SPRAYED ON BOTTOM ASH FALLING THROUGH HOPPER FOR QUENCHING ASH FALLS INTO TROUGH BELOW HOPPER ONE SCREW CONVEYOR ,INCLINED UPWARDS, PROVIDED IN TROUGH TO REMOVE THE ASH CONTINUOUSLY
SCREW CONVEYOR
DEWATERED ASH SLUICED VIA TRENCH TO SLURRY DISPOSAL PUMPHOUSE
JET PUMP
Scraper Conv
Open Hearth
Screw Conv
Experience High + Med Less _ Less _ (India) BA HANDLING COMPARISON Power High _ Med High OF OPTIONS_ Med cons.
_ Med
+ High _ + High _ Med
High _
Less + Less + Med
Med
Med Med Med
Less Less
FLUSHING BOX
TYPICAL CONVEYING AIR PRESSURE (BAR) TYPICAL ASH/AIR RATIO BY WT. TYPICAL CONVEYING VELOCITIES(M/S) TYPICAL AIR SOURCE
Up to 2
<20 15-20
20-30 10-15
>50 5-8
BLOWER/COMPRESSOR
Design concentration for ash slurry pumping is 60% by weight. Range of concentration - 55% to 70% Ash pipe line velocity - 1.8 M/Sec. (max.) HCSD pump operating range - 10% to 100% of rated flow. Shut-down Restart for pumping operation Minimum 12 hrs. The High Concentration ash slurry disposal pump shall be positive displacement type. The high concentration slurry shall be disposed in disposal area such that no significant free water is released from the slurry.
Flushing Apparatus
HBN-1
CAT
HBN-2
HP Water LP Water Bottom Ash hopper OFT BAH Gates HBN-3
CG
CG HEs
From OFP/Ps
Hydro-bins
Settling Tank
To Hydro-bins Sludge Pumps To Hydro-bins Surge Tank
Ash Mound