Ash Handling System

What are the types of Ash in Thermal

Power Plant ?
Bottom Ash
Fly Ash
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Bottom Ash
The ash which is directly collected

from bottom of boiler.

Bottom ash directly falls down in

water filled bottom due to gravity.

Bottom ash is 20% of total ash.

Fly Ash
It is collected from :-

1-ESP hoppers
2-Air preheaters hoppers
3-Economiser hoppers
It is 80% of total ash.

Wet system
In this system ash conveying

media is water.
It has two main component:1-Hydro-vactor
2-Hydro-ejector

Hydro-vactor
Working Principle:-

Hopper ash is directly sucked by

vaccum, which is created by high
water
Jet (hydrovactor).
This ash mix with water in collecting
tank and finally slurry collects in
slurry sump.

Hydro-ejector
Working Principle:-

High pressure water jet carries slurry

from the bottom to slurry sump.
This system operates once in a day
(24 hrs).

Final disposal of slurry

Finally slurry from slurry sump is

conveyed by pair of big centrifugal

pumps to Ash ponds.

This slurry system is common

1-for D & E station

2-for C & F station

Fly Ash in Forestry

Ash pond No 1

Fly Ash in Forestry

Ash pond No 1

Fly Ash in Forestry

Ash pond No 2

Different Auxillaries in wet

system (Fstation)
1-H.P. pump
3 Nos. 11 kg/cm2
2-L.P. pump
3 Nos. 6 kg/cm2
3-Ash slurry pump 3 Nos. in each path
2.5 kg/cm2
4-Air washer pump 2 Nos. 5 kg/cm2
5-Seal water pump 2 Nos. 18 kg/cm2

What is the need of dry

system?
It has some good characteristics over

the wet system:1-Huge quantity of water is saved.

2-Power consumption is less.
3-Reduction in surface pollution.
4-Earning, by selling dry ash to cement
factory & bricks manufacturer.

Components of dry system

K-pump
P.D.pump
Centac compressor
Acher silo

K-pump
It is nothing but the combination of

silo,Transfer vessel,Dispencing
vessel &
Centrifugal compressor.
D & E station has common K-pump
C & F station has another common
K-pump.

Working Principle of Kpump

It works on the principle of

pressure difference.
Its operation is sequential

,because Dome Valves from DV-1

to DV-6 operate in sequence.

Acher Silo
Finally Dry ash is disposed to acher

silo
which is located in AEC campus.
These are 2 in nos.
Each has capacity of 750 ton .

INTEGRATED FLY ASH HANDLING SYSTEM: (Schematic flow diagram)

Stage- I
C stn.
Fly ash
Hoppers
Exist.
Recip
Compr

30 TPH

Fine Ash

C 1 Existing
Silo
(Cap:350 T)

F stn.
Intm.
Hopper

Silo (New)
130 Cu.Mtr.
( 'C' stn)

F stn.
Fly ash
Hoppers

Stage I
Centrifugal
Compr.

Compr.

(After rehibilitation)
Stage II
CentrifugalCo
mpr.

Stage-II

80 TPH

80 TPH
Stage-I

Fine Ash

FINAL FLY ASH

FINAL FLY ASH
STORAGE SILO AT STORAGE SILO AT
ACHER
ACHER
Capacity :
750 Cu.Mtr.

Silo (New)
130 Cu.Mtr.
('D/E' stn)

D/E Exist.
RCC Silo
(Cap :450 T)

E stn.
Fly ash
Hoppers

Capacity :
750 Cu.Mtr.

D stn.
Fly ash
Hoppers

80 TPH

80 TPH

Stage-II 80 TPH

To final ash disposal area by closed tanker / truck

Stage II
Centrifugal
Compr.

Stage I
Centrifugal
Compr.

Loading of trucks &

tankers at acher
There are 2 system of loading :-

1-For truck - water spray system

2-For tankers by gravity

Acher
Ash collection in closed tanker at Acher silo

Acher
Ash collection in closed tanker at Acher silo

Use of Fly Ash

For building construction
For Cement manufacturing
For bricks manufacturing
Ash customers:-

1-Gujrat ambuja cement

2-Binani cement, laxmi cement
3-GCL (RCC pipe mfg.)

Fly Ash used in Bldg. Mat.

Private
Private Private Bungalow Gadhinagr

Fly Ash used in Bldg. Mat.

Ghodasar Shriji Complex

Construction

RCC road near D.M. Plant area

Construction

RCC road from Crusher house to Coal JN - M

Future strategies
Now a days we are using almost dry

system.
In future our planning is to stop
whole wet system except bottom
ash which is only 20%.
For loading trucks & tankers we are
thinking about loading in night shift
too.