Brainware group of Institutions Barasat

Power Plant Engineering

Boiler accessories, Super heater, Economizer
ME 701
( Module 4)

Dr. Shyamal Goswami

Department of Mechanical Engineering
( July – Dec 2018 / 7th semester ME )
 Boiler Accessories (Module 4)
• Super heater
• Economizer
• Air – pre heater
• Handling of coal and ash
 Heat absorption in water tube Boilers
Three kind of Heat exchangers :
• Economizer
• Evaporator (down comer – riser circuit)
• Super heater

• Feed water from h.p heater –enters economizer heated

by flue gases till it is saturated liquid then fed to the
drum > falls through the down comer into the bottom
header and moves up through the riser where water is
partially boiled back into the drum . This section is
called evaporator > saturated steam goes to super heater
for heating to desired temperature.
Heat absorption in water tube boiler
 Economizer
• Economizers are mechanical devices intended to
reduce energy consumption, or to perform another useful
function such as preheating a fluid. The term economizer
is used for other purposes as well. In simple terms, an
economizer is a heat exchanger.
• In boilers, economizers are heat exchange devices that
heat fluids, usually water, up to but not normally
beyond the boiling point of that fluid. Economizers are
so named because they can make use of the enthalpy in
fluid streams that are hot, but not hot enough to be used
in a boiler, thereby recovering more useful enthalpy
and improving the boiler's efficiency. They are a device
fitted to a boiler which saves energy by using the
exhaust gases from the boiler to preheat the cold water
used to fill it (the feed water).
Schematic Diagram of Economiser
 Economizer
• Is a heat exchanger which utilizes the waste heat from
the exhaust gases to heat the feed water before its entry
into the boiler. – supply of preheated water reduces the
amount of heat to be added in the boiler for converting
the same into steam. Preheated water also reduces the
thermal stresses which will be induced due to the
variations in the temperature of water in the drum.
• Provision of an economizer increases the efficiency of
the boiler : 1% for each 5 deg C rise in feed water
temperature.
• In the economizer, the heating surface is built of a
number of tubes arranged in groups. The number of
tubes in each row, the length of the tubes, and the
number of groups depend on the performance required.
 Economizer
• Water flows through the economizer tubes and the
hot gases over the tubes.
• Temperature of feed water entering the economizer
should not fall below 35 deg C. otherwise external
corrosion will result due to condensation of steam
contained in flue gases at the cold end of the
economizer. The lowest flue gas temperature to
prevent a similar problem is about 150 deg C
depending on the sulphur content present in the fuel.
• To prevent corrosion and separation of steam and
water mixture in the outlet loop, the water velocity in
the economizer tubes should not be less than 0.5 m/s
and 1 m/s in non steaming and steaming economizers
respectively.
 Economizer
• Heat exchanger - raises temperature of feed water to about
saturation temperature corresponding to boiler pressure
• Term economizer – used because it utilizes high energy gases.
• By using these gases for heating feed water – higher efficiency
and better economy achieved
• Done by flue gases exiting super heater or re heater from 370 deg
C to 540 deg C
• Modern economizers allow some boiling of feed water – termed as
“steaming economizers”
• Tubes are 45 -70 mm outside diameter
• Types :
Finned Tube Economizers
C.I Gilled Tube Economizers
Plain Tube Economizers
 Economiser
• Gas side heat transfer coefficient - much less than water side
heat transfer coefficient – to compensate finned outer surface.
• forced convection : Nu = f (Re, Pr)
 Economiser

• Economizer coil and temperature profiles of flue gas

and water heated to saturation temperature
Economiser
 T-s diagram
• A temperature entropy diagram, or T-s diagram, is
used in thermodynamics to visualize changes to
temperature and specific entropy during a
thermodynamic process or cycle. It is a useful and
common tool, particularly because it helps to visualize
the heat transfer during a process. For reversible
(ideal) processes, the area under the T-s curve of a
process is the heat transferred to the system during that
process.
• An isentropic process is depicted as a vertical line on a
T-s diagram, whereas an isothermal process is a
horizontal line.
T-s diagram
 Flue Gases
• Flue gas is the gas exiting to the atmosphere via a
flue, which is a pipe or channel for conveying
exhaust gases from a fireplace, oven, furnace, boiler
or steam generator. Quite often, the flue gas refers to
the combustion exhaust gas produced at power
plants. Its composition depends on what is being
burned, but it will usually consist of mostly nitrogen
(typically more than two-thirds) derived from the
combustion air, carbon dioxide (CO2), and water
vapor as well as excess oxygen (also derived from
the combustion air). It further contains a small
percentage of a number of pollutants, such as
particulate matter, carbon monoxide, nitrogen
oxides, and sulfur oxides
 Log mean temperature difference
• The log mean temperature difference is used to determine the temperature
driving force for heat transfer in flow systems, most notably in heat exchangers.
The LMTD is a logarithmic average of the temperature difference between the
hot and cold streams at each end of the exchanger. The larger the LMTD, the
more heat is transferred. The use of the LMTD arises straightforwardly from the
analysis of a heat exchanger with constant flow rate and fluid thermal properties.

• A generic heat exchanger has two ends at which the hot and cold streams enter or exit on
either side; then, the LMTD is defined by the logarithmic mean as follows:

• where ΔTA is the temperature difference between the two streams at end A, and ΔTB is the
temperature difference between the two streams at end B. With this definition, the LMTD
can be used to find the exchanged heat in a heat exchanger:
• Where Q is the exchanged heat duty (in watts), U is the heat transfer coefficient (in watts
per kelvin per square meter) and Ao is the exchange area.
• This holds both for parallel flow, where the streams enter from the same end, and for
counter-current flow, where they enter from different ends.
 Heat transfer coefficient
• The heat transfer coefficient or film coefficient,
in thermodynamics and in mechanical and
chemical engineering, is the proportionality
coefficient between the heat flux and the
thermodynamic driving force for the flow of heat
(i.e., the temperature difference, ΔT):

• where
• q : heat flux, W/m2 i.e., thermal power per unit
area, q = dQ/dA h : heat transfer coefficient,
W/(m2•K) ΔT : difference in temperature between
the solid surface and surrounding fluid area, K
 Superheater
• convert saturated steam or wet steam into dry steam.
• ca. 40% of total heat absorbed in the generation of
steam takes place in super heater
• One of the most important accessories of a boiler
- affects improvement and economy in the
following ways :

Increases the overall cycle efficiency.

reduces moisture content and thus increases
turbine internal efficiency.
Eliminates corrosion of the steam turbine.
 Superheater
• Consists of inlet and outlet headers . These headers
are connected by a number of U shaped tubes ( hot
drawn seamless type of comparatively small
diameter) in a parallel or a series form.
• Furnace gases at high temperature and velocities are
made to sweep over the super heater tubes carrying
steam raising temperature to the desired level at
practically constant pressure. This also increases the
quality of steam.
• Final temperature of superheated steam depends on
boiler exit gas temperature, quantity of gas flowing,
velocity of gas, steam flow
Schematic Diagram of Superheater
Boiler showing Economiser, superheater arrangement
 Disadvantages of Superheaters
Without careful maintenance super heaters
are prone to a particular type of hazardous
failure in the tube bursting at the U-shaped
turns in the super heater tube. This is
difficult to both manufacture, and test
when installed, and a rupture will cause the
superheated high-pressure steam to escape
immediately into the large flues, then back
to the fire and into the cab, to the extreme
danger of operators.
 Classification of Superheaters
depending on how heat is transferred from the gases to steam

• Convection superheater (primary superheaters) - located

in the path of the hot gases usually ahead of economisers.
. Radiant superheater - placed directly in the combustion
chamber.
. Pendant superheater - combined superheater , receives
heat partly by convection , partly by radiation
• Separately fired superheater - , as its name implies, is
totally separated from the boiler.
Desuperheater – pure water directly sprayed on the steam
in such quantity that temp. does not exceed rated value after
last stage
Convection superheater (primary superheaters)
Radiant superheater
Superheater
Superheater
 Superheater

• Since Tf >> Tw , QRSH

Superheaters
 Air Preheater
An air preheater (APH) is a general term to describe any device designed to heat air before
another process (for example, combustion in a boiler) with the primary objective of
increasing the thermal efficiency of the process.

The purpose of the air preheater is to recover the heat from the boiler flue gas which
increases the thermal efficiency of the boiler by reducing the useful heat lost in the flue gas.
As a consequence, the flue gases are also conveyed to the flue gas stack (or chimney) at a
lower temperature, allowing simplified design of the conveyance system and the flue gas
stack. It also allows control over the temperature of gases leaving the stack (to meet
emissions regulations, for example).
 Air Preheater
• Feedwater temperature in present day’s power plant with five or
more feedwater heaters goes upto 170-280 deg C.
• Temp. of flue gases leaving economiser can not be below 270 – 480
deg C
• Loss of energy with stack exhaust is high , efficiecy of Boiler low
• This energy can be recovered and used for heating of air for
combustion – makes combustion process more efficient and
lessening the energy losses – temp. exiting air preheater vary from
135-180 deg C.
• Advantages : prevention of acid corrosion, proper dispersion of
exhaust gases from the stack to the atmosphere, preheating of air
saves fuel – increase of boiler efficiency
• Preheated air also required for pulverized coal furnaces. Primary air
at temp. range 150-420 deg C needed for drying coal
 Regenerative and Recuperative Air pre heater
• Two types : recuperative – heat directly transferred
from the hot gases to the air - commonly tubular
(helping to return to normal health or strength.
regenerative : The term "regenerative" describes
processes that restore, renew or revitalize their own
sources of energy and materials, creating sustainable
systems that integrate the needs of society with the
integrity of nature. )

• In recuperative type air pre heater, heat is directly

transferred from the hot gases to the air across the heat
exchanging surface. They are commonly tubular
[Counter flow shell and tube type( air outside the tube
and hot gas inside the tube)] but sometimes also plates
are used.
 Regenerative Air pre heater
• Regenerative also known as storage type have an
energy storage medium called the matrix which is
alternately exposed to hot and cold fluid. When
the hot flue gases flow through the matrix in the
first half of the cycle, the matrix gets heated and
the flue gas gets cooled. In the next half of the
cycle when air is passed through the matrix, air
gets heated and matrix gets cooled ( periodic) –
advantage :large exchange surface, cheap and
good heat transfer characteristics . Disadvantage :
large pressure drop, flow opening plugged by fly
ash, sealing of gas to air path and vice versa
 Air Preheater
There are two types of air preheaters for use in steam generators in thermal power stations: One is a
tubular type( built into the boiler flue gas ducting, and the other is a regenerative air preheater.
These may be arranged so the gas flows horizontally or vertically across the axis of rotation .
•
Air Preheater (Regenerative)
Rotating-plate regenerative air preheater.
 Air Preheater
• Rate of heat transfer from gas to air is given by :

• Where : n = number of tubes , di = inside diameter of tubes (- 50mm)

Air Preheater
 Coal and Ash handling
• The basic layout of Coal Handling Plant is shown by
block diagram.
• coal is unloaded at various unloading station and
transported by conveyors to crushing and screening
plant via transfer house.
• After crushing required quantity of coal is
transported to bunker via transfer house and
remaining coal is stored in stockyard.
• This coal is reclaimed as per requirement. From the
bunker the coal flows through coal mills to boiler
furnace.
• The main aim of CHP to maintain level of coal in
bunkers for smooth coal supply to boiler
 Coal requirement per Kwh
• Thermal energy content of coal : 6150 kWh/ton
• Conversion thermal energy into electrical energy : 40%
• Electricity generated per ton of coal : 0.4 x 6150 = 2460 kW h/ton

• We'll start by figuring out how much energy in kilowatt-hours the light bulb
uses per year. We multiply how much power it uses in kilowatts, by the
number of hours in a year. That gives 0.1 kW x 8,760 hours or 876 kWh.
• The thermal energy content of coal is 6,150 kWh/ton. Although coal fired
power generators are very efficient, they are still limited by the laws of
thermodynamics. Only about 40 percent of the thermal energy in coal is
converted to electricity. So the electricity generated per ton of coal is 0.4 x
6,150 kWh or 2,460 kWh/ton.
• To find out how many tons of coal were burned for our light bulb we divide
876 kWh by 2,460 kWh/ton. That equals 0.357 tons. Multiplying by 2,000
pounds/ton we get 714 pounds (325 kg) of coal. That is a pretty big pile of
coal, but let's look at what else was produced to power that light bulb.
• A typical 500 megawatt coal power plant produces 3.5 billion kWh per
year. That is enough energy for 4 million of our light bulbs to operate year
round. To produce this amount of electrical energy, the plant burns 1.43
million tons of coal. It also produces:
 Coal requirement per Kwh
• The energy density of coal can also be expressed
in kilowatt-hours for some unit of mass, the units
that electricity is most commonly sold in, to
estimate how much coal is required to power
electrical appliances. One kilowatt-hour is 3.6 MJ,
so the energy density of coal is 6.67 kW·h/kg.
The typical thermodynamic efficiency of coal
power plants is about 30%, so of the 6.67 kW·h of
energy per kilogram of coal, 30% of that-2.0
kW·h/kg-can successfully be turned into
electricity; the rest is waste heat. So coal power
plants obtain approximately 2.0 kW·h per
kilogram of burned coal.
 Calorific value of coal
• The calorific value Q of coal [kJ/kg] is the heat liberated by its
complete combustion with oxygen. Q is a complex function of
the elemental composition of the coal. Q can be determined
experimentally using calorimeters. Dulong suggests the
following approximate formula for Q when the oxygen content
is less than 10%:
• Q = 337C + 1442(H - O/8) + 93S, where C is the mass percent
of carbon, H is the mass percent of hydrogen, O is the mass
percent of oxygen, and S is the mass percent of sulfur in the
coal. With these constants, Q is given in kilojoules per
kilogram.

• The calorific value of coal equates to 15,000 to 27,000 kJ/kg

Coal Handling plant
 Coal Handling plant
• Coal delivered to the site
• Weighed, emptied from wagon, ship
• Lifted and discharged ( using skip hoist, bucket
elevators, belt conveyors, telphers, together with trucks,
tipplers, cranes, wagon hoists, drag line buckets and
winches) into overhead bunkers
 Coal storage
• Coal storage : to provide against failure of coal supply -
adequate coal reserve should be kept near the station
site.
• Factors to be considered for Coal storage:
• area and rent,
• risk of spontaneous combustion,
• loss of storage and deterioration of coal,
• interest on capital cost of coal lying dormant,
• cost of insurance,
• handling cost necessitated by storage and reclamation
ability to overcome fire,
• local condition of wind and climate.
 Coal handling in a thermal power plant
• Introduction :The huge amount of coal is usually
supplied through railways. A railway siding line is
taken into the power station and the coal is delivered
in the storage yard. The coal is unloaded from the
point of delivery by means of wagon tippler. It is
rack and pinion type. The coal is taken from the
unloading site to dead storage by belt conveyors.
The belt deliver the coal to 0m level to the pent
house and further moves to transfer point 8.
• The transfer points are used to transfer coal to the
next belt. The belt elevates the coal to breaker
house. It consists of a rotary machine, which rotates
the coal and separates the light dust from it through
the action of gravity and transfer this dust to reject
bin house through belt.
 Coal handling in a thermal power plant

• The belt further elevates the coal to the

transfer point 7 and it reaches the crusher
through belt. In the crusher a high-speed 3-
phase induction motor is used to crush the
coal to a size of 50mm so as to be suitable
for milling system. Coal rises from crusher
house and reaches the dead storage by
passing through transfer point 8.
Stages in Coal handling plant
 Coal handling in a thermal power plant
• Steam generation from coal :
• 1. Tipplers : Coal from the coal wagons is
unloaded in the coal handling plant. This unloading
is done by the “Tipplers”. This coal is transported
up to the raw coal bunkers with the help of
conveyor belts.
• 2. Crush House : After hand picking foreign
material, coal is transported to the Crush house by
conveyor belts where it is crushed to small pieces
of about 20 mm diameter. The crushed coal is then
transported to the store yard. Coal is transported to
bowl mills by coal feeders.
 Coal handling in a thermal power plant
• 3. Bowl Mill : The coal is pulverized in the
bowl mill, where it is grounded to a powder
form. The mill consists of a round metallic
table on which coal particles fall.
• This table is rotated with the help of a motor.
There are three large steel rollers, which are
spaced 120” apart. When there is no coal, these
rollers do not rotate but when the coal is fed to
the table it packs up between rollers and the
table and this forces the rollers to rotate.
Coal is crushed by the crushing actions
between the rollers and rotating tables.
 Coal handling in a thermal power plant
• Steam generation from coal :
• 1. Tipplers : Coal from the coal wagons is
unloaded in the coal handling plant. This unloading
is done by the “Tipplers”. This coal is transported
up to the raw coal bunkers with the help of
conveyor belts.
• 2. Crush House : After hand picking foreign
material, coal is transported to the Crush house by
conveyor belts where it is crushed to small pieces
of about 20 mm diameter. The crushed coal is then
transported to the store yard. Coal is transported to
bowl mills by coal feeders.
 Coal handling in a thermal power plant
• 3. Bowl Mill : The coal is pulverized in the
bowl mill, where it is grounded to a powder
form. The mill consists of a round metallic
table on which coal particles fall.
• This table is rotated with the help of a motor.
There are three large steel rollers, which are
spaced 120” apart. When there is no coal, these
rollers do not rotate but when the coal is fed to
the table it packs up between rollers and the
table and this forces the rollers to rotate.
Coal is crushed by the crushing actions
between the rollers and rotating tables.
 Coal handling in a thermal power plant
• 4. Furnaces : This crushed coal is taken away to the furnace
through coal pipes with the help of hot and cold air mixture from
P.A Fan. P.A Fan takes atmospheric air, a part of which is sent to
Air pre-heaters for heating while a part goes directly to the mill for
temperature control.
• Atmospheric air from F.D Fan is heated in the air heaters and
sent to the furnace as combustion air.
• 5. Boiler : Boiler used in the power plant is suspended type. This
prevents it from getting deformed, when a subjected to very high
temperatures.
• The boiler is divided into two cylindrical parts namely the Primary
and the Secondary boiler. Water from the boiler feed pump passes
through economizer and reaches the boiler drum. Water from the
drum passes through down comers and goes to bottom ring header.
Water from the ring header is divided to all the four side of
furnace.
• Due to heat and density difference the water rises up in the water
wall tubes.
 Ash Handling
• Ash : Ash is the residue remaining after the coal
is incinerated.
• Composition of ash handling system:
• SiO2, Al2O3, Fe2O3, CaO , MgO.
• Requirement of Handling System :
• In Thermal Power Plant’s coal is generally used as
fuel and hence the ash is produced as the
byproduct 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.
 Ash Handling
• Ash terminology in power plants:
• Fly Ash ( Around 80% is the value of fly ash generated)
• Bottom ash (Bottom ash is 20% of the ash generated in
coal based power stations.
• Fly ash :
• Ash generated in the ESP which got carried out with the
flue gas is generally called Fly ash. It also consists of Air
pre heater ash & Economiser ash (it is about 2 % of the
total ash content).
• Bottom ash:
• Ash generated below furnace of the steam generator is
called the bottom ash.
•
 Ash Handling System
• The ash handling system handles the ash by bottom ash handling
system, coarse ash handling system, fly ash handling system, ash
disposal system up to the ash disposal area and water recovery
system from ash pond and Bottom ash overflow. Description is as
follows:
• A. 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/ W type steel- fabricated
bottom ash hopper having a hold up volume to store bottom ash
and economizer ash of maximum allowable condition with the rate
specified. The slurry formed shall be transported to slurry sump
through pipes.
• B. Coarse Ash (Economizer Ash) handling System :
• Ash generated in Economizer hoppers shall be evacuated
continuously through flushing boxes. Continuous generated
Economizer slurry shall be fed by gravity into respective bottom
ash hopper pipes with necessary slope.
 Ash Handling System
• C. Air Pre Heater ash handling system
• Ash generated from APH hoppers shall be evacuated once in a shift
by vacuum conveying system connected with the ESP hopper
vacuum conveying system.
• D. Fly Ash Handling System
• Fly ash is considered to be collected in ESP Hoppers. Fly ash from
ESP hoppers extracted by Vacuum Pumps up to Intermediate Surge
Hopper cum Bag Filter for further Dry Conveying to fly ash silo.
• Under each surge hopper ash vessels shall be connected with Oil
free screw compressor for conveying the fly ash from Intermediate
Surge Hopper to silo. Total fly ash generated from each unit will be
conveyed through streams operating simultaneously and in parallel.
• E. Ash Slurry Disposal System
• Bottom Ash slurry, Fly ash slurry and the Coarse Ash slurry shall
be pumped from the common ash slurry sump up to the dyke area
which is located at a distance from Slurry pump house.
Ash collection and transportation
Ash collection
 Vacuum-Pneumatic Conveying System

• Fly ash is collected at an intermediate silo first

and conveyed pneumatically to a silo placed
apart. This system is employed for long
distance conveying to the storage silo.
• This is a system taking advantage of both the
features of the vacuum conveying and
pneumatic conveying and suitable for
distributing fly ash to multiple storage places.
Bottom ash sluice conveyor
Flyash Hydraulic vacuum conveyor
Vacuum-Pneumatic Conveying System
 Ash Handling
• Ash handling refers to the method of collection, conveying,
interim storage and load out of various types of ash residual left
over from solid fuel combustion processes.

• most common types of ash include bottom ash, bed ash, fly ash
and ash clinkers resulting from the combustion of coal, wood and
other solid fuels.

• Ash handling systems may employ pneumatic ash conveying or

mechanical ash conveyors.

• A typical pneumatic ash handling system will employ vacuum

pneumatic ash collection and ash conveying from several ash pick
up stations-with delivery to an ash storage silo for interim holding
prior to load out and transport. Pressurized pneumatic ash
conveying may also be employed.
• Electrostatic precipitator main source of flyash
• indian coal contains about 30% of ash. The hourly
consumption of coal of a 200MW unit is about
110 tons. With this, thehourly production of ash
will be 33 tons.If such large amount of ash is
dischargein atmosphere, it will create heavy
airpollution thereby resulting healthhazards.
Hence it is necessary toprecipitate dust and ash
of the fluegases.Precipitation of ash has
anotheradvantage too. It protects the wear
anderosion of ID fan. To achieve the above
objectives,Electrostatic Precipitator (ESP) is
used.As they are efficient in precipitatingparticle
form submicron to large sizethey are preferred to
mechanicalprecipitation.
 Different type of ash in a power plant
• The ash produced on the combustion of coal is collected byESP. This ash is now required to be
disposed off. Thispurpose of ash disposal is solved by Ash Handling Plant(AHP). There are basically 2
types of ash handling processesc undertaken by AHP

• Dry ash system

• •Ash slurry system
• :>Dry ash system:>Ash slurry system
• Ash from boiler is transported to ash dump areas bymeans of sluicing type hydraulic system which
consists of two types of systems:•Bottom ash system•Ash water system
• :Bottom ash system
• In this system, the ash slag discharged from the furnace iscollected in water impounded scraper
installed belowbottom ash hopper. The ash collected is transported toclinkers by chain conveyors.
The clinker grinders churn ashwhich is then mixed with water to form slurry.
• :Ash water system
• In this system, the ash collected in ESP hopper is passed toflushing system. Here low pressure water
is appliedthrough nozzle directing tangentially to the section of pipeto create turbulence and
proper mixing of ash with waterto form slurry.Slurry formed in above processes is transported to
ashslurry sump. Here extra water is added to slurry if requiredand then is pumped to the dump
area.
• :>Fly ash system
 Bottom ash and its disposal
•
• Bottom ash
• refers to the non-combustible constituents of coal
withtraces of combustibles embedded informing clinkers
and sticking to hotside walls of a coal-burning
furnaceduring its operation. The portion of the ash that
escapes up the chimneyor stack is, however, referred to as
• fly ash
• . The clinkers fall bythemselves into the water orsometimes
by poking manually, andget cooled. The clinker lumps get
crushed tosmall sizes by
• clinker grinders
• mounted under water and fall downinto a trough from
where a waterejector takes them out to a sump.From there
it is pumped out bysuitable rotary pumps to dumpingyard
far away. In anotherarranement a continuous link chain
 Clinker Grinder
• A clinker grinder is a useful component in
those ashconveying systems where coarse
bottom ash or othercoarsely sized material
must be reduced in size so asto be suitable for
pneumatic conveyance or othermeans of ash
handling
 Ash handling system
• Dry ash system
• Dry ash is required in cement factories as itcan be
directly added to cement. Hence thedry ash
collected in the ESP hopper isdirectly disposed to
silos using pressurepumps. The dry ash from
these silos istransported to the required
destination
• Fly ash system
• Even though ESP is very efficient, there isstill
some ash, about 0.2%, left in flue gases.It is
disposed to the atmosphere along withflue gases
through chimney
•
• Coarse ash material such as bottom ash is most often
crushed in clinker grinders (crushers) prior to being
transported in the ash conveyor system. Very finely
sized fly ash often accounts for the major portion of
the material conveyed in an ash handling system. It
is collected from bag house type dust collectors,
electrostatic precipitators and other apparatus in the
flue gas processing stream. Ash mixers
(conditioners) and dry dustless telescopic devices are
used to prepare ash for transfer from the ash storage
silo to transport vehicles.
•
 Ash Handling
• Coal has 40 – 50% ash content ( Proximate analysis)
• 20% of this collected at the bottom of the furnace – called Bottom Ash
• Rest 8)% collected by other collection device- called Fly Ash
• Collection of Bottom Ash :
• Mechanical System :
• Trough filled with water is placed at the bottom of the furnace
• Ash while falling down gets quenched in the trough and cooled down
• Ash is simultaneously removed with the help of motor driven scraper
chain conveyor.
• Ash is fed into clinker grinder, which crushes the large
amount of ash into fine particles
• Ash slurry is made for transporting it to ash dyke – area
outside the plant for storing or dumping ash.
 Ash Handling
• Hydraulic system : Only difference to mechanical system is that water
jets are placed to quench the falling ash which moves to the clinker
grinder due to slope and water pressure.
• Collection of Fly Ash : Fly ash ( fine particles size < 100 micron) is the
part of ash which flows with flue gases and goes out of furnace through
chimney.
• mixed with flue gases and are separated by following ways :
• Gravitational or mechanical : To collect fly ash, weight of ash particles
and its mechanical properties are used. Ash particles being heavier than
air have larger inertia and continue to move in same direction. Different
techniques used for ash collection are :
• (a) sudden change in cross section : cross section of the duct carrying
dust laden flow is suddenly increased. The velocity of ash particles and
flue gas is reduced which causes ash particles to fall down in the ash
hopper. – arrangement good for big size particles – fine particles quickly
pickup the velocity of the flue gas and move out without collecting in
the hoppers.