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Fly Ash Handling System – Wherever products are burned it is necessary to have an energy efficient ash handling system, especially in a power station environment where large quantities of pulverized fuel ash (PFA) are created. Such ash can be a considerable environmental nuisance as well as being awkward to handle due to its abrasiveness and hygroscopic characteristics. With the growing environmental awareness that hydraulic ash removal systems are costly in the use of water and land, emphasis has been placed on finding an environmentally safe system.
The unique and comprehensive range of products and technologies from Pneuconveyor systems & engineers for the Power industry include several innovative methods to handle Ash products to increase the operating efficiency of the power generation process.
Utilising a range of technologies from Mechanical Chain and Belt conveyors to Pneumatic conveying with Dense Phase technology.
Pneuconveyor systems has a proven solution available regardless of plant size.
For installations with a relatively low volume of fly ash or short transit distances Mechanical Conveying is an ideal solution.
Where the through put of fly ash are longer or long transit distances Dense phase Pneumatic Conveying is more suitable.
Dense Phase Pneumatic Conveying System
The main benefits of the Dense Phase pneumatic conveying systems are :
Dens Phase Methodology :-
Dense phase pneumatic conveying systems operate with higher material : air ratios typically >10:1 giving greater conveying efficiency, capable of handling a wide range of ash, from Coarse to fine.
Slide Gate Valve :-
Every system incorporates the original Dome Valve at the critical point of any pneumatic handling system; the material to air interface, which can operate up to 1,00,000 cycles between scheduled maintenance
Environmentally Friendly :-
Totally enclosed conveying system and pipework greatly reduces the impact on the environment.
Low Conveying Velocity :-
Low conveying velocity typically less than 10 m/sec which minimises the wear on critical components such as conveying pipe and bends.
Standard steel conveying pipe :-
Readily available standard steel pipes are used for the conveying pipelines with no special manufacturer requirements.
Low pressure compressed air requirements :-
Uses medium to low pressure conveying air, typically around 2 – 4 bar(g) generated from standard compressed air plant or blowers provide energy efficient use of absorbed power.
The Dense Phase Conveying System is the most reliable; efficient to minimize particularly the problems for handling the wide and adequate range of dry bulk solids up to 100TPH Capacity at the exceeding terminal distances – 1,100 meters. This system includes weighing, batching, blending, lump breaking, storage, master control equipments etc. through Dense Phase Conveying System for bulk material handling in the plant.
pneuCONVEYOR, specializes in Dense Phase pneumatic system for collecting and conveying of dry coarse/fine fly ash collected at Economizer/ Air pre heater / Duct / Electrostatic precipitator hoppers. Dense Phase pneumatic system is generally adopted on account of many of its advantages like positive pressure system, low material conveying velocity, lesser erosion rates, conveying of fine & coarse ash separately as collected (thus increasing utility of fly ash) capability to convey longer distances in a single stretch etc.
The system consists of installation of Ash Conveying Vessels directly below the fly ash hoppers. The conveying vessels are equipped with our unique Slide gate valve at inlet. Expansion Joint and isolation valve are provided above slide gate valve. Numbers of conveying vessels are connected to conveying pipe. To reduce number of conveying pipes from ash hoppers, it is possible to join them together. There are different ways to join the conveying lines, either as directed by the client / consultant or in view of optimized design. At fly ash Silo(s), suitable vent filters are provided to vent out clean air. Level sensors are provided in silos and ash hoppers. Fly ash silos are equipped with “dry” and “wet” unloading system for disposal of fly ash in trucks. The system operates on a batch mode for the first stage conveying system and on a continuous mode for second stage transportation system. Compressed air from compressors is used as medium of conveying. Instrument air from a separate source is required for slide gate valve operation and for instrumentation purpose.
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Mechanical Conveying Systems - Drag chain conveyor
For the Mechanical Conveying of Fly Ash Pneuconveyor systems has considerable expertise and experience in such sector with the – Tubular chain drag conveying system. This system offers a robust and simple solution that does not require a high level of operator or maintenance skill. The Pneuconveyor – principle of conveying is now firmly established worldwide for the mechanical handling of pulverized fly ash (PFA).
The Benefits of the – Tubular Drag Conveyor System
Cost Effective :-
- Capital Costs prove very competitive with pneumatic systems.
- The power running costs are significantly lower than most other forms of equipment.
- Heavy duty rigid construction in simple modules, high strength chain, choke detectors, overload and underspeed switches all ensure easy maintenance.
Totally Enclosed :-
Machines, transfer points, joints and slides are of dust-tight and weatherproof construction.
Pressure Tight :-
The totally enclosed construction minimises the ingress of air into a negative pressure system and the escape of gases from a positive pressure system.
Labor Saving :-
The system is free of complicated electronic controls with the mechanical components making it easily maintainable.
Continuous Discharge :-
The Pneuconveyor systems has the ability to maintain a continuous discharge from the primary hoppers.
Intermittent Discharge :-
The system has the ability to discharge primary hoppers, which have an accumulated load of ash. The machine capacity can be arranged to clear the accumulated ash over a period of time in addition to the normal drop-out loading.
Robust :-
The system is of robust durable construction. The Pneuconveyor – principle of a slow moving chain offers absolute minimum degradation and separation and minimises wear to both casing and chain.
Simple :-
Does not require a high level of operator maintenance skill.
Tolerant :-
The system is by nature robust and therefore more able to cope with foreign bodies welding rods, gasket material etc. or lumps of ash which may find their way into the system.
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