Presentation about ash handling plant

1. Exploring the Ash-Handling
Plant of MSPGCL Koradi
The MSPGCL Koradi's Ash handling plant is responsible for managing the
generated ash efficiently to enhance air quality and preserve the
environment.

2. The Types of Ash Generated at 3x660 MW KTPS
1 Bottom Ash
This fine powdery residue is
generated after combustion of
coal in the thermal power plant.
Its removal prevents air pollution
and soil degradation in the
surrounding area.
2 Coarse Ash
Bottom ash is the solid products
of combustion that have
sufficient mass, either as a
monolith or as an agglomeration
of smaller particles, to fall
against the gas flow to the
bottom of the furnace.
3 Fly Ash
The ash that accumulates after
the flue gas passes through
Economiser and Air Preheater is
termed as coarse ash. It lies
somewhere between Fly ash and
Bottom ash. Most literature
consider it to be Fly Ash

3. Bottom Ash Handling Plant
• The free falling Ash from boiler furnace is collected and stored in a ‘W’ shaped
water impounded bottom ash hopper provided below boiler furnace for its periodic
removal twice in a shift of eight (8) hours per unit.
• The Hot Ash from the furnace gets quenched as it enters into the water minimizing
the clinker formation.
• The mixture of Ash and Water (SLURRY) stored in the hopper is discharged through
feed gate to clinker grinder to crush the over size clinkers to 25mm and below.
• The crushed clinker along with water, which forms bottom ash slurry is conveyed to
Ash.
• Slurry sump Water required for jet pumps is supplied from high pressure (HP) ash
water pumps

4. Coarse Ash Handling
• Coarse Ash from Economizer hoppers is extracted continuously and mixed with
water in flushing box provided below each hopper.
• It is then discharged in to the Ash Slurry Sump.
• Water required for mixing economizer Ash is provided through separate Water
Pumps.
• Continuous generated Economizer slurry is fed by gravity into respective bottom
ash hopper pipes with necessary slopes
• Ash generated from APH hopper is evacuated once in a shift by Vacuum conveying
system connected with the ESP hopper vacuum conveying system

5. • Fly ash carried along with the flue gas from the boiler is collected continuously in
ESP hoppers
• Ash collected and stored in hoppers is extracted in dry form through pneumatic
extraction system and taken to buffer hoppers for further transportation to ash
silos in next stage
• Ash from the air ash mixture is separated from the air and collected in the primary
collector
• Air is passed through reverse pulse jet type bag filter for further separation of
carryover ash
• Clean air from the outlet of the bag filter is discharged from vacuum pump to
atmosphere
Fly Ash Handling

6. • An electrostatic precipitator is a filtration device that removes fine particles like
dust and smoke from flowing gas.
• It uses induced electrostatic charge minimally impeding the flow of gases
• The charge induced fly ash particles are collected on the ESP plates which are then
removed with the help of a rapper system.
• No of ESP Passes : - 6
• No of ESP Fields :- 9
• No of hopper per field :- 2
• No of Gas Passages :- 37 (38 plates)
• Total collection area = 25146 cm2
Electrostatic Precipitator

7. • This system uses significantly less water, using 15% water or less by weight, and is
used generally to transfer high throughputs of fine fly ash over very long distances
using high pressure diaphragm pumps (GEHO Pump) with velocities of around 2
m/s.
• However, proper monitoring of the slurry properties (homogenous mixing of ash
and water) is the key to success of this system.
• Systems such as this have been installed for over 10 kilometer transfer distance.
• Ash disposal at the ash mound is very simple as the ash solidifies easily into an
inert mass and the system does not produce the waste water problems
High Concentration Slurry Disposal

8. The Process of Ash Handling
1
Transportation
The ash is carried by trucks to the ash dump area, ash
pond, or disposal site.
2
Storage
In the ash pond, the ash slurry is stored until it reaches a
specific height. It is then transported to the ash disposal
area by hydraulic transporters.
3
Disposal
The ash is disposed of in a lined landfill, fly ash bricks,
and cement plants for processing. Mechanical
submergence and wet ash disposal technologies are used
for ash disposal.

9. Challenges Faced in Ash Handling
Safety Hazards
The workforce implements various safety
measures while working in the plant due
to possible hazards of radiation exposure
due to radioactive elements present in
the ash.
Land Management
The disposal sites are constructed
carefully, following the standard norms to
prevent landslides and to avoid affecting
the water table and soil fertility around
the site.
Maintenance costs
The continuous wear and tear of rubber
lining in conveyors and mixers require
regular maintenance. Otherwise, it can
result in frequent breakdowns of
equipment leading to delays in the ash
handling process.

10. Maintenance and Safety Measures
Monitoring System
A proper monitoring system
periodically scrutinizes every
device to detect faults and rectify
them as soon as possible.
Disaster Management
System
In case of any putative disaster, a
disaster management system is in
place to sensitize workers who can
summarily respond to it.
Regular Inspections
The Ash handling plant is
thoroughly inspected by authorities,
who perform a check on the
equipment, the working condition of
workers, and ensure if safety
measures are being followed.
Training Programs
Training programs are conducted for workers on the safe handling of ash, the proper maintenance of equipment, and the
best practices to prevent possible hazards.

11. Conclusion and Future Plans
The Importance of Ash Handling
Proper ash handling is a crucial requirement for protecting
the environment and human health. The MSPGCL Koradi is
committed to setting an example with its efforts and
commitment to preserve the environment.
Future Plans
MSPGCL has plans to improve its efficiency by enhancing
the capacity of its machinery, modernizing the ash handling
equipment, and adopting innovative technologies for better
and organic disposal.